Guangzhou vulcanization plant, 3 units, 1.3 tons
Cases Details
A tire company in Guangzhou has introduced three 1.3-ton Kaida steam generators, with significant benefits
Rubber vulcanization is the core process of rubber product production, and the precision of temperature control and steam stability directly determine the physical properties (such as tensile strength, wear resistance) and appearance quality of the product. Traditional steam boilers suffer from low thermal efficiency (80% -85%), large temperature fluctuations (± 5 ℃), and accumulation of condensate water, which can easily lead to uneven sulfurization, under sulfurization, or over sulfurization, becoming a bottleneck for improving industry quality. In this context, a tire company in Guangzhou introduced Kaida steam generators to achieve precise temperature control and efficiency improvement in the vulcanization process through technological upgrades.
Technical Highlights
1. Precise temperature control technology
Dynamic pressure regulation: Through the Siemens PLC intelligent control system, the steam pressure (0.1-1.2MPa) is adjusted in real time to control the sulfurization temperature fluctuation within ± 1 ℃, ensuring that the sulfurization uniformity is improved to 95%.
2. Breakthrough in Energy Conservation and Environmental Protection
Low nitrogen combustion technology: Adopting water-cooled ultra-low nitrogen combustion technology, the NOx emission concentration remains stable below 30mg/m ³, in compliance with the latest environmental regulations.
Condensing heat recovery: Recovering waste heat from flue gas to 60 ℃, with an overall thermal efficiency of over 95%, significantly improving the thermal efficiency compared to traditional boilers. Annual production of 10000 tons of rubber products saves fuel costs of over 400000 yuan.
3. Intelligent operation and maintenance system
Modular design: supports multiple parallel devices, automatically adjusts power (10% -100%) according to production needs, and reduces unplanned downtime.
Remote monitoring and predictive maintenance: Automated operation and remote monitoring are achieved through PLC (programmable logic controller)+SCADA (data acquisition and monitoring system).
Predictive maintenance: Predicting equipment failures through data analysis to reduce unplanned downtime.
Implementation effect
1. Quality leap
Physical performance improvement: tensile strength increased by 25%, wear resistance increased by 40%, and product yield rate increased from 85% to 99%.
Appearance optimization: The steam dryness reaches 99%, eliminating local sulfur deficiency caused by condensed water, and significantly improving surface smoothness.
2. Significant economic benefits
Energy consumption reduction: Gas consumption has decreased by 12%, saving over 400000 yuan in fuel costs annually.
Capacity improvement: The vulcanization cycle has been shortened by 20%, supporting synchronous operation of multiple production lines.
Labor cost: The intelligent operation and maintenance system reduces manual intervention, saving over 120000 yuan in labor costs annually.
3. Environmental compliance and social benefits
Emission standard: particulate matter emissions<30mg/m ³, successfully passed the environmental impact assessment.
Policy adaptation: Meet the requirements of the "dual carbon" target and provide benchmark cases for low nitrogen and energy-saving transformation in the industry.
