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According to industry sources, the rubber industry is a large energy consumer. As long as energy consumption is reduced by a few percentage points, its benefits will be enormous. Rubber enterprises to start circular economy and energy-saving emission reduction will inevitably start from the source of production equipment. It is understood that after years of exploration and efforts, a number of energy-saving products have emerged in the fields of vulcanization equipment, rubber refining equipment, tire component preparation and molding equipment, etc. in China.
In terms of vulcanization equipment, the main vulcanizer manufacturers vigorously promote the hot plate heating technology so that the vulcanization process can save more than 50% of energy consumption. For example, the tire vulcanizers and nitrogen supply systems for nitrogen vulcanization produced by Beijing Hezhong Entrepreneurship Technology Co., Ltd. etc. have been successfully applied in several tire factories. Sichuan Chuanxi Rubber Co., Ltd. has cured at least every tire without recycling nitrogen. It can save 1.79 yuan. The equal pressure variable temperature vulcanization process developed by Guilin Rubber Machinery Factory can also achieve the same effect. When the tire is vulcanized with this technology, the consumption of overheated water is reduced by more than half, and the power consumption is only 30% of the original; the mileage of tires produced with this technology can be increased by 5% to 10%, and the production capacity can be increased by 10% to 15%. Qingdao University of Science and Technology is currently working with Guilin Rubber Machinery Plant to produce an electric screw type tire vulcanizer. The steel consumption and production cost of this vulcanizing machine are respectively reduced by 65% ​​and 35% compared with the crank-joint vulcanizing machine, 25% and 65% lower than the hydraulic vulcanizing machine, and the floor space is also reduced by more than 20% compared with the ordinary vulcanizing machine.
In the area of ​​rubber mixing equipment, rubber machinery companies have made many explorations to improve the use efficiency. Dalian Rubber and Plastic Machinery Co., Ltd. studied the internal mixer rotor and developed a variety of new rotors, which greatly improved the mixing efficiency. According to reports, after the mixer has used its new rotor developed, the homogeneity of mixing can be improved, and the production capacity can be improved by more than 10%. Another rotor with a new structure has 6 ribs, which can complicate the flow of the compound, reduce the coking time by 12%, increase the filling amount by 1.2%, and increase the production efficiency by 13%. The large-capacity intermeshing internal mixer developed by Yiyang Rubber & Plastics Co., Ltd. adopts a number of patented technologies on the mixer rotor and the hydraulic jackbolt, which not only shortens the mixing time, but also improves the quality of the rubber compound and prolongs the service life of the machine. . Increasing the mixer rotor speed and pressure pressure can also increase production efficiency and save energy.
The use of intelligent mixer control system energy saving is another bright spot in the domestic mixer industry. The auxiliary machine series of the amphibious intelligent mixer jointly developed by Qingdao University's soft-control company and Zhejiang University utilizes statistical theory, population intelligence, and expert systems to eliminate the fluctuation of the mixing quality. After the mixer was installed and used, the dispersity of carbon black was increased by more than one grade under the same kneading procedure and stable quality of raw materials. The mixing time and energy consumption were reduced by approximately 7% and 11%, respectively. After the intelligent control system of the computer developed by South China University of Technology was put into use, the mixing efficiency could be increased by 20%, and the qualified rate of the rubber material could be increased.
In terms of tire component preparation and molding equipment, Guilin Rubber Industry Research and Design Institute has developed a three-composite, four-compound extrusion tread production line in recent years. All of its materials are fed with pin barrel cold feed extruders, and the quality and energy saving of extruded rubber. The effect is obvious. The Pin Cold Feed Extruder developed by Inner Mongolia Furte Rubber & Plastics Machinery Co., Ltd. replaced the open mill as a glue feeding system for steel wire calenders at Hefei Jiatong Company, etc., a production line reduced the installed power by 560 kW, and the investment cost was reduced by 30%. ~40%. Wuxi First Rubber and Plastics Co., Ltd. cooperated with Bridgestone to produce a 6-station hexagonal wire coil extrusion wrap production line that can simultaneously form 6 wire loops. Its production efficiency is at least 4 times that of a single station. The radial tire forming machine has developed rapidly in recent years. From the two-drum forming machine to the three-drum to four-drum forming machine, the production efficiency has greatly increased. Tianjin Saixiang, Guilin Rubber Machinery, Beijing Aviation Manufacturing Engineering, Qingdao Higher Education Software Control, and Shenyang Lanying and other companies increased the output of three-drum forming machines from 50 to 60 drum machines to 100 to 120. The output of the four-drum forming machine of the Beijing Aviation Engineering Institute increased to more than 130 tires.
Professor Lu Baiyuan of Qingdao University of Science and Technology said that rubber machinery companies are increasingly paying attention to the energy saving and consumption reduction of equipment and are in line with the development trend of the rubber industry. Nowadays, rubber tire companies are shifting from extensive use of energy to energy-saving enterprises. Equipment with low energy consumption and high efficiency will be the first choice for equipment purchase by rubber companies.
New machinery for the rubber industry "source energy saving"
At present, the rubber industry is vigorously promoting circular economy and energy saving. The rubber machinery industry fully considers factors such as improving efficiency, saving energy and reducing pollution in product development, and provides technical equipment support and guarantee for the energy saving and consumption reduction of the rubber industry.