| ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Off Road vehicles with an aggressive tire tread, add 2oz to the recommended application.
ABC Balancing Beads can be installed through the valve stem. For any questions please feel free to contact us at the number located at the top of your screen.
Light Truck
6000 lbs or less
6001 lbs to 10,000 lbs
Delivery & Light Truck
10,001 lbs to 14,000 lbs
14,001 lbs to 16,000 lbs
Medium Duty Truck
16,001 lbs to 19,500 lbs
19,001 lbs to 26,000 lbs
Heavy Duty Truck & Bus
26,001 lbs to 33,000 lbs
33,001 lbs to 105,000+ lbs
Off Road and Lifted Pickups
Tire Size:
215/75R14 4oz
205/70R14 4oz
215/70R14 4oz
Tire Size:
700R15 4oz
7.50R15 6oz
8.25R15 6oz
9R15 8oz
10R15 8oz
215/80R15 4oz
195/75R15 40z
205/75R15 40z
215/75R15 4oz
225/75R15 4oz
235/75R15 4oz
245/75R15 40z
255/75R15 40z
265/75R15 40z
235/70R15 40z
245/70R15 40z
255/70R15 4oz
265/70R15 4oz
285/70R15 40z
315/70R15 6oz
245/65R15 4oz
225/60R15 4oz
325/60R15 6oz
Tire Size:
325/75R20 80z
275/65R20 6oz
275/60R20 6oz
325/60R20 6oz
255/60R20 6oz
275/55R20 4oz
285/55R20 4oz
255/50R20 4oz
285/50R20 4oz
305/50R20 6oz
325/50R20 6oz
355/50R20 6oz
325/45R20 6oz
275/40R20 6oz
315/35R20 6oz
Tire Size:
6.
5R16 4oz
7.50R16 4oz
8.25R16 6oz
1R16 8oz
215/85R16 4oz
225/85R16 4oz
245/85R16 4oz
255/85R16 4oz
265/85R16 6oz
275/85R16 6oz
205/80R16 4oz
325/80R16 6oz
175/75R16 4oz
195/75R16 4oz
225/75R16 4oz
235/75R16 4oz
245/75R16 4oz
265/75R16 6oz
285/75R16 6oz
315/75R16 6oz
215/70R16 4oz
225/70R16 4oz
235/70R16 4oz
245/70R16 4oz
255/70R16 4oz
265/70R16 4oz
275/70R16 4oz
305/70R16 4oz
315/70R16 6oz
355/70R16 6oz
365/70R16 6oz
395/70R16 6oz
195/65R16 4oz
215/65R16 4oz
225/65R16 4oz
245/65R16 4oz
255/65R16 4oz
305/65R16 4oz
345/65R16 6oz
375/65R16 6oz
215/60R16 4oz
225/60R16 4oz
235/60R16 4oz
285/60R16 4oz
255/55R16 4oz
315/55R16 4oz
345/55R16 6oz
355/55R16 6oz
375/55R16 6oz
245/50R16 4oz
Tire Size:
8R16.5 6oz
8.75R16.5 6oz
9.50R16.5 6oz
10R16.5 6oz
12R16.5 6oz
Tire Size:
235/80R17 6oz
235/75R17 6oz
245/75R17 6oz
255/75R17 6oz
245/70R17 6oz
255/70R17 6oz
285/70R17 6oz
305/70R17 6oz
315/70R17 6oz
355/70R17 6oz
255/65R17 6oz
235/65R17 4oz
245/65R17 4oz
255/65R17 4oz
265/65R17 6oz
305/65R17 6oz
375/65R17 8oz
225/60R17 4oz
235/60R17 4oz
255/60R17 6oz
275/60R17 6oz
285/60R17 6oz
225/55R17 4oz
255/55R17 4oz
275/55R17 6oz
345/55R17 6oz
255/50R17 4oz
Tire Size:
325/55R22 6oz
335/55R22 6oz
325/50R22 6oz
305/45R22 6oz
305/40R22 6oz
285/35R22 6oz
Tire Size:
8R17.
5 6oz
8.5R17.5 6oz
9R17.5 6oz
9.5R17.5 8oz
10R17.5 80z
11R17.5 80z
225/90R17.5 8oz
205/80R17.5 8oz
225/80R17.5 8oz
205/75R17.5 6oz
215/75R17.5 6oz
225/75R17.5 6oz
235/75R17.5 6oz
245/75R17.5 6oz
195/70R17.5 6oz
215/70R17.5 6oz
235/70R17.5 6oz
195/60R17.5 6oz
205/60R17.5 6oz
225/60R17.5 6oz
Tire Size:
7.50R18 8oz
255/70R18 6oz
285/60R18 6oz
325/60R18 6oz
375/60R18 8oz
395/60R18 8oz
255/55R18 4oz
275/55R18 4oz
285/55R18 4oz
285/50R18 4oz
375/50R18 6oz
Tire Size:
255/55R19 4oz
255/50R19 4oz
275/45R19 4oz
285/45R19 4oz
Tire Size:
325/45R24 6oz
Tire Size:
8R19.5 8oz
9R19.5 80z
18R19.5 14oz
280/75R19.5 8oz
285/75R19.5 8oz
225/70R19.5 8oz
245/70R19.5 8oz
265/70R19.5 8oz
275/70R19.5 10oz
285/70R19.5 10oz
305/70R19.5 12oz
385/65R19.
5 14oz
445/65R19.5 14oz
Tire Size:
7.50R20 10oz
8.25R20 10oz
9.00R20 12oz
10.00R20 12oz
11R20 14oz
12.00R20 14oz
12.5R20 14oz
14/80R20 14oz
14.00R20 16oz
365/80R20 16oz
395/80R20 16oz
Tire Size:
525/65R20.5 20oz
615/65R20.5 20oz
Tire Size:
10.00R22 12oz
1.00R22 12oz
Tire Size:
9R22.5 10oz
10R22.5 10oz
11R22.5 12oz
12R22.5 14oz
13R22.5 12oz
15R22.5 12oz
16R22.5 14oz
16.5R22.5 14oz
18R22.5 16oz
235/80R22.5 6oz
255/80R22.5 8oz
275/80R22.5 12oz
295/80R22.5 14oz
315/80R22.5 14oz
365/80R22.5 14oz
245/75R22.5 10oz
265/75R22.5 10oz
285/75R22.5 12oz
295/75R22.5 12oz
315/75R22.5 12oz
345/75R22.5 12oz
350/75R22.5 14oz
235/70R22.5 8oz
255/70R22.5 10oz
11/70R22.5 10oz
265/70R22.5 10oz
275/70R22.5 12oz
305/70R22.5 12oz
315/70R22.5 12oz
365/70R22.
5 120z
365/65R22.5 12oz
385/65R22.5 12oz
425/65R22.5 14oz
445/65R22.5 160z
285/60R22.5 10oz
295/60R22.5 10oz
305/60R22.5 10oz
315/60R22.5 10oz
385/55R22.5 12oz
455/55R22.5 16oz
275/50R22.5 10oz
445/50R22.5 16oz
Tire Size:
1.00R24 14oz
12.00R24 14oz
14.00R24 16oz
445/70R24 16oz
495/70R24 16oz
Tire Size:
11R24.5 12oz
12R24.5 14oz
285/75R24.5 12oz
305/75R24.5 12oz
315/75R24.5 12oz
275/80R24.5 12oz
295/80R24.5 12oz
MUD TERRAIN
Tire Size:
35/12.5 R20 14oz
35/13.5 R20 14oz
36/13.5 R20 14oz
37/13.5 R20 14oz
38/13.5 R20 14oz
33/12.5 R20 12oz
37/12.5 R20 14oz
33/12.5 R22 14oz
35/12.5 R22 14oz
37/12.5 R22 14oz
36/13.5 R22 112oz
37/13.5 R22 16oz
38/13.5 R22 16oz
33/12.5 R18 12oz
34/12.5 R18 12oz
35/12.5 R18 12oz
36/12.5 R18 12oz
37/12.5 R18 12oz
42/12.
5 R18 12oz
33/13.5 R18 12oz
36/13.5 R18 12oz
37/13.5 R18 14oz
38/13.5 R18 14oz
40/13.5 R18 14oz
35/14.5 R18 12oz
38/14.5 R18 14oz
40/14.5 R18 14oz
41/14.5 R18 16oz
33/12.5 R17 12oz
35/12.5 R17 12oz
37/12.5 R17 14oz
33/13.5 R17 12oz
36/13.5 R17 14oz
37/13.5 R17 14oz
40/13.5 R17 14oz
35/14.5 R17 12oz
31/12.5 R16 10oz
32/12.5 R16 10oz
33/12.5 R16 10oz
34/12.5 R16 10oz
35/12.5 R16 12oz
36/12.5 R16 12oz
37/12.5 R16 12oz
33/13.5 R16 10oz
36/13.5 R16 12oz
40/13.5 R16 14oz
33/14.5 R16 12oz
35/14.5 R16 12oz
36/14.6 R16 14oz
38/14.5 R16 14oz
40/14.5 R16 16oz
31/12.5 R15 8oz
32/12.5 R15 10oz
33/12.5 R15 10oz
34/12.5 R15 10oz
35/12.5 R15 10oz
36/12.5 R15 12oz
37/12.5 R15 12oz
38/12.5 R15 12oz
31/13.5 R15 8oz
33/13.5 R15 610oz
35/13.5 R15 12oz
37/13.5 R15 12oz
40/13.5 R15 14oz
31/14.5 R15 10oz
33/14.
5 R15 12oz
35/14.5 R15 12oz
36/14.5 R15 14oz
37/14.5 R15 14oz
40/14.5 R15 14oz
Tire Size:
27/8.5R14 4oz
Tire Size:
31/10.50R16.5 6oz
33/12.50R16.5 8oz
35/12.50R16.5 8oz
37/12.50R16.5 10oz
33/14.50R16.5 10oz
35/14.50R16.5 10oz
38/15.50R16.5 12oz
33/16.50R16.5 10oz
36/16.50R16.5 12oz
40/17B16.5 14oz
44/18.50B16.5 14oz
Tire Size:
33/12.50R17 10oz
35/12.50R17 10oz
37/12.50R17 10oz
37/13.50R17 10oz
40/13.50R17 10oz
ALL TERRAIN
Tire Size:
35/12.5 R20 12oz
35/13.5 R20 12oz
36/13.5 R20 12oz
37/13.5 R20 12oz
38/13.5 R20 12oz
33/12.5 R20 10oz
37/12.5 R20 12oz
33/12.5 R22 12oz
35/12.5 R22 12oz
37/12.5 R22 12oz
36/13.5 R22 12oz
37/13.5 R22 14oz
38/13.5 R22 14oz
33/12.5 R18 10oz
34/12.5 R18 10oz
35/12.5 R18 10oz
36/12.5 R18 10oz
37/12.
5 R18 10oz
42/12.5 R18 10oz
33/13.5 R18 10oz
36/13.5 R18 10oz
37/13.5 R18 12oz
38/13.5 R18 12oz
40/13.5 R18 12oz
35/14.5 R18 10oz
38/14.5 R18 12oz
40/14.5 R18 12oz
41/14.5 R18 14oz
33/12.5 R17 10oz
35/12.5 R17 10oz
37/12.5 R17 12oz
33/13.5 R17 10oz
36/13.5 R17 12oz
37/13.5 R17 12oz
40/13.5 R17 12oz
35/14.5 R17 10oz
31/12.5 R16 8oz
32/12.5 R16 8oz
33/12.5 R16 8oz
34/12.5 R16 8oz
35/12.5 R16 10oz
36/12.5 R16 10oz
37/12.5 R16 10oz
33/13.5 R16 8oz
36/13.5 R16 10oz
40/13.5 R16 12oz
33/14.5 R16 10oz
35/14.5 R16 10oz
36/14.6 R16 12oz
38/14.5 R16 12oz
40/14.5 R16 14oz
31/12.5 R15 8oz
32/12.5 R15 8oz
33/12.5 R15 8oz
34/12.5 R15 8oz
35/12.5 R15 8oz
36/12.5 R15 10oz
37/12.5 R15 10oz
38/12.5 R15 10oz
31/13.5 R15 8oz
33/13.5 R15 8oz
35/13.5 R15 10oz
37/13.5 R15 10oz
40/13.5 R15 12oz
31/14.5 R15 8oz
33/14.
5 R15 10oz
35/14.5 R15 10oz
36/14.5 R15 12oz
37/14.5 R15 12oz
40/14.5 R15 12oz
Tire Size:
29/9.50R15 8oz
30/9R15 8oz
33/9.50R15 8oz
31/10.50R15 8oz
33/10.50R15 8oz
31/11.50R15 8oz
32/11.50R15 8oz
31/12.50R15 8oz
32/12.50R15 8oz
33/12.50R15 8oz
35/12.50R15 8oz
36/12.50R15 10oz
37/12.50R15 10oz
35/13.50R15 10oz
31/14.50R15 8oz
33/14.50R15 10oz
36/14.50R15 10oz
38/15.50R15 12oz
33/16.50R15 10oz
36/16.50R15 12oz
40/17R15 12oz
44/18.50R15 12oz
Tire Size:
35/12.50R20 12oz
ALL SEASON
Tire Size:
35/12.5 R20 10oz
35/13.5 R20 10oz
36/13.5 R20 10oz
37/13.5 R20 10oz
38/13.5 R20 10oz
33/12.5 R20 8oz
37/12.5 R20 10oz
33/12.5 R22 10oz
35/12.5 R22 10oz
37/12.5 R22 10oz
36/13.5 R22 10oz
37/13.5 R22 12oz
38/13.5 R22 12oz
33/12.5 R18 8oz
34/12.5 R18 8oz
35/12.
5 R18 8oz
36/12.5 R18 8oz
37/12.5 R18 8oz
42/12.5 R18 10oz
33/13.5 R18 8oz
36/13.5 R18 8oz
37/13.5 R18 10oz
38/13.5 R18 10oz
40/13.5 R18 10oz
35/14.5 R18 8oz
38/14.5 R18 10oz
40/14.5 R18 12oz
41/14.5 R18 12oz
33/12.5 R17 8oz
35/12.5 R17 8oz
37/12.5 R17 10oz
33/13.5 R17 8oz
36/13.5 R17 10oz
37/13.5 R17 10oz
40/13.5 R17 10oz
35/14.5 R17 8oz
31/12.5 R16 6oz
32/12.5 R16 6oz
33/12.5 R16 6oz
34/12.5 R16 6oz
35/12.5 R16 8oz
36/12.5 R16 8oz
37/12.5 R16 8oz
33/13.5 R16 6oz
36/13.5 R16 8oz
40/13.5 R16 10oz
33/14.5 R16 8oz
35/14.5 R16 8oz
36/14.6 R16 10oz
38/14.5 R16 10oz
40/14.5 R16 12oz
31/12.5 R15 6oz
32/12.5 R15 6oz
33/12.5 R15 6oz
34/12.5 R15 6oz
35/12.5 R15 6oz
36/12.5 R15 8oz
37/12.5 R15 8oz
38/12.5 R15 8oz
31/13.5 R15 6oz
33/13.5 R15 6oz
35/13.5 R15 8oz
37/13.5 R15 8oz
40/13.5 R15 10oz
31/14.
5 R15 6oz
33/14.5 R15 8oz
35/14.5 R15 8oz
36/14.5 R15 10oz
37/14.5 R15 10oz
40/14.5 R15 10oz
Tire Size:
32/9.50R16 6oz
35/10.50R16 6oz
31/12.50R16 6oz
32/12.50R16 6oz
33/12.50R16 6oz
35/12.50R16 6oz
36/12.50R16 8oz
37/12.50R16 8oz
33/14.50R16 8oz
36/14.50R16 10oz
38/15.50R16 10oz
Tire Size:
35/12.50R18 6oz
37/12.50R18 8oz
NOTE – For aggressive Mud Terrain Tires add an additional 2oz per tire application.
preparatory workshop except for specialized lines for uterine or ready mixes are usually included lines with universal piping, designed for the manufacture of both mother and finished rubber compounds, as well as for their repeated processing. Inclusion in the technological the scheme of universal lines allows improve technological agility complex equipment, flexibly change program in case of productive peaks and in emergencies, increase equipment utilization rate.
Worm gears are installed under the mixers aggregates with a roller head (ACHVL-1200) for the refinement of the rubber compound, providing processing of 3-8 tons of mixture per hour. Such performance has a scalloped installation AFT "B", included into the unit.
3.7 Mixing control
Continuous temperature control during mixing mixing chamber of the rubber mixer (using an electronic recorder EPD potentiometer), duration mixing (mode clock or using command electro-pneumatic device KEP-12U with light signals) and pressure compressed air to the upper shutter of the rubber mixer (by manometer). In addition, periodically check the temperature of the rolls of the rolls beam thermocouple.
3.8 Quality control of received rubber compounds
The quality of the compounds is controlled to prevent marriage. To the main defects of rubber compounds include deviations in density, plasticity, scorching, understated indicators of mechanical impurities.
To prevent these defects should be accurately weighed and dosed the materials provided for in the recipe, maintain specified mixing temperature and do not apply moisture content ingredients. For control, an express method is used, with which within 1 - 2 minutes you can get indirect data (ring modulus, density), allowing to judge about the degree of dispersion of the components in the mixture.
Laboratory quality control of mixtures is of great importance because it allows Eliminate the entry of low quality rubber compounds into the production. For masterbatch after passing through the drum dryer selectively (25%) viscosity is checked according to Mooney, and for ready-made mixtures, the strength in tension, relative elongation and other indicators of vulcanizates. For all ready-made mixtures are determined density, Shore hardness, dynamic modulus shift on the MS-MSO instrument and rheometer Monsanto-100. With full automatic mixing process control practically no rubber compounds are required.
Rubber compounds are considered suitable if the test results correspond to the specified technological regulations. In case of deviation of individual indicators from the established mixture is sent to finalization in a rubber mixer or on rollers. Finally rejected mixtures are transferred to recovery plants or use for other purposes.
4 Calculation of main and auxiliary equipment
use of the most advanced equipment that provides high performance, good product quality, precise execution the company's annual program. In counting defines the minimum number of units equipment that will provide the planned full release of the product.
Based on material data balance, work schedule of the planned production, scheduled preventive maintenance of equipment (see Appendix A)
Table 1 Equipment preventive maintenance plan
| Equipment | Capital | Medium | Current |
| RS-250-30-30 | 51840/720 | 47960/450 | 17280/288 |
Material balance of semi-finished products
Calculation of the material balance of semi-finished products is carried out taking into account the gross cost norms semi-finished products for 1000 pcs.
tires and material balance of the finished product. results calculations of the material balance of semi-finished products in accordance with the annual, daily and shift the release of tires 185 / 65R14 are given in table. 3
Table 2 - Material balance of semi-finished products.
| Name of semi-finished products | dyn. meas. | Per 1000 pcs, kg | For annual output, kg | For daily output, kg | For replacement outlet, kg |
| Rubber compounds: | |||||
| Running P-1.1 | kg | 6385.7 | 14048540 | 55309.22 | 18436.41 |
| Sidewall P-2.1 | kg | 2419. | 5323340 | 20958.04 | 6986.02 |
| Frame K-2.1 | kg | 1636.4 | 3600080 | 14173.55 | 4724.52 |
| Breaker Br-1.1 | kg | 1406.5 | 3094300 | 12182.28 | 4060.77 |
| Insulation Bk-1.1 | kg | 389.9 | 857780 | 3377.09 | 1125.67 |
| Hermetic layer Br-1.1 | kg | 1908.75 | 4199250 | 16532.48 | 5510.83 |
| Total | kg | 14119. | 31063890 | 122298.78 | 40766.26 |
Rubber mixer calculation.
Knowing the production schedule, we calculate fund of time required for the release of the rubber compound given power.
Calendar time fund Tk:
Tk=24∙365=8760 hours
Nominal time fund Tn:
Тн=21∙254=5334 hours
Effective time fund Тeff:
Тeff= Тн – Тр
determined on the basis of the PPR schedule.
Operating time between regular and major repairs 51840 hours Duration of major repairs 720 hours
Repeating major repairs will be occur in:
51840/5334 = 9.7 years;
Then the time for overhaul:
720/9.7 = 74.2 hours
Operating time between the next and the average repairs 47960 h Duration of medium repairs 480 h
Recurrence of medium repairs will occur through:
47960/5334 = 9 years.
Then the time for an average repair per year:
480/9 = 53.3 hours
repairs 17280 hours Duration of average repairs 288 hours.
Medium repairs will be repeated in:
17280/5334=3.2
Then the average repair time per year:
288/3.2 = 90 hours
TR = 74.2+53.3+90 = 217.5 hours;
TEF = 5334 - 217.5 = 5116.5 hours
At the stage of rubber compound production for the pressure layer we use
rubber mixer RS-250-30
then
h
where Pg is the annual production program taking into account the selection of products for
analysis, kg;
PCS.
This means that 1 rubber mixer is required at the mixing stage RS-250-30.
At the rubber compound production stage: running, breaker, insulating, as well as for sidewall and frame rubberizing we use the rubber mixer RS-250-30
then
h
where Pg is the annual production program taking into account the selection of products for
analysis, kg;
PCS.
This means that 2 rubber mixers are required at the mixing stage RS-250-30.
Table 3 Number of equipment required for the issue of the annual program
| Equipment name | Annual program, kg | Prod. equipment, kg/h | Tmh, h | Teff, h | Number of equipment Nr/Ny | Kz |
|
RS-250-30 (sealed) | 4199250 |
3078 |
1364.3 |
5116.5 |
1 | 27% |
|
RS-250-30 | 26864640 |
3078 | 8728 | 5116. | 2 | 85% |
9000 9000 9000 9000 9000 9000 9000 9000 9000 9000 9000 9000
2
Conclusion
The term paper provides a description technological process of mixing rubber compounds for tires 185/65R14.
Calculations of the required equipment for the preparatory workshop, including includes the calculation of equipment performance, the amount of equipment needed.
For 185/65R14 tires with a capacity of 2.
2 million pieces per year, it is necessary three rubber mixers RS-250-30
Reference list
1. Pneumatic tire technology: textbook allowance / I. A. Ososhnik, O. V. Karmanova, Yu. F. Shutilin. - Voronezh, Mrs. technol. acad. Voronezh, 2004.-508 p.
2. Technology of rubber products: Proc. Manual for universities / Yu.O. Averko-Antonovich, R.Ya. Omelchenko, N.A. Okhotina, Yu.R. ebich / Ed. P.A. Kirpichnikova.- L .: "Chemistry", 1991.- 352s: ill.
3. Machinery and apparatus for rubber production. Ed. D. M. Barskova. M., "Chemistry", 1
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| Design | Chelnokov P. | ||||||||||
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| Karmanova O.V. | ||||||||||
| T.control. | Sheet 2 | Sheets 19 | |||||||||
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| VGUIT Khr-101 | ||||||||||
| N.control. | |||||||||||
| Approved | |||||||||||
One of the methods of waste processing is pyrolysis. Pyrolysis is a method of thermal decomposition of polymeric materials or organic substances under the action of temperature in the absence of an oxidizing environment.
In contrast to the methods of combustion and gasification, pyrolysis usually aims to obtain products during the processing of raw materials or waste.
As a result of the pyrolysis of polymeric materials, three competing products are inevitably formed: liquid products, coke residue and gas. The output of these products depends on the conditions of the process and the properties of the processed raw materials. At elevated temperatures, the main product is pyrolysis gas, as a product of a more complete thermal decomposition of a high-molecular organic compound into low-molecular ones. At low intensity of the process (heating rate) and high pressure, the predominant product is coke residue coal, as a product of secondary and tertiary processes, mainly synthesis and condensation from intermediate products. At high intensity and moderate temperature (usually 450-550 degrees C for most organic polymers), liquid organic products are the main product.
Table 1
Types of pyrolysis
Table 2 presents the material balances in the processing of various types of raw materials by fast ablative pyrolysis.
Table 2
Material balance for various types of raw materials
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Pyrolysis plants have a very extensive classification and many types. Distinguish between installations of periodic and continuous action, classified according to the design of the reactor, condenser and type of process. However, each pyrolysis plant, as a rule, has a reactor (retort, in the case of a batch process), a condenser, and an energy module (furnace). Sometimes, when the goal is to get only a solid product, the condenser is excluded from the circuit and the entire gas-vapor mixture is burned in the furnace. Some designs to reduce energy losses provide for the combination of the reactor and the energy module, however, in this case, temperature control becomes more complicated and higher requirements are imposed on the structural materials of the reactor, since the temperature of the pyrolysis process and the temperature of the effective combustion of the pyrolysis gas differ significantly.
Batch-type plants are less efficient than continuous ones, since it is difficult to ensure the stability of product quality as a result of cyclic heating. And if the retort is cyclically removed from the temperature zone, then the thermal efficiency decreases, due to the need to heat and cool a retort comparable to the load by weight during each cycle. In addition, the structural material of the reactor during cyclic operation has a low resource as a result of frequent “stresses” caused by heating and cooling.
According to the degree of automation, pyrolysis plants are divided into fully automated complexes, partially automated and mechanized plants that require manual labor, and non-mechanized solutions that have lost their importance. Important in the process of pyrolysis is the control of temperature and pressure, since the safety of the process and the quality of the products depend on these parameters.
FPP02 Waste Processing Plant is a specialized technical complex that processes waste in several technological stages.
The main ones are:
- preparation of raw materials,
- drying,
- pyrolysis,
- condensation.
Depending on the type of raw material and its granulometric composition, it is initially pre-grinded, sorted or cleaned.
Further, depending on the moisture content of the raw material, it is dried to a moisture content not higher than 15%. Drying of wet and hydrophilic materials is necessary to increase the efficiency of the pyrolysis plant. The fact is that it is problematic to heat wet raw materials to temperatures above the boiling point of water, since the process of phase transition (evaporation) is associated with very significant heat costs, sometimes an order of magnitude different from the specific energy costs for thermal decomposition. As a result, the pyrolysis reactor turns into a large “pot” in which water boils away, but not pyrolysis. It is more efficient to evaporate water from raw materials in special dryers. In addition, the evaporated water in the pyrolysis reactor also degrades the quality of the pyrolysis products.
Therefore, the drier the raw material, the more efficiently the pyrolysis process will proceed.
Rapid pyrolysis is the thermal decomposition of biomass without access to oxygen at temperatures of 450-550°C, a high heating rate of 500-1000°C/s and a short residence time of products in the reaction space (up to 5 sec). As a result of the process, a gas-vapor mixture is formed.
Condensation is the transition of a substance from a gaseous to a liquid or solid state. As a result of rapid cooling and condensation, the vapor-gas mixture of the pyrolysis process is formed into liquid and solid products.
For the implementation of the above technological stages FPP 02 fast pyrolysis plant consists of the following main blocks and elements:
The technological process in the FPP 02 plant is carried out as follows: crushed and dried raw materials are fed into the feed hopper of the loading modules, from where it is fed into the reactor through a two-valve sluice device.
In the reactor, under the action of heat generated in the power module, in the absence of oxygen, mechanically activated thermal decomposition of raw materials is carried out, resulting in the formation of coal and a vapor-gas mixture. The vapor-gas mixture is fed into the cleaning module, where the vapor-gas mixture is separated from coal dust with its subsequent supply to the condenser module. Fine coal from the reactor is fed by a screw feeder to the unloading module, where it is accumulated and distributed. It is possible to supply coal either for unloading or for combustion in the power module.
Rapid cooling and condensation of the gas-vapor mixture in the condenser module makes it possible to separate the liquid component and combustible gas. In this case, the combustible gas is fed to the combustion in the energy module in order to provide energy for the pyrolysis process.
This unit can be used to dispose of various materials, including the Oily Waste Treatment Plant .
Management is carried out from a separate room in which the operator's console is installed. From here, the operator controls the process and, if necessary, adjusts the pyrolysis temperature.
Waste treatment plant allows you to dispose of the following materials:
This Waste Recycling Complex will be especially useful for the disposal of organic waste from farms, poultry farms and agricultural fields (manure, husk, straw, leaves, food waste).
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