Compared with traditional waste rubber recycling molding equipment, Changzhou Sanyal Machinery Co., Ltd. developed a new, energy-saving remanufactured rubber molding automated production line with a 25% reduction in installed power, a 30% increase in output, and a 30% reduction in energy consumption per ton of rubber. , Renewable rubber industry to further reduce energy consumption. On August 25, the production line passed the expert appraisal organized by the China Petroleum and Chemical Industry Federation in Changzhou. Experts believe that the equipment has an innovative design, the technology production process meets environmental protection requirements, has good economic and social benefits, and the overall technology is leading domestically.

The traditional waste rubber reclaiming complete sets of equipment mainly consist of four XK-450 refiners and one XKJ-480 refiner. The entire production line has an installed capacity of 220 kilowatts, with 4 people operating, a production capacity of about 1.5 to 1.8 tons per shift (0.2mm fine reclaimed rubber), a power consumption of about 630 kWh/ton, high production costs, large power consumption, and low production efficiency. Can not meet the requirements of energy saving and emission reduction in China's reclaimed rubber industry.

The new reclaimed rubber molding automated production line independently developed by Changzhou Sanjuji Machine Co., Ltd. adopts a new, highly efficient, energy-saving type of kneader for reclaimed rubber, and a conch machine to form a “three machines and one line” production line, which reduces one piece of equipment. 3 people operation, effectively reducing the manufacturing cost, can save 20% of the investment for the user; at the same time increase the roller speed ratio, increase the shear force, increase the speed of the film, its class production up to 2.5 to 2.8 tons (0.2mm fine reclaimed rubber), with an installed capacity of 165 kilowatts, and a power consumption of about 400 to 420 kWh/ton, which greatly saves resources and energy and satisfies the requirements of the renewable rubber industry for energy-saving equipment.

According to Xu Xiao, Assistant to General Manager of Changzhou Sanyuki Machinery Co., Ltd., the molding of reclaimed rubber is to subject the desulfurized powder to a strong shearing and shearing effect, and comb the relaxed mesh structure into a strip structure to achieve regeneration. purpose. According to this feature, increasing the shear ratio of the kneader used for reclaimed rubber has become the most important technological development direction. After the shear ratio is increased, the proper mid-height of the roller is matched to improve the thin-pass effect. The number of kneading processes required to produce reclaimed rubber can be reduced by 2-3 times compared to the conventional production line. Therefore, the “three machines and one line” can fully satisfy the recycled rubber. Molding quality requirements. At present, more than 20 domestic users have used this production line, and also exported to Malaysia, Thailand, Kazakhstan and other countries.

The expert group's opinion on the production line is that the production line adopts a low-shaft-diameter, wide-roller-face (Φ450/510X900) high-shear-speed-ratio roller according to the characteristics of the reclaimed rubber process, and adopts a mechatronics design to develop a high shear. Chebi's special kneading production line for reclaimed rubber improves the kneading effect of the rubber compound and reduces the number of kneading processes. It improves the “four machines and one line” commonly used for traditional reclaimed rubber molding to “three machines and one line”; the design uses four column columns. Roller bearings and anti-axial deep groove ball bearings improve transmission efficiency and reduce operating noise. After reclaimed rubber products are kneaded, they meet the technical requirements in GB/T13460-2008 "Reclaimed Rubber" standards.

According to Cao Qingxin, secretary general of the Waste Rubber Comprehensive Utilization Subcommittee of the China Rubber Industry Association, the annual production of waste rubber in China is between 120 and 15 million tons. The waste rubber comprehensive utilization industry bears the historical mission of harmless recycling and environmentally friendly use of domestic waste rubber. Reclaimed rubber is a large household of comprehensive utilization of waste rubber in China, accounting for more than 70% of various forms of comprehensive utilization of waste rubber in China. However, recycled rubber is still a low value-added product. In the processing process, the energy consumption per million yuan of industrial output is above 1500 kWh. Compared with other industries, the overall energy consumption per unit product is still very large. According to the "12th Five-Year Plan" requirement of the waste rubber comprehensive utilization industry, the consumption of plastics in the reclaimed rubber production molding section is reduced to 440 kWh. Therefore, traditional equipment can no longer meet the requirements of energy-saving, emission-reduction and sustainable development in the industry. The development and promotion of this new type of energy-saving equipment will accelerate the technological progress and energy conservation and emission reduction of the reclaimed rubber industry.

Jiang Zhongqin, chief economist of the Beijing Rubber Industry Research and Design Institute, believes that natural rubber resources in China are seriously deficient and prices are rising. Recycled rubber will undoubtedly become an alternative product closely watched by the rubber industry and can effectively reduce the production cost of rubber products companies. Therefore, the ability to provide recycled rubber products of high quality and variety is also required by the rubber industry. For the recycled rubber industry itself, low pollution, low cost, and low energy consumption are also the direction of its process improvement. The design of the new reclaimed rubber molding automated production line is innovative and has significant energy-saving effect. It is a useful exploration for the improvement of high-quality recycled rubber production and refining processes.

Fan Rende, president of the China Rubber Industry Association, said that the kneader and the refiner belong to the roll-type rubber mixer, and the roller-type rubber mixer is widely used in the rubber industry, thus reducing the energy consumption of the roll-type rubber mixer and improving Efficiency is of practical significance not only to the waste rubber industry but also to the entire rubber industry. At present, the international community also attaches great importance to the energy saving and emission reduction of roller type rubber mixers. Japan proposed to reduce energy consumption by more than 30% a year ago. This is the development direction of the world. He believes that there are many areas where the waste rubber industry needs to be improved. It is necessary to discuss together, actively develop and further reduce energy consumption. He pointed out that many rubber product lines in foreign countries are operated by robots, and the domestic rubber industry, especially the waste rubber industry, has a lot of manual operations. Therefore, research on automation control should be accelerated.

It is understood that the Changzhou Sanyuki Machinery Co., Ltd. has successfully developed a prototype of a reclaimed rubber turn-over robot that was used to realize the “three-machine-one-line” linkage in July. This robot is an innovation in the waste rubber industry and has been tested in the factory at present. . The next step is to put the robot into actual production test and improve and improve it, complete the pilot test as soon as possible and design and finalize the model, and then put it on the market. The robot has caused extensive concern in the recycled rubber industry. If it can be successfully applied to the production of recycled rubber, it can greatly increase the degree of automation and production efficiency and improve the operating environment of workers.

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