All-round improvement in steam trapping stations
/ ONE OF THE MOST IMPORTANT PARTS OF THE TIRE MANUFACTURING PROCESS IS THE VULCANIZING OF RUBBER. FAILURE TO CARRY OUT THIS STEP TO THE REQUIRED QUALITY, DIRECTLY INFLUENCES THE QUALITY AND PERFORMANCE OF THE FINISHED ARTICLE. SO WHEN A LEADING TIRE MANUFACTURER IN CHINA EXPERIENCED PROBLEMS WITH THEIR VULCANIZING PRESSES, THEY CALLED IN ERIKS COMPANY ECONOSTO CHINA TO LOOK FOR THE CAUSE AND DEVISE A SOLUTION.
Vulcanizing uses steam to achieve the correct temperature to carry out the process. With 192 vulcanizing presses in operation, the tire manufacturer consumed a large amount of steam – but also wasted a great deal. This was due to the design of the system, featuring controlled on/off valves which spilled the costly live steam. At the same time, when the system’s drain valves were closed, condensate built up in the presses. Since condensate has less energy than steam, this led to inefficiency in the process.
€950,000 saved per year on steam costs
After a thorough review of the system and an assessment of the problem, Econosto China designed and engineered an effective solution. Econosto’s engineers devised a steam trapping station containing a so-called ball float steam trap. This device enables condensate to drain away rather than entering the presses, but at the same time prevents steam from escaping – so all its energy is released into the presses.
The result was a three-fold success. Firstly, the new solution saved the company around €950,000 per annum on steam costs. Secondly, it ensured improved production quality by maintaining the integrity of the vulcanizing process. And thirdly, it reduced levels of CO2 emissions from the plant – delighting the tire manufacturer with the all-round improvement.
Total savings: 950,000 EUR
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