Custom-Built Vulcanizers
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Custom-Built Vulcanizers
Melco Vulcanizer Operator Inside Alarm
Combining over 3 decades of autoclave manufacturing expertise, Melco Steel, Inc. designs and builds vulcanizers in a broad range of custom configurations, primarily for the rubber industry. Our standard and custom-built vulcanizers can be used for curing plastic and rubber products. Depending on your specific rubber processing needs, we can build vulcanizing autoclaves in direct steam-injected as well as electric dry-heated models. Our custom dry vulcanizers offer optimal heat and pressure combinations ideal for processing advanced materials, a feature absent in conventional steam heated systems.
Available in either horizontal or vertical orientations, Melco Steel's rubber curing autoclaves can be easily integrated into OEMs' production facilities. Typical auxiliary systems provided with our vulcanizers include vacuum pumps, carts, and steam generators. Our instrumentation options range from simple microprocessor-based controls to network compatible computer-based controls systems. These controls can be specifically configured in accordance with your process control needs.
Operators can document process data using circular/strip chart recorders or data loggers. As a complete turnkey fabrication shop, we design, engineer, fabricate, and test autoclaves to meet your specific vulcanizing requirements. In addition to manufacturing solutions, Melco Steel also offers support services such as installation, FOB Factory, and on site start-up.
 Vulcanizer Autoclave Brochure (PDF - 618KB)
Custom-Built Vulcanizers Specifications
Autoclave Specifications
| Equipment Capabilities |
Adhesive Bonding
Curing Rubber/Plastics |
| Vulcanizer Designs |
Direct Steam Injection Vulcanizers
Electric Dry Heat Vulcanizers |
| Vulcanizing Process Cycle Types |
Conventional Vulcanizing Cycle
Vacuum/Steam Vulcanizing Cycle |
| Materials |
Carbon Steel
Stainless Steel |
| Maximum Working Diameter |
32 ft |
| Maximum Working Length |
200 ft |
| Maximum Operating Pressure |
3000 psi |
| Maximum Operating Temperature |
1500 ºF |
| Maximum Wall Thickness |
8 in |
| Pressurizing Medium |
Air
CO2
GN2 |
| Heating Methods |
Electric
Heat Transfer Fluid
Steam |
| Standard Features |
- Encapsulated blower motor eliminates the high maintenance necessary for through the vessel shaft sealing.
- Proprietary blower motor design allows operation at any combination of pressure and temperature.
- Engineered circulating fan assures excellent heat transfer to the load and exceptional temperature uniformity.
- Proprietary method of placing and securing insulation minimizes heat loss through the pressure vessel and minimizes operating costs.
- Location of typical electrical heating unit is shielded by cooling coil to prevent radiant heating of load.
- Cooling coil is a single pass heat exchanger designed for precise temperature control with ample provisions for thermal expansion to minimize thermally induced stresses and failure.
- "Man-Inside" emergency alarm cables are provided on larger autoclaves, which allows operator to completely disable all autoclave sub-systems. It requires autoclave door to be opened to reset the alarm.
- Load track and floor is designed to allow for thermal expansion yet provide full structural support.
- ASME approved safety relief valve and rupture disc are provided on separate vessel penetrations to assure independent and safe operation. Many other redundant safeties are incorporated to assure operator and equipment protection.
- Most vessel penetrations, such as vacuum, thermocouple and cooling are built into removable and replaceable ANSI flanges. This allows easy modification or repairs without compromising the structural integrity of the vessel.
|
| Harris Quick Opening Door Features |
- This proprietary breech lock door allows full and easy access to the autoclave interior within one minute after completion of a curing cycle.
- Safety is inherent in its design, but we also include mechanical, hydraulic, electrical, and pneumatic interlocks to prevent door operation while the autoclave is pressurized.
- No relative motion of the door with respect to the pressure seal provides long o-ring life.
- An oxygen sensor/fresh air purge safety interlock is available to prevent opening the door unless safe levels of oxygen are present. This complies with recent OSHA rulings.
|
| Autoclave Parts |
Blower Motor
Circulating Fan
Cooling Coil Heat Exchanger
Quick Opening Door
|
Rupture Disc
Safety Relief Valve
Shielded Electrical Heating Unit | |
Instrumentation Options
| Control Capabilities |
Multiple Equipment Computer Control Monitoring
Recording with Backup |
| Control Options |
Honeywell Computer Controls
Manual Controls
Network Compatible Computer-Based Control Systems
|
Programmable Microprocessor-Based Controls Systems
Set Point Controls | |
| Recording Options |
Circular Chart
Computer
|
Data Logger Recorder
Strip Chart | |
| Vacuum Control Types |
Automatic
Manual |
| Vacuum Monitoring Options |
Gauges
Transducers |
Auxiliary Systems
| Options Available |
Vacuum Pumps
Lift Tables
Bridges
Load Carts
|
External Cooling System
Bridge Mechanism
Oxygen Sensor/Air Purge/Safety Interlocks | |
| Process Controls |
Piping
Pumps
Related Safety Equipment
Valves |
| Safety Features |
'Operator-Inside' Alarms
Blower Motor Cooling Alarms
|
Door Safety Interlocks
Over-Pressure and Over-Temperature Protection Options | |
| Cooling Systems |
Cooling Towers
Pumps
|
Steam Separators
Storage Tanks | |
Capabilities
| Services |
Analysis of Equipment
Design and Engineering
Evaluation
Fabrication |
| Inspection
Installation
Non-Destructive Field Testing
Training for New Systems |
| Support Services |
Complete Turnkey Installation
Freight On Board (FOB) Factory Services
On Site Start-Up/Operation/Maintenance Training |
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www.melcosteel.com