Why should the rubber tire industry use nitrogen generators?
The special nitrogen generators for the rubber and tire production industry are applicable to nitrogen protection during the vulcanization process, molding, and other fields. Especially in the production of all-steel radial tires, the new nitrogen vulcanization process has gradually replaced the steam vulcanization process. They have the characteristics of high nitrogen purity, continuous production, and higher nitrogen pressure.
The traditional domestic process uses hot water to shape and vulcanize tires. The so-called hot water vulcanization means that the shaping of the tires uses low-pressure steam, while during the positive vulcanization process, the medium in the capsule (similar to the function of a mold) is 170°C or higher high-pressure hot water, and the external temperature uses low-pressure steam for vulcanization.
While nitrogen vulcanization means that the shaping of the tires uses low-pressure nitrogen (0.4-0.5MPa), during the positive vulcanization process, the medium in the capsule is a mixture of high-pressure steam and high-pressure nitrogen (2.5MPa), and the external temperature uses low-pressure steam for vulcanization. Both methods utilize high temperature to change the chain-like molecular structure of natural rubber into a network structure, while closely combining the layer of the belt and forming patterns on the tread. In the performance indicators of tires such as mileage, durability, uniformity, and puncture resistance tests, nitrogen vulcanization has higher performance indicators than traditional hot water vulcanization.
The purchase cost of the nitrogen generator equipment can basically be recovered within one year and a half.
Nitrogen vulcanization means that the shaping of the tires uses low-pressure nitrogen (0.4-0.5MPa), during the positive vulcanization process, the medium in the capsule is a mixture of high-pressure steam and high-pressure nitrogen (2.5MPa), and the external temperature uses low-pressure steam for vulcanization. It utilizes high temperature to change the chain-like molecular structure of natural rubber into a network structure, while closely combining the layer of the belt and forming patterns on the tread. Nitrogen vulcanization has higher performance indicators than traditional hot water vulcanization in terms of mileage, durability, uniformity, and puncture resistance tests.
Ⅰ. Advantages of nitrogen generator nitrogen vulcanization for rubber tires:
1. The performance indicators of tires, such as mileage, durability, uniformity, and puncture resistance tests, are significantly better than traditional hot water vulcanization.
2. It effectively reduces equipment configuration and operation costs.
3. The process is simplified, and it overcomes the shortcomings of the traditional hot water vulcanization system being large, complex, and occupying a lot of space.
4. It solves the problem of difficult regulation of pressure and temperature in steam and hot water systems, making the vulcanization process stable and significantly reducing the phenomena of rubber shortage, delamination, and bubbles during tire vulcanization.
5. The performance of nitrogen is stable, with excellent heat insulation properties, greatly improving the phenomenon of severe heat loss in hot water vulcanization and saving energy.
6. The high-purity nitrogen eliminates the early sulfidation phenomenon of the capsule and increases the average lifespan of the capsule by 10%.
7. It eliminates the large amount of steam used for heating hot water, reducing the necessary investment in public engineering to meet the process requirements.
8. It reduces water, electricity consumption, and eliminates leakage, dripping, and running phenomena, meeting the requirements of environmental protection operation.
Ⅱ. Superiority of nitrogen generator tire nitrogen filling
Compared with tires filled with air, filling dry and low-oxygen nitrogen will stabilize the tire pressure, significantly reduce the chance of tire blowouts, and improve the safety of high-speed driving.
A. Reducing the chance of blowouts and improving driving safety
1. Nitrogen is an inert gas, avoiding the oxidation of the rim and tire cord layer.
2. The speed at which nitrogen fills the tire wall is only 1/6 of oxygen, so nitrogen-filled tires have a strong pressure retention ability, do not need to frequently add air, and save fuel by reducing friction.
3. For tireless with an inner tube, filling dry nitrogen avoids the corrosion of the rim by water vapor and high oxygen content.
B. Extending the lifespan of tires
1. Nitrogen-filled tires can maintain a stable pressure for a long time, extending the lifespan of the tires.
2. The inner cavity of tires filled with ordinary air has a high content of oxygen and water. Oxygen gradually penetrates from the inner cavity of the tire to the deeper part of the tire wall. Oxygen molecules react chemically with the unsaturated molecules in the rubber, causing rubber aging and eventually leading to tire failure. In contrast, tires filled with nitrogen have a nitrogen concentration of at least 95%, and the oxygen content in the tires is relatively low. Nitrogen can protect the rubber from aging, thereby extending the service life of the tires.
3. The compressed air used for filling ordinary tires contains a certain amount of oil, pollution, and gradually swells the inner tube, reducing its service life. Drying filling can extend the service life of the tires. C. Reducing abnormal tire deformation and saving additional fuel consumption
The leakage of air pressure inside the tire leads to an increase in the additional deformation of the tire, an increase in rolling resistance, and a subsequent increase in fuel consumption. Nitrogen-filled tires, due to their stable tire pressure over a long period, reduce the abnormal deformation of the tires during use, lower the fuel consumption of the vehicle, save exhaust emissions, and protect the environment.
