Modern vacuum technology increases energy efficiency during vulcanization

ContiTech Antriebssysteme GmbH (ContiTech Power Transmission Group) was able to significantly increase the energy efficiency of its vulcanization systems by using the latest vacuum technology for degassing the molds in vulcanization boilers.

ID: 1555356
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(businesspress24) - Previously, only liquid ring vacuum pumps were used in all systems

As a manufacturer of the entire spectrum of drive belts, ContiTech offers a comprehensive range of rubber belts used in practically all industrial applications. The belts are manufactured in vulcanization systems consisting of several autoclaves. Depending on the size of the vulcanization systems, one vacuum pump can be connected to one system or several systems can be supplied with vacuum simultaneously by a single vacuum pump. Operations are carried out in three shifts in batch mode. This means that the vacuum pumps are permanently in use around the clock.

Liquid ring vacuum pumps were originally used for degassing the rubber mass. Because the central cooling water network at ContiTech Antriebssysteme reached the limit of its capacity, Anja Horn, who is responsible for energy efficiency, analyzed the individual water consumers in the plant. On average, the liquid ring vacuum pumps consumed about seven cubic meters of water per hour. In addition, a container with a fresh water reservoir was installed on each vacuum pump. Due to rapid contamination, the water had to be replenished or replaced with fresh water on a regular basis. In addition to the high water consumption, the high water temperatures had a negative effect on the cycle and the supply. As a result of excessive water temperatures, the desired vacuum level of 200 millibar in the autoclaves could not always be achieved. The reason for this is that the vacuum to be achieved in a liquid ring vacuum pump depends, among other things, on the water temperature. Liquid ring vacuum pumps only reach their optimum vacuum level at a water temperature of 15

The liquid ring vacuum pumps used had a power consumption of six kilowatts each. As the vacuum pumps operated in three shifts seven days a week, each machine worked a total of 8,000 operating hours per year. This corresponded to 48,000 kilowatt hours per year.

Maintenance was looking for a technical solution to reduce both energy and water consumption. It was also important to improve reliability as much as possible. If, for example, a leak in the system caused vapor to enter a liquid ring vacuum pump, they reached their capacity limits and the vacuum level in the autoclaves deteriorated drastically. In the past, an average of one liquid ring vacuum pump per year had to be replaced because the vulcanization process caused deposits and corrosion in the vacuum pumps.

ContiTech found an alternative to its previous vacuum generation approach in the Mink claw vacuum pump from Busch. As early as 2017, a Mink claw vacuum pump was installed in a vulcanization system for test purposes as an alternative to a liquid ring vacuum pump. Mink claw vacuum pumps do not require water or any other operating fluid to generate vacuum. The reason for this is the completely contact-free operating principle, which enables dry compression, meaning compression without the use of operating fluids. For ContiTech Antriebssysteme, this meant no more costs for the operating fluid water and the associated operating costs such as refilling, replacing, treating and disposing the water.
Added to this are the savings in electricity costs. With nine kilowatts, the Mink claw vacuum pump has a larger motor than the liquid ring vacuum pump previously used. However, Mink''s variable speed drive adapts the motor frequency to the actual demand. In normal operation, the motor sometimes only runs at frequencies of around 30 Hertz. This means that it requires about three kilowatts at this frequency. However, if vapor is suddenly sucked in due to a leak, the Mink vacuum pump immediately increases its rotational speed and thus its pumping speed so that the required operating pressure of 200 millibar can always be maintained.
Thus, average power consumption can now be estimated at four kilowatts. Projected over one year, this corresponds to a consumption of 32,000 kilowatt hours. Compared to the previously used liquid ring vacuum pump, this is a reduction of 16,000 kilowatt hours per year. ContiTech Antriebssysteme GmbH tested the first Mink claw vacuum pump very carefully and analyzed its performance and energy costs precisely. Even before the end of the test phase, ContiTech had decided to purchase three more Mink claw vacuum pumps and operate them on vulcanization systems. The aim now is to gradually install Mink claw vacuum technology on all vulcanization systems in order to guarantee maximum reliability and efficiency in the future.

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Busch Vacuum Solutions is one of the world’s largest producers of vacuum pumps, vacuum systems, blowers and compressors.
Its extensive product portfolio comprises solutions for vacuum and overpressure applications in all industries, including the chemical, semiconductor, medical technology, plastics, and food sectors. It also covers the design and construction of customized vacuum systems, as well as a global service network.
The Busch group is a family-owned company and is still managed by the Busch family. Busch Vacuum Solutions has 3,500 employees in more than 60 companies in over 40 countries worldwide. Busch is headquartered in Maulburg, in southwest Germany. This is the location of Busch SE headquarters, as well as the German production facility and German sales company. In addition to Maulburg, Busch also has its own production plants in Switzerland, the UK, Czech Republic, Korea and the USA.

Busch Vacuum Solutions was founded by Dr.-Ing. Karl Busch and his wife Ayhan Busch in 1963. Dr.-Ing. Karl Busch developed the “HUCKEPACK”, which was the first vacuum pump that could be used for vacuum packaging of foodstuffs. The follow-up product, the compact “R5” rotary vane vacuum pump, revolutionized food packaging. A further milestone represented the development of the “COBRA” screw vacuum pump. In 1971 the international expansion of the Busch group started with the founding of a sales company in the UK. The first production plant outside Germany was established in the USA in 1979.

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Jasmin Markanic
Coordinator Global Press & Media Relations

+49 (0) 7622 681-3376

Busch Vacuum Solutions
Global Marketing / Marketing Services
Schauinslandstraße 1
79689 Maulburg, Germany

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published by: SabrinaHeinecke
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Date: 01/21/2020 - 04:14
Language: English
News-ID 1555356
Character count: 2295
Firma: Busch Vacuum Solutions
Ansprechpartner: Jasmin Markanic Feedback to about Pressrelease-id:
Stadt: Maulburg
Telefon: +49 7622 681-3376

Meldungsart: Success
Versandart: send
Freigabedatum: 21.01.2020

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