Rubber Tire Industry Gas Detection Solutions: Nexisense Ensures Vulcanization and Mixing Safety

Rubber tire manufacturing is a typical chemical-mechanical composite process, involving natural and synthetic rubber mixing, extrusion, cord lamination, and vulcanization. Raw materials such as natural rubber, synthetic rubber, carbon black, accelerators, antioxidants, solvents, and vulcanization chemicals release hazardous gases: acetylene (C₂H₂), methane (CH₄), benzene compounds (benzene, toluene, ethylbenzene, xylene), gasoline/ethanol vapors, TVOC, hydrogen sulfide (H₂S), carbon monoxide (CO), etc. These gases are more reactive at high vulcanization temperatures (140-180℃), and even small leaks can form explosive mixtures or cause acute/chronic poisoning.

According to the "Tire Industry Safety Technical Specification" (AQ 4270) and GB 50016 "Code for Fire Protection Design of Buildings," high-risk areas such as vulcanization workshops, mixing zones, and solvent recovery areas must have fixed gas detection and alarm systems for continuous monitoring, automatic alarm upon threshold exceedance, and interlocked control. Nexisense provides high-precision, high-temperature-resistant online detection solutions to create a protective network at key points such as vulcanization tanks, mixers, and exhaust systems, ensuring personnel safety, equipment stability, and continuous production.

Gas Risk Analysis in Rubber Tire Production

• Vulcanization Stage: High-temperature accelerators release H₂S, CS₂, SO₂; sulfur volatilization and reactions with organics produce benzene compounds and TVOC.

• Mixing & Extrusion: Carbon black dust adsorbs solvents; stirring generates gasoline/ethanol/toluene vapors; acetylene leaks during cutting or welding.

• High-Temperature Characteristics: 140-180℃ accelerates gas volatilization and diffusion; ordinary sensors may drift or fail.

• Multiple Sources: Concurrent equipment causes cross-interference, creating localized high concentration zones.

Early leaks are often odorless, making traditional inspections insufficient. Effective monitoring can intervene at 10-20% LEL or occupational exposure limits, activating ventilation, heating shutdown, or sprinklers, greatly reducing fire, explosion, and health risks.

How to Choose Rubber Tire Gas Detection Equipment

• Target Gases & Ranges: Acetylene 0-100ppm toxicity-priority; benzene compounds/TVOC 0-100/500ppm; combustible gases 0-100%LEL; H₂S/CO 0-50/100ppm.

• Temperature Resistance: Vulcanization zones require high-temperature probes (800℃) with cooling pretreatment; diffusion sensors sufficient for normal zones.

• Sensor Principles: Electrochemical (H₂S, CO, benzene compounds, high sensitivity); Catalytic combustion/IR (combustible gases, anti-poisoning).

• Explosion Protection: Ex d IIC T6 Gb, IP65+, resistant to oil mist and carbon black dust.

• System Compatibility: 4-20mA/RS485 Modbus RTU output; supports PLC/DCS integration and alarm controller linkage.

Nexisense Core Products

SGA-500 Series Online Fixed Gas Detector
24V power, ready to use, real-time LCD display, automatic audible/visual alarm and relay output. Supports single or multi-gas configurations covering acetylene, benzene compounds, TVOC, H₂S, etc.

• High precision, fast response, suitable for mixing and vulcanization zones.

• Multiple outputs for PLC/DCS integration.

• Aluminum alloy explosion-proof housing, corrosion and dust resistant.

  
  

High-Temperature Sampling Probes & System Integration

SGA-GWTG series probes withstand 800℃, combined with explosion-proof vacuum pumps for high-temperature gas sampling in vulcanization tanks/ducts. After dust removal and cooling, gases enter detectors. Multi-gas systems integrate combustible and toxic gases, linked with SGA-800 controllers for centralized monitoring and automatic ventilation/shut-off.

Extensions include portable inspection instruments (workshop checks) and online exhaust monitoring systems (emission compliance).

Installation Guidelines

• Heavier-than-air gases (benzene compounds, H₂S, gasoline vapors): 30-60cm below leak source.

• Lighter-than-air gases (NH₃, CH₄, acetylene): above or 30-60cm below the highest point.

• Horizontal distance: toxic gases ≤1m, combustible gases ≤7.5m.

• High-temperature zones: probes inserted into tanks/ducts, detector body in normal-temperature area.

• Wiring: shielded cable connected to S+/V+/V- terminals; avoid high heat and vibration zones.

Proper installation ensures rapid detection of leaks, maximizing emergency response time.

Typical Applications

• Vulcanization workshop: monitor acetylene/H₂S/benzene compounds, linked to exhaust and heating cut-off.

• Mixing zone: multi-gas detection for TVOC/gasoline vapors, preventing solvent poisoning.

• Exhaust system: high-temperature probes + online systems monitor emissions for compliance.

• Cutting/welding stations: portable acetylene inspections, explosion-proof safety.

  
  

Frequently Asked Questions (FAQ)

1. Gases monitored by SGA-500: acetylene (0-100ppm toxicity-priority), benzene compounds (0-100ppm), TVOC (0-500ppm), methane (0-100%LEL), H₂S (0-50ppm), CO (0-1000ppm). Acetylene is monitored for toxicity first to ensure alarms >10ppm.

2. Explosion protection and suitability for high-temperature/dust environments: Ex d IIC T6 Gb, aluminum alloy IP65+, resistant to carbon black dust, oil mist, and acidic corrosion. Suitable for Zone 1/2 vulcanization areas; probe in high temp, detector in normal temp.

3. High-temp tank sampling and probe installation: SGA-GWTG probes up to 800℃, mounted via threaded ports, inserted into central airflow; vacuum pump draws sample, filtered and cooled. Clean filters regularly.

4. Sensor lifespan and calibration in high-temp environments: Electrochemical 2-3 years, catalytic/IR 3-5 years. 6-month function check, annual zero & span calibration; self-diagnosis alerts in advance.

5. Installation in mixing and vulcanization zones: heavy gases 30-60cm below, light gases above; horizontal ≤1m (toxic)/7.5m (combustible). Shielded cables, avoid dust/solvent splashes, controller wiring per point, height considers breathing zone and gas accumulation.

6. Multi-level alarms and interlocks: 3 levels—ventilation, heating/feed cut-off, sprinklers+evacuation. Controller relays programmable; RS485/4-20mA to PLC/DCS for trend analysis and remote monitoring.

7. Emission and multi-parameter monitoring extensions: SGA-900 multi-gas + particulates, multi-gas instruments integrate combustible + toxic + TVOC, portable SGA-600 for inspection, wireless HJ212 environmental network compliance.

8. How to obtain custom solutions, manuals, or project cases: submit process, target gases, layout, point count; 24h response with selection table, manuals, examples, 3D models. Standard products 1-3 workdays, custom high-temp systems 5-10 workdays.

Conclusion: Nexisense Protects Every Aspect of Rubber Tire Production

Safety in rubber tire production is essential for product quality and sustainable operations. Nexisense provides high-precision sensors, high-temp probes, and flexible system integration for vulcanization, mixing, and exhaust stages, effectively preventing risks from acetylene, benzene compounds, TVOC, ensuring safe production and efficient operations. Contact Nexisense for custom solutions, site surveys, and technical support. Safe manufacturing starts with precise early warning.