Cooling System for Rubber Extrusion Lines

DESCRIPTION:

Eltrex served as the general contractor for the installation of a new cooling system for seven rubber extrusion lines in a tire manufacturing plant. The project focused on enhancing energy efficiency by implementing a system that operates in different modes depending on the season:

Winter: The system utilized free cooling mode where the heating agent was cooled using a cooling tower in a closed circuit.

Summer: The heating agent was cooled using a 910 kW chiller.

INDUSTRY:

Tire Manufacturing

FOCUS:

The primary challenge was designing an energy-efficient cooling system that could adapt to seasonal temperature variations while ensuring seamless integration with the existing local automation systems.

OBJECTIVE:

The objective was to deliver a fully functional and energy-efficient cooling system for the rubber extrusion lines, capable of operating in different modes for optimal performance throughout the year.

SOLUTION:

  • Siemens S7 1515-2 PN PLC for the main MCC panel.
  • Siemens TP1900 Comfort HMI for operator interface.
  • Siemens G120C Frequency Inverters for motor control.
  • Schneider protection devices for electrical safety.
  • Phoenix Contact switches and power supplies for reliable electrical connections.
  • Siemens S7 1214C PLCs for local automation panels.
  • WinCC SCADA for supervisory control and data acquisition.

PROJECT DURATION:

8 months

SCOPE OF WORK:

Electrical Design:

  • 1 MCC panel with S7 1515-2 PN PLC, TP1900 Comfort HMI, Siemens G120C Frequency Inverters, Schneider protection devices, Phoenix Contact switches, and power supplies.
  • 6 local automation panels featuring S7 1214C PLCs and Schneider protection devices.
  • Creation of a block diagram for the entire automation system.
  • Detailed electrical installation plans, including cable trays and fiber optic routes.

Automation:

  • PLC software development.
  • Configuration and commissioning of frequency inverters.
  • HMI software development.
  • Development and integration of WinCC SCADA software.
  • Interfacing the system with the local automation of all six extrusion lines via digital IO and Profinet.

Installation:

  • Complete electrical installation, cabinet manufacturing, and commissioning performed by Eltrex teams.