Equipment for drying and hardening of ZBV, SmartSet, Kyiv

Equipment for drying and hardening of ZBV, SmartSet™

Advanced technologies of drying and hardening of ZBV:

Direct heating steam generators
Control and air supply systems
Spray and drying components
Furnaces, pipelines
Specialized technical team and service

At Afinitas, our mission is to provide manufacturers with all the tools and expertise they need to succeed. In many markets, the key to producing the highest quality concrete products is ensuring that they can be cured under controlled temperature and humidity conditions.

That is why we have developed our SmartSet™ hardening systems, which ensure proper hydration of cement and obtaining the strongest possible concrete.

Our SmartSet™ systems include:

Steam generators with direct heating, advanced and basic models
Furnace control systems
Air circulation systems and hoods
Installation and turnkey services
Fog-forming and dry burners
Drying systems
Installation of pipelines and equipment
Stoves
Modernization and Modernization
Troubleshooting and Preventive Maintenance
A large selection of spare parts
Special technical team and service car

We serve a wide range of clients and industries.

Whyonly steam generators with direct heating?

As energy costs continue to rise and profitability shrinks, precast manufacturers are looking for new ways to increase production efficiency. One of the main sources of energy consumption is the boiler, which supplies steam to the steaming zone. The steam generated by outdated boilers is literally throwing money to the wind and literally throwing it down the drain!

No more wasted energy! SmartSet™ combines direct heating with our unique combustion system, significantly reducing costs.

With SmartSet™ you will get:

Absence of losses during short-term burning.
Absence of unnecessary (and expensive) preheating of water
Lack of heating of excess water

Savings of funds

SmartSet™ produces steam directly after the combustion process, eliminating the need for boiler tubes and the associated high maintenance, insurance and inspection costs. There is no pressure vessel and there is no risk of pressure increase.

When replacing the boiler with a steam generator with direct heating, cost savings are felt immediately. Customers typically save up to 50% on their gas bills from day one.

Instant supply of steam at the right moment

SmartSet™ works automatically at the push of a button and produces the required amount of steam within seconds of activation. This quick start/stop is ideal for an efficient vulcanization system.

Compactness - ease of installation.

Our system is completely self-contained, allowing for easy installation. The set includes electrical disconnectors, gas and water regulators.

Also availablepump increase water pressure.

We also offer complete installation solutions, from CurePak to management and piping. All that is required is a simple connection to utility networks.

With SmartSet™ on, it instantly produces the steam you need to process with virtually 100% thermal efficiency. (The maximum efficiency of the boiler is 50%).

In the disabled state, it is disabled! Backup heating is not needed, energy is not wasted.
(//tractor-service.com)
Features of the system:

SmartSet™ is extremely versatile and can automatically produce steam at a wide range of temperatures, humidity and quantities to suit the manufacturer's changing production requirements and load needs.

Reliable work
Operators or automatic control systems constantly change the position of valves in steaming zones according to production requirements. This changes the load required by the steaming system. SmartSet™ automatically adjusts the steamer's burning intensity to efficiently steam your product and maintain the proper temperature regime. The system automatically adjusts the power of the burner to compensate for changes in water pressure at the inlet.

Automated temperature control
Accurate temperature control at the outlet of the SmartSet is critical for steaming a wide range of concrete products. Even a slight change in water flow leads to a significant change in the outlet temperature.

Our system automatically takes into account the reaction time of the thermocouple for changes in the output temperature. SmartSet™ also automatically compensates for any changes in inlet or supply water pressure.

Provides precise and effective quality control of curing steam
Prevents head loss caused by excess water, which is common in low-performance curing systems

Burner designed taking into account the features of the combustion process
The heart of the combustion system is a precision burner. The burner is designed to provide effective flame propagation and retention over a wide range of gas/air ratios and pipeline pressures. Thanks to this, the SmartSet™ starts and burns stably at different operating pressures.

Large combustion chamber
The combustion chamber ensures the three "T"s of proper combustion: Time, Temperature and Turbulence:

Large enough to allow time for combustion to complete before water is supplied.
Lining with fire-resistant material ensures the temperature of the flame for proper burning.
Creates the necessary turbulence for clean combustion.

Automatically adjustable water supply chamber
Water enters a separate chamber located below the combustion chamber. This eliminates any possibility of water coming into contact with the flame, which could lead to incomplete combustion and release of dangerous carbon monoxide. The adjustable automatically controlled water supply allows the operator to select and vary the steam temperature (from 80°C to 315°C) and humidity (from wet mist to dry steam) to ensure complete reliability according to any curing product.

Additional system characteristics:

AutoFog Control Panel

This control panel is designed to supply steam and maintain a set temperature in the oven, as well as to provide periodic misting. It also has logic for periodically controlling the misting system. It can perform any of these three functions in each PRE-SET or CURE cycle. The dual-set temperature controller displays and adjusts the oven temperature during each cycle when the steam option is selected. When selecting the "FOG" or "MIST" option, the on and delay time is programmed to achieve the desired humidity in the curing oven during winter or a hot summer day.

Circulation system:

Our revolutionary circulation system ensures an even circulation of heat and moisture throughout the oven, ensuring that each product is properly dried and achieves optimal strength. Accurate SmartSet™ outlet temperature control is essential for drying a wide range of concrete products. Even a slight change in water flow leads to a significant change in the outlet temperature.

Our control system automatically takes into account the reaction time of the thermocouple when the outlet temperature changes. The system also automatically compensates for changes in water pressure at the inlet or its supply. This exclusive outlet temperature control system provides precise control of the quality of the drying steam and prevents the heat loss caused by excess water, characteristic of drying systems with low outlet temperature.

Drying block systems:

If your customer needs a product classified as dry block, our drying system is what you need. The drying depth is determined by the drying time of the block. As a component of our drying system, this universal dryer allows you to achieve optimal surface dryness without reloading the unit into a separate drying system. In addition, our dryer can be used as a stand-alone system. It is ideal for the production of blocks that will be treated with an epoxy coating, providing a perfectly dry surface for optimal adhesion.

Spray system:

Our spray system keeps your product moist before curing. We offer different types of atomizers depending on the required degree of automation and ease of maintenance of your process. Our spray systems can also be used to independently control humidity and temperature.

Burner series A:

This unique curing system includes a wide range of solutions that can be adapted to any concrete product. We take our proven burner as a foundation and add components that best suit your product and curing requirements.

For example, our block production equipment is equipped with A-series burner, A-series evaporator, mist control system, circulation system and fogging system. It can also be fitted with an exhaust system to remove moisture from the furnace before it is opened to prevent it from entering your plant.

Our A series system can also be equipped with a furnace control panel. In summer or in desert climates, when curing requires less energy, you still need to maintain the required amount of moisture at a given stage.

Complex resource for hardening:

At Afinitas, we are committed to providing you with curing solutions that best suit your needs to produce strong, quality products with high efficiency and minimal downtime. Our trained technicians are available to assist on-site, over the phone or remotely, troubleshooting, repairing, installing, consulting and recommending the most efficient curing processes.

Technical support and training:

We are proud to have industry-leading curing experts on our team. They have many years of experience helping customers around the world find curing solutions. Whether you already have an existing system or are interested in a brand new system, you can count on their advice to keep your systems running safely and efficiently.

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