Applications - Industrial - Rolls

O-Rings / Oil Field / Rolls / Seals

Description

Elastomeric roll coverings are found in a wide range of industries. Elastomers from ZEON Chemicals are used in rolls for graphic arts, steel processing, pulp and paper milling, textile manufacturing and many other material handling applications.

Environment

The service environment a roll may encounter depends on the industry served. Fluid exposure ranges from hydrocarbon and water based inks in graphic arts applications to extremely acidic or alkaline solutions used in steel processing.

Fluid resistance requirements, service temperature and pressure, and the type of material being processed have a significant impact on the polymer selection and rubber compound design. Roll hardness and abrasion resistance are two key properties that will vary based on service conditions. In low pressure applications such as printing, softer (low durometer) stocks are used to form the roll cover. Higher durometer compounds with exceptional abrasion resistance are required for high pressure / high heat applications where hard, abrasive materials such as wood pulp or steel are conveyed.

Recommended Polymers

Nipol/Sivic Polyblends And Pre-Plasticized Nitrile Elastomers
Nipol Carboxylated Nitrile Elastomers
Zetpol HNBr

Additional Application - End Cap Seals

Description

End caps protect the roll core from exposure to the various service fluids. The seal compound should be formulated to match the fluid and abrasion resistance requirements of the roll cover. Seals are typically compression molded and must have low compression set.

Environment

End cap seals may encounter a broad range of fluids depending on the roll application. The seal compound should be designed to withstand the same fluids as the corresponding roll cover. Fluid exposure ranges from hydrocarbon and water based inks in graphic arts applications to extremely acidic or alkaline solutions used in steel processing. In addition to fluid resistance properties, the seal compound should be injection or compression moldable and exhibit low compression set.

Recommended Polymers

Nipol NBR

Additional Application - Graphic Arts

Description

There are four main types of printing processes in the graphic arts industry that require different types of roll compounds. The four types are:

  1. Letterpress - printing from a raised surface
  2. Offset/Lithography - printing from a flat surface
  3. Gravure - printing from a sunken surface
  4. Flexography - printing from flexible plates

Each type of printing process presents a diffent service environment dictating variations in compound formulation.

Environment

All four of the main types of printing require resistance to solvents and heat build-up. The demands for increased press productivity dictate increased press speeds and faster drying inks. The consequences of this include greater heat build-up on the roll and the use of more powerfull wash solvents. NBR has found a place of prominence among several elastomers serving this industry owing to the inherent chemical resistance and hysteresis properties.

Recommended Polymers

Nipol NBR

Additional Application - Industrial

Description

The general category of industrial rollers encompasses a broad range of applications and service conditions. Some examples include:

  • Agricultural (grain or nut hullers)
  • Timber (log or lumber conveyors)
  • Glass Processing (glass washing)
  • Mining (raw ore conveyors)

There are a host of other applications where NBR elastomers are well suited.

Environment

Most industrial rolls require varying degrees of abrasion, heat, chemical, and fluid resistance. In agricultural applications, such as the removal of hulls from grain or nuts, the rolls may require a high degree of abrasion resistance while withstanding exposure to natural oils that are contained in the processed natural product. Much the same would be true for timber processing.

Glass washing machines mark another challenge to the rubber roll compound. This application requires good abrasion, heat, and water resistance. Enhanced chemical resistance should also be factored into compound design depending on the type of chemical treatment the glass will experience prior to washing.

Mining (ore processing) applications present further environmental challenges. Rollers and belts used in mining service must have high abrasion, heat, and water/chemical resistance. As raw ore is conveyed, the washing process exposes the rubber compounds to hot, aqueous solutions of varying pH. Good low temperature properties may also be a factor when equipment may be exposed to variable weather conditions.

Recommended Polymers

Nipol NBR

Additional Application - Paper

Description

In the pulp and paper industry, NBR roll covers are used for a wide range of functions. At the onset of the paper manufacturing process, raw timber is chemically converted to pulp through an aqueous digesting process. The wet pulp is squeezed through rollers that must withstand heat build-up, sudden torque changes, and exposure to digesting chemicals of varying pH and composition. Some typical roll types that are used to convert wet pulp into the final paper product include:

  • Forming rolls
  • Suction rolls
  • Couch rolls
  • Breaker rolls
  • Press rolls
  • Calender gloss rolls

Forming and suction rolls form the pulp into sheets, breaker and press rolls remove excess water, while calender rolls and others types may be used to add texture, coating, and finish. NBR based compounds are often found in any of these types depending on the actual service conditions.

Environment

Typical service requirements and environmental conditions of various pulp and paper rollers are summarized below:

Formers, suction, and couch rolls: wet environment requiring chemical and abrasion resistance; low operating pressure.

Breaker and press rolls: wet environment at elevated temperatures (~100°C) and high pressure; good abrasion, high heat, water and chemical resistance is required.

Calender and other finishing rolls: dry process at low pressure; typically high hardness and textured to provide final surface characteristics.

Recommended Polymers

Nipol NBR

Additional Application - Steel

Description

In the steel processing industry, rubber rollers perform very basic functions such as material conveyance and very demanding services such as buffing, polishing, and coating. NBR elastomers from Zeon are available for rollers serving most steel processing applications.

Environment

Environments in the steel industry are the most severe, particularly in terms of chemical exposure. Highly acidic fluids are used for cleaning and pickling. Other fluids, particularly in plating applications are highly corrosive. Processing oils are often used requiring oil resistant polymers. High temperature service can be taken to extremes. Very heavy loads are often conveyed and very high pressures are often applied.

Recommended Polymers

Nipol NBR

Additional Application - Textile

Description

In the textile industry, rollers are used to convey woven and non-woven fabrics. Carrying rolls convey fabrics through the washing process and pad rolls are used to apply dyes and other chemical treatments.

Environment

Chemical and heat resistance are two key properties in this type of roll application. The demand for abrasion resistance is not as severe as in other material handling applications, but remains a significant factor. Carrying or web rollers should be formulated to withstand high temperature aqueous and organic washing fluids. Highly acidic or basic fluids as well as chlorinated solvents may be used depending on the type of fabric. Pad rollers may be used to apply dyes or other fluids and may also be used to remove excess oils, acids, or bases before final drying.

Recommended Polymers

Nipol NBR

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