Project Showcase: Steam Drying Automation at the Z21 Sensitive Production Facility

The Rigorous Drying Challenge in a Sensitive Production Environment

In the production of highly sensitive materials (such as the Z21 explosive manufacturing room), the product drying phase is a "life-or-death" process. Using standard glowing electrical resistance heaters is absolutely prohibited due to the severe risks of sparking and localized thermal overshooting. Instead, the mandatory and safest solution is to utilize a Steam Heater system.

To fully automate this complex procedure, DeAir directly designed, programmed, and successfully handed over 02 custom-built industrial control panels. The unique aspect of this project showcase is that both electrical panels were installed directly inside the production room, demanding absolute perfection in hardware sealing and programming logic.

1. Safety Through an In-Depth Control "Brain" (Process Safety)

Unlike high-pressure gas areas that require cast explosion-proof (Ex-proof) enclosures, the challenge at the Z21 drying room places heavy emphasis on Process Safety. The absolute safety of this project was established by the DeAir team based on two core factors:

• Enclosure Standard: Although placed directly inside the production room, the two electrical panels are fabricated with thick electrostatic-painted steel and equipped with technical rubber gaskets meeting IP65 protection standards (IEC 60529). This design hermetically seals the circuit boards, 100% preventing product dust particles from infiltrating and causing short circuits, while also withstanding the high-humidity environment.
• Fail-safe Logic: The electrical panel acts as the "brain," while the actual heat source is steam. Precise PLC programming ensures the drying process occurs gradually and linearly. The system completely eliminates the risk of excessive heat supply (overshooting), which could jeopardize the chemical structure of the Z21 product.

2. 2 Key Automation Functions of DeAir's Electrical Panels

The two in-room panels have clearly divided tasks, coordinating seamlessly to create a flawless drying cycle:

Function 1: Linear Control of the Steam Heater Valve

The control panel continuously collects data from PT100 air temperature sensors located in the room. Through a PID algorithm programmed into the PLC, the system calculates and automatically regulates the opening degree of the steam supply valve. As the room temperature approaches the Set-point, the valve automatically begins to close gradually. This keeps the temperature maintained on an ideal static line, completely free from thermal shock fluctuations.

Function 2: Smart Dual-Condition Moisture Exhaust (AND Logic)

During the drying process, water evaporates from the Z21 material, causing the room's humidity to spike. However, if the exhaust fan runs continuously, the room will lose heat, wasting expensive steam. DeAir engineers established a dual-activation condition (AND Logic):

• The control panel only commands the exhaust fan to turn on when the environment simultaneously satisfies two factors: (1) The room temperature has reached the required drying level AND (2) The room humidity exceeds the permitted threshold.
• As soon as the excess moisture is vented out and the humidity returns to a safe level, the fan automatically shuts off to continue incubating the batch.

3. Infographic: Operating Principle of the Z21 Steam Drying System

4. The "Non-Standard" Customization Capability of DeAir Engineers

Designing two independent electrical panels placed right inside the drying room provides an incredibly convenient operating experience. Technical workers can easily monitor parameters on the screen and adjust operations on the spot without having to run outside the workshop, ensuring a rapid response to any situation.

The Z21 drying room project is the clearest testament to DeAir's deep understanding of technological processes. We do not force our clients to use cookie-cutter, off-the-shelf control panels. Instead, DeAir's Automation engineering team is always ready to tailor-make, design schematics, and program logic from scratch to meet 100% of the investor's highly specific and sensitive requirements.

Conclusion: With a profound mastery of Mechanical, Thermal, and Electrical engineering, DeAir's control panel ecosystem delivers absolute precision, guarantees life-critical safety, and optimizes productivity for even the most sensitive industrial production lines.

Industry Literature & Standards References:
[1] IEC 60529 (Equivalent to TCVN 4255:2008) - Degrees of Protection Provided by Enclosures (IP Code).