Continuous Hot Dip Galvanizing Production Line Hot Dip Galvanizing Line For HRC Pipe

Continuous Hot Dip Galvanizing Production Line Hot Dip Galvanizing Line

Hot dipped galvanized wire production line can realize the production of ordinary zinc, high zinc, zinc aluminum alloy wire, low carbon steel wire and high carbon steel wire on the same production line and the wire diameter is usually 1.6-4.5 mm.

Ⅳ.Technological process
1.Hot dip galvanizing technological process
2. Fully automatic operation process action

2.1 operating manual crane to loading position,and manually hang in group, signal when completion;

2.2 pre-treatment full automatic roller galvanizing equipment lift workpiece into degreasing tank, rinsing tank, acid tank and fluxing tank successively, then put into unloading area;

2.3workiece in unloading area enter into loading basket after be leaded into drying passage by auxiliary material, workpiece is lifted by unloading machine into zinc liquid;

2.4 immersing into zinc liquid through immersing zinc system, lifted by centrifuge and centrifuge after satisfy immersing time and then move to unloading area;

2.5 pour workpiece into blasting zinc, cooling and passivation;
2.6 finally pour into discharge conveyor belt, storage after testing.

Ⅴ.Production line basic equipment, performance and parameters

1)Automatic running transmission system

1. The equipment performance and component configuration

1.1 gantry type automatic travelling craneThe travelling crane is in the pretreatment seal room, travelling between both sides of tank.

Equipment parameters:

①main engine: L31m(two rails length)*W2.3(two rails center distance)*H4.5m(the surrounding auxiliary facilities)

②gantry type middle rail single pole pickling crane: 1set, level travelling V=6-15m/min(frequency control), lifting operation V=5-15m/min(frequency control), lifting height is 3200mm, lifting quality≤1000kg(contain pole, rack and piece weight)

③running pitch time:10min(above 10min can adjust)

④lifting height of material loading erector is 1m

1.2 auxiliary material trolley and drying gallery:

Size:6500mmx700mm

Power:18KW

1.3 discharging conveyor

Size:3000mmx700mm

Power:12KW

2) equipment, facility corrosion prevention.

1. tank anti-corrosion:
Tank structure: make concrete foundation on the ground and preset anchoring strengthen for external use.
Tank parameters:

2. Weighing system:
Automatic control, the maximum is 100kg/basket, precision is ±2kg
3. The system of putting into pot
Whole equipment, record the into pot time, 1 basket/min(under immersing time allows premise)
4. Immersing system in the pot:
Transmission equipment, control immersing time according to production beat.
5. Out of pot centrifuge system
Whole equipment, automatic control, with auto centrifuge function
6. Galvanizing basket turnaround system:
Control turnaround of basket according to beat automatically
Above total power is 20KW
4) Post-treatment:
1. Blasting zinc system:
Loading and unloading material automatically, power is 2KW
2. Cooling system:
Loading and unloading material automatically, power is 2KW
3. Passivation system:
Loading and unloading material automatically, power is 2KW
4. Spin-drying system:
Loading and unloading material automatically, power is 5KW

Ⅵ.Environmental protection equipments(Zinc dust,waste water and waste acid)
1. Hydrochloric acid mist and exhaust gas treatment system
Hydrochloric acid mist i mainly from the acid washing tank and flux tank vapor, is mixture of acid mist and steam.
1.1Technology design

Acid mist absorption process flow diagram
1.2 device description:
1.2.1 acid fog sealed room:size is about 16500*2500*3000mm

Ⅰ.Production line technology key points:
The project is consist of three system, is automatic hot dip galvanizing, environmental control system, logistical system, total project is based on environmental protection, energy saving and reduce manpower.
Key technology:
1.A project of fully automatic environmental protection hot galvanizing production line
2. Auto logistical control system, can go on real time adjustment according to production beat, use resource efficiently.
3. furnace adopts clean energy to heat zinc pot, furnace temperature automatic control, prolong the service life of zinc pot
4.All waste gas collection closed, centralized treatment and discharging standard, zero emission.

Ⅱ. technical parameters
1. Zinc pot size:non-ferrous pot, ceramic pot 4×1×1m, capacity is about 26t.
2. Output:1000t/year
3. Type of heating: electrical heating
4.Work shift: 3 shift(8 hours/shift, year working time 300 days,3 shifts,day working time 20h)
5.Layout:loop shape,three across span is 6.5m, length is 36.4m,details in layout plan.
6. Electric and water
6.1 The max power of electrical equipments is about 500Kw.
6.2 In average 1ton production need 0.01m³ water, the pressure can't lower than 0.2MPa.
6.3 The PH level of water is 6.5 to 8, tap water, river water or well water is adoptable,mainly for supplementing consumption during production.
7. Environmental protection treatment system:waste gas and waster solid treatment for producing healthily.
8. Compressed air: bleed pressure 0.6Mp/cm², air demand 6m³/h.

Sealed room structure: Stick profiling synthetic resin plate on the steel structural frame,can realize anti-corrosion more than twenty years, is custom-made sealed room plate only in our company. Insert transparent window on the sealed room wall, it is benefit workers who are on the steel structure platform to observe and operate working condition. Install flue on one side of acid tank wall and the distance to ground is 2.5m high, suction acid fog to acid fog scrubbing tower by induced draft fan.

1.2.2Purification tower design parameters:

The acid mist flue acid mist washing tower in closed indoor treat acid fog produced pickling. 3 sets of collection system collect production of acid mist according to the actual capacity of the facilities, again through the alkali liquor spray and purifying washing system to purify it.

a.glass fiber reinforced plastic centrifugal fan

blast capacity: 13000m3/h

wind pressure:2600pa

rate of work:15kw

b.the tank to purify acid mist

Equipment appearance: Φ1.8m ×5.1m

Material : pp

Processing volume: 18000 m3 / h empty tower wind speed: 1.5 m/s

Spray layer: 2 levels contact time: total resistance: 10 s

Purification tower : 900 Pa

Raschig ring, pall ring filler height: 500 mm (3 levels)

gas liquid ratio: 500:1

c.circulating pump

Flow:25 m3 / h

Lift:24m power:15KW(3sets)

1.3 Effect prediction

Initial concentration of acid mist is about 43 mg/m3, after cover closed trap into the water spray absorber, hydrochloric acid mist purification efficiency is about 95%, after spray absorption of exhaust gas into the atmosphere.

2. Zinc dust processing system

Governance 2.1process

2.2.Process description:

use fan extracting dust from sealed room to bag filter and then through the barrier of tower and the hollow ball to increase the treatment surface area, adopt atomized spraying wahout and filter the harmful particle ,reaching purify effect

2.3 Equipment introduction:
2.3.1 smoke sealed room in production line : 1 set(8000*3700*3000mm)

Both sides of sealed set entrance and exit in advance, Stick the corrosion resistant plate on steel structure, install Windows on both sides, can observe the conditions of sealed room.Cooling water sealed the same, in order to prevent moisture evaporation caused erosion of equipment.

2.3.2 off-line pulse-jet bag dust collector

Parameters:

Deposing air volume:7200m³/h filter area:120㎡

Filter rate:1m/min Facility resistance:1200-1500Pa

Facility sustained negative pressure:5000Pa

2.3.3 Induced draft fan

Choose induced high temperature resistance centrifugal fan, 1 set, rate of work is 11 KW, handling capacity: 7200m³/h.

2.3.4 Air hose: according structure of the factory building to determine (refer to process layout )

2.3.5.After processing ,the dust concentration (powder) ≤120mg/m³

Ⅶ. Electrical design

1.project adopts TN - C - S electric control system .
2.adopt good grounding design, with electric protection measures such as short-circuit, overload, leakage.The design principle wire separately heavy current and weak current.
3.start, stop, control, and at the same time have current, voltage, running, stop instructions.
4.heat-resisting cable.

Ⅷ.Technology service

1.Provide design plan for hot galvanizing: technology diagram for hot galvanizing except workshop.

2.Provide material,equipment,electricity design,manufacturing, install and construction for the whole productionline. Work-shop and public equipments are excluded.

3.Providing debugging overall in productionline and people training.

Ⅲ. System layout
1. Layout description
1.1Considering rationality of each hot dip galvanizing tanks and loading&unloading workpiece,the whole productionline adopts 1 across,6.5m,factory layout.Loading*unloading in one across,raw material&finished products and across connection in one across,primary hot dip galvanizing equipments in one across.(details in CAD)
1.2 Manaully loading and unloading workpiece, other operation all run automaticlly.
1.3 All automatic equipments are set hand/automatic operation.
2. Plane layout diagram

Jiangsu XinLingYu Intelligent Technology Co., Ltd. is a professional company which is engaged in intelligent hot dip galvanizing technology research and output of services. We provide consultings including project research, planning, energy saving evaluation, EIA; provide technical services including plant layout, processing, production management, and provide services including equipment design & manufacturing, installation and commissioning. Our main products: acid mist recycling system, zinc smoke collection and treatment equipment, waste acid recycling system, flux recycling and reusing system, galvanizing line automatic transportation equipments, waste heat utilization system, energy saving and environmental protection type biomass combustion furnace.

Our co-founders are experts who has 20 years of practical experience in hot dip galvanizing, 10 years of experience in chemistry, 10 years of experience of intelligent manufacturing. Combined with their experience and knowledge, relying on our two leading galvanizing plants, we develop intelligent hot dip galvanizing line which subverts existing production mode. Many of our independent R&D products have been declared the national patent.