High Speed Customizd Hot Dip Galvanizing Line Tube Production Line

hot dip galvanized tube production line Hot Dip Galvanizing Line

• 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)

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.

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

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. Equipment base corrosion
Flux processing system ground anti-corrosion, pretreatment tank foundation ground anti-corrosion, cooling and passivation tank ground anti-corrosion.
Anti-corrosion: Apply 5 mm FRP on surface of concrete structure
3) Zinc pot and heating control system
1. Zinc pot and heating system:
1.1 Zinc pot
According to the geometry size and output demands of workpiece galvanized, the size of galvanizing tank(length ×width ×depth ×thickness): 4000×1000×1000×300 , high temperature resistance castable once casting to form zinc pot, capacity is about 18t, round bottom. Its guarantee period is 4 years, normal use

1.2 Zinc tank heating equipment: to satisfied to production re quirement and consider molten zinc speed, is loading about 324KW by calculated. The equipment is adopting galvanizing spec ial heating rod made by international advanced silicon carbide rod, high hot efficiency, long servicing life, completely replace outdated quartz tube protection cover resistance wire heating. Each heater power is 18KW,380V, Y connection, total 18 groups. Each heater use SSR module, intelligent instrument control temperature by automatic accommodation. High controlling precise, trouble-free, maintenance-free.

1.3 Flux tank heating
The inner circulation electric heating system.
Specifications and technical 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

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.

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.

Wuxi CMC machinery Co., Ltd. is located in wuxi, Jiangsu province, near Shanghai, which is specializing in designing, manufacturering, sales and service of light pole machines.

Our company has own unique technology and good customer base in the development and production of light pole machines complete line. Our main products include cut to length line, CNC tandem hydraulic press brake, base plate welding machine, CNC light pole door cutting machine, high mast assembly & straightening machine, CNC portable flame cutting machine, gantry type welding machine for high mast, steel plate slitting machine, light pole shut-welding machine, hot dip galvanizing equipment and so on.

Our self-developed cut to length line, output from steel coil to isosceles trapezoidal plate directly. It has high automation, fast speed, and obtained the national new practical patent. Based on CNC tandem hydraulic press brake, we have made many improvements, making the machine especially suitable for the rapid and efficient production of light poles. To meet customers’ demands, we developed CNC light pole door cutting machine, base plate welding machine, automatic double / four head drilling machine, high mast automatic welding machine, etc.. we continuously optimize and improve our products to meet the light pole industry. It greatly changes the situation of manual work and improve the quality and efficiency of light pole production.    

More than 80% of our products are exported to overseas markets, such as Thailand, Malaysia, India, the United States, Mexico, Brazil, Russia, Latvia, kazakhstan, Algeria, Egypt, Ethiopia, the Middle East, etc.

Our engineers have rich experience in installation and commissioning abroad, good skills in English communication, technical skill and remote service ability to solve problems.

After years of running, we have become a team with innovative working habits, close cooperation with each other, holding the key technology of light pole machines, growing up to a 100% trustworthy team.

More than light pole machine produciton, we also set up a joint venture named Jiangsu XinLingYu Intelligent Technology Co., Ltd. in Xuzhou city, Jiangsu province in 2017 year. It fabricates hot dip galvanizing line/equipments, can meet customers' requirements of anti-corrosion treatment for light pole and high mast pole. Based on years of experience and knowledge of the original hot-dip galvanizing, we continue to develop and innovate the HDG process. It has reached a very advanced technical level. We have supplied both light pole machines / lines and hot-dip galvanizing lines to multiple customers.

At present, our company runs very stably, has good financial condition and step in a strong growth period.

We hope to establish a good relationship with more customers, develop and make progress synchronous.