Structural Components Hot Dip Galvanizing Production Line

Name: Material Transfer Rail Cart

Specification: The equipment is customized according to the product type and load capacity required by the user.

Overview:

This transfer cart is suitable for handling hot-dip galvanized structural components, power fittings, steel pipes, profiles, and similar materials, with a load capacity ranging from 1 to 16 tons. The cart can be powered via cable or wireless power supply. Control options include a fixed control panel or remote control operation.

The cart features a welded steel structure with a surface coated in anti-corrosion resin paint. The drive system consists of an electric motor and a reduction gearbox.

Name: Loading and Unloading Rack

Specification: The equipment is customized according to the maximum length, weight, and type of the workpieces.

Overview:

This equipment is suitable for loading and unloading hot-dip galvanized structural parts, power fittings, steel pipes, profiles, and similar materials. Workpieces to be galvanized are suspended on racks for pre-treatment preparation, while galvanized products are placed on the unloading rack for removal.

The loading and unloading rack is equipped with a lifting mechanism that can move up and down, making it convenient for hanging and removing workpieces.

Name: Enclosed Pickling Room For Structural Components Hot dip Galvanizing Production Line

Specification: The equipment is customized according to the maximum workpiece length and lifting height required by the user.

Overview:

This system is designed for the pre-treatment of workpieces such as hot-dip galvanized structural components, power fittings, steel pipes, and profiles. All pre-treatment processes including pickling, rinsing, and fluxing are enclosed within a sealed room, effectively isolating the pre-treatment area from the main workshop and minimizing the emission of harmful gases.

The enclosure is constructed with a steel structure, coated externally with polyurea or anti-corrosion resin paint, and internally lined with FRP or UPVC panels for corrosion resistance. An acid fume neutralization and filtration tower is installed outside the enclosure to absorb and treat acidic gases before discharge.

Name: Pre-treatment Cleaning Tank

Specification: The equipment is customized according to the maximum workpiece length, single load weight, and product type required by the user.

Overview:

This tank is suitable for pre-treatment cleaning of hot-dip galvanized structural components, power fittings, steel pipes, profiles, and similar workpieces.

The tank can be manufactured using various materials depending on operating conditions, including corrosion-resistant granite combined with epoxy resin and FRP, PP plates with steel structure and polyurea coating, or steel structure with PE polymer lining. Users can select the appropriate material based on actual requirements.

The materials used for the pre-treatment cleaning tank are consistent with those used in post-galvanizing water cooling tanks and passivation tanks.

Name: Drying Transfer Area For Structural Components Hot dip Galvanizing Production Line

Specification: The equipment is customized according to the maximum workpiece length, single load weight, and product type required by the user.

Overview:

This area is designed for transferring hot-dip galvanized structural components, power fittings, steel pipes, profiles, and similar workpieces after pre-treatment cleaning. The transfer area is equipped with a stainless steel continuous chain conveyor at the front, which moves the pre-treated workpieces out of the enclosed pickling room for subsequent processing.

Name: Enclosed Dust Hood For Structural Components Hot dip Galvanizing Production Line

Specification: The equipment is customized according to the zinc pot dimensions and production requirements.

Overview:

This system is designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces. Zinc fumes generated during the galvanizing process are collected through suction at the side of the zinc pot and the top of the enclosed dust hood, ensuring controlled exhaust.

The zinc fume collection chamber features sealed entry and exit doors for workpieces, operated pneumatically. Automatic lift doors are installed on both sides of the working surface, which can be opened for ash removal and cleaning.

Name: Galvanizing Furnace for Zinc Pot

Specification: The equipment is customized according to the zinc pot dimensions and production requirements.

Overview:

This furnace is designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces, and is used in conjunction with an XG08 metal zinc pot.

The galvanizing furnace adopts a modular structure, allowing for easy installation. The furnace body is lined with customized refractory ceramic fiber insulation, which is integrally formed according to the furnace shell dimensions. The specially designed refractory ceramic fiber lining ensures high quality with fewer joints, improving thermal efficiency and durability.

Name: Zinc Pot Burner

Specification: The equipment is customized according to the zinc pot dimensions and production requirements.

Overview:

This system is designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces, and is used in conjunction with an XG08 metal zinc pot furnace.

Burners are arranged diagonally within the combustion chamber to form a circular flame path. Each high-speed pulse burner is equipped with an imported intelligent combustion controller, enabling ignition, power regulation, and flame failure protection for each burner. Flame monitoring and alarm functions are provided for every burner. The combustion system operates under automatic control, featuring flame-out detection and automatic gas shut-off in case of power failure, ensuring safe and stable operation.

Name: Zinc Pot Furnace Exhaust Gas Heat Recovery System

Specification: The equipment is customized according to the exhaust gas volume of the zinc pot furnace.

Overview:

This system utilizes the high-temperature flue gas discharged after heating the zinc pot to recover waste heat. Through a two-stage heat exchange process, the residual heat in the flue gas is converted into usable thermal energy to meet process temperature requirements, improve production efficiency, and enhance the working environment. It also contributes to energy saving, emission reduction, and low-carbon operation.

A modular high-efficiency tubular heat exchanger is installed in the flue duct to recover waste heat from flue gas at temperatures of 466 to 518 degrees Celsius. The recovered heat is used to raise water temperature to approximately 90 degrees Celsius. Through a heat storage tank with insulation, along with pipelines, a titanium alloy heat exchanger, high-temperature pumps, and an electrical control cabinet, the system transfers heat to the flux solution tank, maintaining it at the optimal process temperature.

Name: Circular Rail Hoist for Hot-Dip Galvanizing

Specification: The equipment is customized according to the workpiece size and lifting capacity required by the user.

Overview:

This system is designed for handling hot-dip galvanized structural components, power fittings, steel pipes, profiles, and similar workpieces. The galvanizing process adopts a circular rail system, with 3 to 4 sets of explosion-proof galvanizing hoists arranged along the track, each using a four-rope single-line configuration. The lifting capacity of each hoist ranges from 3 to 8 tons.

The hoist travel rails are installed beneath the main workshop beams, with maintenance access reserved between the rails and the enclosed dust hood. The electric hoists are of a single-line type with a protection rating of IP65. The control system supports both automatic and manual operation modes.

Name: XG08 Metal Zinc Pot For Structural Components Hot dip Galvanizing Production Line

Specification: The equipment is customized according to the workpiece specifications and production capacity required by the user.

Overview:

This zinc pot is designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces. It is fabricated from XG08 special steel plates supplied by Ansteel, with a plate thickness of 60 mm.

The pot features a round-bottom and rounded-corner structure, along with a primary rim and secondary rim design, ensuring excellent structural stability, no deformation, and long service life.

On the diagonal sides of the pot, corresponding to the burner positions, 310S stainless steel plates are installed from top to bottom as fire-resistant liners. These liners prevent localized overheating near the burners and protect the zinc pot from damage. The 310S stainless steel plates are securely fastened with stainless steel bolts, ensuring strong integrity, resistance to detachment, and extended service life. This design effectively enhances the durability of the zinc pot and ensures uniform temperature distribution of the molten zinc.

Name: Cooling Tower

Specification: The equipment is customized according to the specifications of the user's water-cooling tanks.

Overview:

The cooling tower is designed for reducing the temperature of water in post-hot-dip galvanizing processes for structural components, power fittings, steel pipes, profiles, and similar workpieces. The cooling system includes a temperature control unit that continuously monitors water temperature. When the temperature exceeds 50°C, the system activates the hot water circulation pump.

In winter, the cooling water can be circulated to pre-treatment tanks for heating, while in summer, the water is pumped to the cooling tower for forced cooling before returning to the cooling tanks. The system is also equipped with a soft water system. In case of water spotting issues on galvanized surfaces, the system allows manual switching to soft water for improved surface quality.

Name: Acid Mist Tower

Specification: Customized according to the dimensions of the user's enclosed acid pickling room.

Overview:

The acid mist tower is designed to treat exhaust gases generated from hydrochloric acid cleaning during hot-dip galvanizing pre-treatment, as well as steam and vapor from water washing and fluxing processes. The system uses a water spray absorption method to capture and neutralize acid mist.

The working principle involves passing the collected acid-laden exhaust gas through a counterflow spray of absorbent water solution, achieving purification and removal of acid mist. The absorption liquid is periodically replenished into the acid tank for reuse in the pickling process. During normal operation, the liquid is continuously circulated via a water pump for spraying.

Name: Dust Collector with Ammonia Scrubber

Specification: Customized according to the dimensions of the user's zinc pot.

Overview:

The system is designed to treat and discharge smoke, dust, and fumes generated during the hot-dip galvanizing process in compliance with environmental standards.

The bag-type dust collector features an optimized pulse-jet cleaning system. Unlike conventional dust collectors that only blow compressed air into the bag cage once, this design allows the filter bags to expand during the air pulse and contract when the air stops, effectively achieving a double-shake effect for superior dust removal.

The maximum particulate emission concentration is 120 mg/m³, and for a 15-meter high exhaust stack, the maximum allowable particulate emission rate is 3.5 kg/h.

An ammonia scrubber tower is connected at the dust collector outlet to neutralize ammonia contained in the smoke and dust, ensuring safe discharge.

Name: Wastewater Treatment Equipment

Specification: The system is customized according to the volume of wastewater generated from the user's pre-treatment tanks.

Overview:

Rinsing wastewater from the workshop is pumped into an aeration equalization tank, where air is introduced by a blower to regulate flow, homogenize water quality, and provide pre-oxidation. The effluent then flows into a neutralization reaction tank.

This type of wastewater is typically acidic and contains suspended solids. Under appropriate pH conditions, hydroxide precipitation occurs. When the pH is adjusted above 5.2, the precipitation reaction is largely completed. However, due to the potential release of soluble iron under acidic conditions, the neutralized and coagulated wastewater is further treated in an aeration reaction tank to form stable Fe(OH)₃ precipitates.

After sufficient oxidation, stable ferric hydroxide is formed and flows into a flocculation reaction tank, where a flocculant such as PAM is added. The chemicals are thoroughly mixed with the wastewater, and colloidal hydroxide particles aggregate into larger flocs through adsorption and bridging, facilitating effective solid-liquid separation.

Name: Flux Solution Iron Removal System

Specification: The equipment is customized according to the volume of flux solution in the user's pre-treatment flux tank.

Overview:

This system is designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces. It is used to treat the flux solution in the pre-treatment process, with equipment capacity matched to the volume of the flux tank.

Practical data shows that excessive ferrous chloride (FeCl₂) concentration in the flux solution significantly affects zinc consumption and the surface quality of workpieces. By reducing the iron ion content in the flux solution, this system can effectively lower zinc consumption by 5 to 30 percent overall, typically reducing zinc usage by 3 to 10 kg per ton of workpieces.

With reduced iron content, the fluidity of the molten zinc improves, resulting in better surface quality of the galvanized workpieces and minimizing defects such as zinc runs and spikes.

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