Structural Components Automatic Hot-dip Galvanizing Production Line

Name: Rail Guided Transfer Cart

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

Overview:

This transfer cart is designed for handling hot-dip galvanized structural components, power fittings, steel pipes, profiles, and similar workpieces, with a load capacity of 1 to 16 tons.

The cart can be powered via wired or wireless power supply systems. Control options include a fixed control panel or remote control operation. The cart body is fabricated from welded steel structure and coated with anti-corrosion resin paint. The driving system consists of an electric motor and a reducer.

Name: Loading and Unloading Rack

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

Overview:

This equipment is designed for loading and unloading operations of structural components, power fittings, steel pipes, profiles, and similar workpieces in hot-dip galvanizing processes.

It is used to suspend workpieces on lifting frames for pre-galvanizing preparation or to place galvanized workpieces on the rack for unloading. The loading and unloading rack is equipped with a lifting mechanism that can move up and down, facilitating convenient handling, hanging, and removal of workpieces.

Name: Enclosed Pickling Room For Structural Components Automatic 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 structural components, power fittings, steel pipes, profiles, and similar workpieces in hot-dip galvanizing processes.

All pre-treatment operations, including pickling, rinsing, and fluxing, are arranged a sealed enclosure, effectively isolating the pre-treatment tanks from the main workshop and minimizing the leakage of harmful gases.

The enclosure is constructed with a steel structure, with the exterior coated in polyurea or anti-corrosion resin paint. The interior is lined with FRP or UPVC panels for enhanced corrosion resistance. An acid gas neutralization and filtration tower is installed outside the enclosure to absorb and treat acid fumes before discharge.

Name: Pre-treatment Cleaning Tank

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

Overview:

This tank is designed for pre-treatment cleaning of structural components, power fittings, steel pipes, profiles, and similar workpieces in hot-dip galvanizing processes.

The tank can be constructed using various corrosion-resistant material combinations, including:

Acid-resistant granite + epoxy resin + fiberglass (FRP)

PP panels + steel structure + polyurea coating

Steel structure + PE high-polymer materials

Users can select the appropriate material configuration based on actual operating conditions. The material specifications of the pre-treatment cleaning tank are consistent with those used in post-galvanizing water cooling and passivation tanks.

Name: Drying Transfer Area

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

Overview:

This area is designed for transferring structural components, power fittings, steel pipes, profiles, and similar workpieces after pre-treatment cleaning in hot-dip galvanizing processes.

The transfer zone is equipped with a stainless steel continuous chain conveyor system, which moves the pre-treated workpieces forward and transfers them out of the enclosed pickling room for subsequent processing.

Name: Enclosed Dust Hood

Specification: The equipment is customized according to the specifications of the user's zinc pot.

Overview:

This system is designed for collecting and exhausting zinc fumes generated during the hot-dip galvanizing process of structural components, power fittings, steel pipes, profiles, and similar workpieces.

Zinc fumes are captured through side suction at the upper edge of the zinc pot and top suction via the enclosed dust hood, ensuring organized collection and discharge.

The fume collection chamber is equipped with sealed access doors on both ends for workpiece entry and exit, which are pneumatically operated. Automatic lifting doors are installed on both sides of the working area of the collection chamber, allowing convenient access for dust cleaning and maintenance operations.

Name: Zinc Pot Furnace

Specification: The equipment is customized according to the specifications of the user's zinc pot.

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 design, allowing for easy installation. The furnace body is lined with customized refractory ceramic fiber insulation, which is integrally formed according to the dimensions of the furnace shell. The specially designed refractory ceramic fiber lining offers high quality with fewer joints, improving thermal insulation performance and durability.

Name: Zinc Pot Burner For Structural Components Automatic Hot-dip Galvanizing Production Line

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

Overview:

Designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and other workpieces, this burner is used in conjunction with the XG08 metal zinc pot furnace. Burners are installed diagonally in the combustion chamber, forming a circular flame path.

Each high-speed pulse burner nozzle is equipped with an imported intelligent combustion controller, which enables ignition, power adjustment, and flame-out protection for each nozzle. All nozzles include flame-out alarm devices. The burner operates under automatic control, featuring automatic flame monitoring and safety functions such as power cut-off and valve shutdown in case of anomalies.

Name: Zinc Pot Furnace Exhaust Gas Heat Recovery System

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

Overview:

This system recovers waste heat from high-temperature flue gas discharged after heating the zinc pot. 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, achieving energy saving and low-carbon emission.

A modular high-efficiency tubular heat exchanger is installed in the flue duct to recover waste heat from flue gas at temperatures ranging from 466 to 518°C, heating water to approximately 90°C. Through integration with an insulated heat storage tank, pipelines, a titanium alloy heat exchanger, high-temperature pumps, and an electrical control system, the recovered heat is transferred to the flux tank solution, maintaining it at the optimal process temperature.

Name: Hot-Dip Galvanizing Circular Rail Hoist

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

Overview:

This hoist system is designed for hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces. The galvanizing process adopts a circular rail system, on which 3 to 4 sets of explosion-proof hoists (four-rope, single-line configuration) are installed.

Each hoist has a lifting capacity of 3 to 8 tons. The hoist traveling rail is installed beneath the main workshop beams, with maintenance access space reserved between the rail and the enclosed dust hood.

The system adopts a single-line electric hoist design with a protection rating of IP65. The control mode supports both automatic and manual operation, ensuring safe and efficient material handling throughout the galvanizing process.

Name: XG08 Metal Zinc Pot

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 (Ansteel), with a thickness of 60 mm.

The pot features a rounded bottom and corner structure, along with a main rim and secondary rim design. It offers excellent resistance to deformation and a long service life.

On the diagonal sides of the pot (corresponding to the positions of the gas burners), 310S stainless steel plates are installed from top to bottom as fire-resistant linings. These linings prevent localized overheating and damage to the zinc pot near the burners. 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 improves the durability of the zinc pot and ensures uniform temperature distribution of the molten zinc.

Name: Cooling Tower For Structural Components Automatic Hot-dip Galvanizing Production Line

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

Overview:

This system is designed for cooling water temperature reduction after hot-dip galvanizing of structural components, power fittings, steel pipes, profiles, and similar workpieces.

The cooling water treatment system is equipped with a temperature control unit that continuously monitors the water temperature online. When the temperature exceeds 50°C, the system automatically starts the hot water circulation pump.

In winter, the cooling water can be diverted to the pre-treatment tanks for heating purposes, while in summer it is circulated to the cooling tower for forced cooling before returning to the cooling tank.

In addition, the system is equipped with a softened water unit. In case of water-mark quality issues during galvanizing, the system can be manually switched to use softened water.

Name: Acid Fume Scrubber Tower For Structural Components Automatic Hot-dip Galvanizing Production Line

Specification: The equipment is customized according to the specifications of the user's enclosed pickling room.

Overview:

This system is designed for treating acid fumes generated during hydrochloric acid pickling in hot-dip galvanizing pre-treatment processes, as well as vapors from rinsing and fluxing operations.

The acid fume exhaust is treated using a water-spray scrubbing method. The system operates by introducing collected acid fumes into a spray chamber, where they come into counter-current contact with the scrubbing solution to achieve effective absorption and purification.

The absorbed solution is periodically replenished into the acid tank for reuse as pickling solution. During normal operation, the system continuously circulates the scrubbing liquid via a water pump to maintain stable absorption efficiency.

Name: Dust Collector + Ammonia Removal Tower

Specification: The equipment is customized according to the dimensions of the user's zinc pot.

Overview:

This system is designed for the treatment and compliant discharge of dust and fumes generated during the hot-dip galvanizing process.

The bag filter dust collector adopts an optimized pulse-jet cleaning system. Unlike conventional designs that only inject compressed air into the cage frame for a single pulse cleaning, this system enables simultaneous filter bag expansion during pulse injection. When the air is cut off, the filter bags contract and recover, achieving a dual-cleaning effect and significantly improving dust removal efficiency.

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

A spray scrubber tower is installed downstream of the dust collector to neutralize ammonia contained in the exhaust gas, ensuring compliant emission.

Name: Wastewater Treatment System For Structural Components Automatic Hot-dip Galvanizing Production Line

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

Overview:

Rinse water from the workshop is pumped into an aerated equalization tank. In this tank, wastewater is treated by blower aeration to regulate flow, homogenize water quality, and achieve pre-oxidation.

The effluent from the equalization tank flows by gravity into a neutralization reaction tank. The wastewater is acidic and contains suspended solids. Under appropriate pH conditions, hydroxide precipitation is formed. When the pH of the wastewater is adjusted above 5.2, the precipitation reaction is largely completed.

However, due to the potential release of soluble iron under acidic conditions, the water after neutralization and coagulation must enter an aeration reaction tank to promote the formation of stable Fe(OH)₃ precipitates.

After sufficient oxidation, stable ferric hydroxide precipitates are formed and transferred to a flocculation tank, where flocculant (PAM) is added. The chemicals and wastewater are fully mixed, and under the adsorption-bridging effect of the polymer flocculant, larger flocs are formed and separated from the water as sediment.

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 for treating the flux solution in the pre-treatment flux tank based on the required processing capacity.

Practical data shows that when the ferrous ion (Fe²⁺) concentration in the flux solution is too high, it significantly affects zinc consumption and product surface quality. By reducing Fe²⁺ content in the flux solution, this system effectively lowers zinc consumption (total reduction of 5–30%, with an average reduction of 3–10 kg of zinc per ton of workpiece).

In addition, reducing iron ions improves the fluidity of molten zinc, enhances surface quality, and helps prevent defects such as zinc drips and zinc spikes.

Name: Automatic Galvanizing Control System

Specification: The system is customized according to the user's production line configuration, process requirements, and automation level.

Overview:

This system is designed for centralized control and automation of the hot-dip galvanizing production line, enabling coordinated operation of all process sections including loading, pickling, rinsing, fluxing, drying, galvanizing, cooling, and unloading.

The system integrates PLC control, industrial HMI, and intelligent process management software to achieve real-time monitoring, data acquisition, and automatic adjustment of process parameters such as temperature, lifting speed, dwell time, and line rhythm.

It supports multi-mode operation including automatic, semi-automatic, and manual control, ensuring stable production, improved efficiency, and consistent product quality. Alarm functions, interlocking protection, and fault diagnosis are also included to enhance operational safety and reliability.

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