Hot Dip Galvanized High Carbon Steel Wire Equipment

Name: Passive I-beam Wire Pay-off Stand
Overview: Passive I-beam Wire Pay-off Stand is designed for wire spooling in electro-galvanizing and hot-dip coating lines. The equipment consists of a rotating base and a spooling frame. The rotating base is equipped with a tensioning device to control the spooling tension. During production, the spooling frame can be easily replaced.

Name: Active I-beam Wire Pay-off Equipment
Overview: This system uses a line accumulation type pay-off unit to ensure stable tension without loosening. The wire accumulation time is no less than 3 minutes, and the I-beam can be replaced without stopping the system. The process of replacing the I-beam is simple and easy to operate.
The electrical equipment is housed in an independent control cabinet, along with the winding machine's electrical devices. The pay-off and winding machines are interlocked for coordinated control, with automatic tracking and tension adjustment.

Customized equipment based on the type of wire products and the user's running speed.
 

Name: Wire Rod Online Conventional Alkali Cleaning Tank
Overview:
The closed steel wire alkali cleaning process takes place in a completely enclosed space, where the steel wire reaches a clean surface through the scouring of hot alkali solution during production. The closed alkali cleaning tank is made by welding reinforced PP (polypropylene) material plates. A sealing cover is installed on top of the tank, and a ceramic air knife is used at the steel wire outlet to prevent the alkali solution on the wire surface from being carried out, thus avoiding contamination of the subsequent process.

Name: Wire Online Electrolytic Alkaline Cleaning Tank
Overview:
The closed electrolytic alkaline cleaning tank adopts advanced and environmentally friendly electrolytic alkaline cleaning technology. The wire cleaning process takes place in a completely sealed alkaline cleaning space, where the wire is cleaned to a pristine surface under the action of the electrolytic alkaline solution during production. The closed electrolytic alkaline cleaning tank is welded using reinforced PP material panels, and it is equipped with a sealing cover on top. The wire outlet is protected by a ceramic air knife to prevent the alkaline solution from splashing out and contaminating subsequent processes.

The wire electrolytic cleaning tank uses a positive-negative electrode exchange cleaning method and an electrolytic liquid overflow tank for external circulation. The rectifier power supply has a voltage range of 0-12V and an output current of 3000A. Under the electrolytic action and liquid flushing, the wire reaches a clean surface.

Name: Wire Online Ultrasonic Cleaning Tank
Overview:
The ultrasonic cleaning tank can replace the functions of both alkaline and acid cleaning tanks, simultaneously removing oil and rust, while shortening the production line length.

The closed overflow-type ultrasonic cleaning technology is used in a fully enclosed cleaning space. It utilizes an environmentally friendly ultrasonic cleaning solution (weak phosphoric acid H₃PO₄ cleaning solution), which is suitable for wire cleaning processes and meets the requirements of hot-dip galvanizing speeds. Ultrasonic cleaning is energy-efficient and environmentally friendly, with no waste acid generated.

The ultrasonic cleaning tank is made from high-strength PP material and equipped with a corrosion-resistant circulating pump. The lower liquid storage tank is divided into two independent parts, A and B. When the liquid in tank A is circulating, the liquid in tank B can be filtered, cleaned, and reused, allowing continuous cleaning of the cleaning solution without halting the production line.

A sealing cover is installed above the cleaning tank to prevent water vapor from escaping. During the cleaning process, the wire is fully immersed in the cleaning solution. The cleaning solution uses two separate liquid storage tanks, each operating independently. The system is equipped with a cleaning solution circulation filtration tank and filtration machine, ensuring the cleaning solution is recycled and reducing material consumption.

Name: Wire Online Hydrochloric Acid Cleaning Tank
Overview:
The integrated acid cleaning tank is made of PP (polypropylene) material. During the cleaning process, the wire moves in a straight line. The integrated tank adopts an overflow method, and the tank body is equipped with two corrosion-resistant pumps (4.0 kW power) for water curtain circulation. The acid cleaning tank is equipped with six acid-resistant pumps (0.55 kW power) to provide overflow power for the acid solution. Both the wire inlet and outlet of the tank use dual water curtains for sealing, with a groove sealing method on both sides to prevent acid mist from leaking.

To ensure fast removal of oxide layers from the wire surface and meet the rapid cleaning requirements for galvanizing, the process liquid is cleaned by acid-resistant pumps in a reciprocating motion. This ensures that the wire achieves the required clean surface before galvanizing.

To reduce acid consumption and prevent acid from entering the next process, the acid cleaning tank's outlet is equipped with a flow-blocking stone and a blowback system to remove any residual acid from the surface of the wire.

Name: Wire Online Water Cleaning Tank
Overview:
The tank body is welded using acid-resistant materials. To quickly and efficiently remove residual impurities from the wire surface, the tank adopts a two-stage overflow cleaning system with separate circulation and reverse water inlet and outlet methods. Each tray is equipped with a corrosion-resistant vertical pump (motor power 0.55 kW) to provide overflow power. During the overflow cleaning process, the water enters the cleaning tray in a spray form, and the cleaning water can be recycled, saving water consumption and reducing wastewater discharge.

To prevent cleaning water from contaminating the next process, the outlet of the cleaning tank is equipped with a flow-blocking stone and a blowback air knife (with a 5.5 kW fan) to remove any residual cleaning water from the wire surface. The design is fully enclosed, with an accessible wire insertion cover and a reserved air intake for the purification tower.

Name: Wire Online Galvanizing Aid Solvent Cleaning Tank
Overview:
The closed galvanizing aid solvent cleaning tank is welded using reinforced PP (polypropylene) material panels. A layer of ammonium chloride aqueous solution is applied to the surface of the wire to prevent secondary oxidation and to enhance the adhesion between the wire and the zinc solution during galvanizing. The solvent cleaning tank adopts an overflow circulation method.

A sealing cover is placed above the closed electrolytic alkaline cleaning tank, and the wire outlet is equipped with a ceramic air knife to prevent the alkaline solution from being carried out with the wire, thus avoiding contamination of subsequent processes.

Customizing appropriate equipment based on the user's wire product type and line speed.

Name: Wire Online Drying Equipment For Hot Dip Galvanized High Carbon Steel Wire Equipment
Overview:
The drying furnace can be powered by electric energy, natural gas, or furnace gas for heating. The furnace body is constructed with 304 material and a Q235 steel structure welded together. The internal insulation of the furnace is made from high-temperature silica-alumina fiber materials.

The heating of the furnace chamber is achieved through hot air circulation ducts. A ventilation fan is arranged at the rear of the furnace. After passing through the galvanizing aid tank, the wire surface still retains residual water. To prevent the wire from causing zinc splashing when immersed in the zinc bath and to avoid uneven zinc coating, the wire must undergo a drying process after the galvanizing aid treatment.

Drying Furnace Specifications: The specifications of the drying furnace are customized based on the user's wire product type and line speed.

Name: Metal Hot-Dip Galvanizing Bath
Specification: Customized based on the user's energy requirements and line speed.
Overview:
Customized to meet the user's energy needs, wire diameter, DV value, and wire production volume, with a zinc capacity ranging from 35 to 180 tons. The metal Zinc Bath is made from XG08 metal material or stainless steel, used in conjunction with a furnace. The heating method is external heating, and the energy source can be either electric energy or natural gas.

The temperature control system uses corrosion-resistant thermocouples to ensure accurate and stable zinc temperature by allowing direct contact with the molten zinc. The Zinc Bath has a service life of 5 to 8 years.

Name: Internal Heating Ceramic Zinc Bath
Specification: Customized based on the user's wire product type and line speed.
Overview:
The equipment is customized according to the user's wire diameter, DV value, and wire production volume, with a molten zinc capacity of 35 to 180 tons. It features a steel shell with a ceramic inner lining and an internal heating structure. The heating system is installed on the inner wall of the Zinc Bath to ensure the temperature of the molten zinc is uniform across the working area. Corrosion-resistant thermocouples are used to monitor the temperature, and these thermocouples come into direct contact with the molten zinc, ensuring stable and accurate temperature control. The service life of the Zinc Bath is over 10 years.

Name: Zinc Bath Gantry Frame (Vertical Steel Frame) For Hot Dip Galvanized High Carbon Steel Wire Equipment
Specification: Customized based on the user's wire product type and line speed.
Overview:
Customized to meet the user's wire diameter, DV value, and wire production volume. The Zinc Bath is installed with a set of vertical steel frames to ensure that the equipment operates smoothly without shaking, allowing for stable hot-dip galvanizing of the wire. The vertical steel frame is constructed using profile steel structures. Additional auxiliary equipment, such as wire support shafts, cooling systems (air and water), wire guide shafts, steel wire guiding shafts, and wiping frames, are mounted on the steel frame to aid in the galvanizing process.

Name: Synthetic Nitride Ceramic Pressing Shaft For Hot Dip Galvanized High Carbon Steel Wire Equipment
Specifications: Customized according to the type of wire products and drawing speed.
Overview:
The wire pressing rollers are made from synthetic nitride ceramic sintering. The ceramic wire pressing rollers come in two independent structural forms: high zinc and regular zinc, with the same installation position, ensuring the required zinc layer weight and reducing production costs. The nitride ceramic wire pressing rollers offer high strength, excellent wear resistance, and good corrosion resistance to molten zinc. The wire pressing roller assembly adopts a two-stage gearbox reversing structure, allowing for adjustable wire exit angles. The service life is greater than or equal to 5 years.

Name: Wire Hot-Dip Galvanizing Wiping System
Specifications: Customized according to the wire diameter, DV value, and wire output requirements.
Overview:
The wire wiping method is selected based on the product's zinc layer thickness, DV value, and wire output requirements. The available wiping methods include fiber pressure block wiping, nitrogen air knife wiping, electromagnetic wiping, and traditional charcoal wiping techniques. These methods are used to control the zinc layer thickness on the wire surface. The zinc layer thickness can be controlled within a range of 50 to 460 g/m².

Name: Wire Hot-Dip Galvanizing Online Zinc Coating Detection System
Specifications: Customized according to the type of wire products and drawing speed.
Overview:
This system is suitable for wire hot-dip galvanizing lines equipped with nitrogen wiping systems and electromagnetic wiping systems. The online zinc coating detection uses a comparison-based detection and control method. During production, the required zinc layer thickness is set on the HMI, with a typical zinc layer deviation value (usually within ±20g). The detection instrument transmits real-time data to the PLC, which adjusts the electromagnetic valve of the nitrogen pipeline based on the detection data. This adjustment controls the flow and pressure of the nitrogen air knife, which in turn controls the zinc coating thickness. The system is easy to operate and adjust, making it more convenient for users.

Name: Wire Take-Up Unit for Hot Dip Galvanized High Carbon Steel Wire Equipment
Specifications: Customized according to the type of wire products and drawing speed.
Overview:
The equipment is customized based on the wire diameter, DV value, and wire output requirements. It is suitable for use after hot-dip galvanizing or electro-galvanizing of steel wire. The appropriate winding machine is selected based on the post-galvanized wire diameter, material, and intended use. The winding weight range is from 35 to 2000 kg.

Name: Wire Bundling Machine For Hot Dip Galvanized High Carbon Steel Wire Equipment
Specifications: Customized according to the wire product's intended use.
Overview:
This machine is suitable for use after winding large steel wire that has undergone hot-dip galvanizing or electro-galvanizing. The hydraulic Bundling Machine's main frame is welded from section steel, making it a full-metal structure. The top is designed with a dual hydraulic cylinder structure, and the hydraulic cylinders are attached to the lower pressure basket with screws for easy transportation. The machine adopts a long-arm extension structure to accommodate coil weights ranging from 800 to 2000 kg.

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