Hot Dip Galvanized Low Carbon Steel Wire Equipment

Name: Passive I-beam Wire Pay-off Stand

Overview: This equipment is suitable for wire pay-off in electro-galvanizing and hot-dip galvanizing production lines. The equipment consists of a rotating base and a pay-off stand. The rotating base is equipped with a tensioning device to control the pay-off tension. During production, the pay-off stand can be freely replaced.

Name: Active I-beam Wire Pay-off Equipment

Overview:The equipment adopts an accumulator-type pay-off unit to ensure stable wire tension without loosening. The wire accumulation time is no less than 3 minutes, allowing the I-beam spool to be replaced without stopping the production line. Spool replacement is simple and convenient to operate. The electrical system is integrated with the take-up machine electrical system and installed in an independent control cabinet. The pay-off and take-up units are interlocked for control, with automatic tension tracking and adjustment.

Customized according to the type of wire products and the operating speed of the production line required by the user.

Name: Online Wire Heat Treatment Furnace For Hot dip Galvanized Low carbon Steel Wire Equipment

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:This furnace is suitable for the online heat treatment process of low-carbon wire. To ensure stable mechanical properties of the steel wire, the furnace adopts a box-type structure with reinforced insulation layers on the furnace walls and roof, ensuring uniform and stable temperature control in the heating chamber. The heat treatment furnace is equipped with multiple heating and temperature measuring points and adopts a PID automatic temperature control system. The process temperature of the heat treatment furnace is controlled within the range of 650–850 °C.

Name: Temperature-Controlled Cleaning Tank For Hot dip Galvanized Low carbon Steel Wire Equipment

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:

The tank body is fabricated by welding 304 stainless steel. To quickly and efficiently remove residual impurities from the steel wire surface, the tank adopts a two-stage overflow cleaning system with independent circulation and a counterflow water supply and drainage design.

The system is equipped with two overflow trays, and each tray is fitted with a corrosion-resistant vertical pump (motor power 0.55 kW) to provide the overflow circulation. During the overflow cleaning process, water enters the cleaning trays in the form of jet spraying, allowing the cleaning water to be recycled, thereby reducing water consumption and minimizing wastewater discharge.

To prevent cleaning water from entering the next process, the outlet of the cleaning tank is equipped with a water interception stone and an air knife (blower power 5.5 kW) to remove residual cleaning water from the wire surface.

The tank is designed with a fully enclosed structure with an openable threading cover, and an air suction port is reserved for connection to a purification tower.

Name: Online Wire Ultrasonic Cleaning Tank

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:

The ultrasonic cleaning tank can replace the functions of both alkaline and acid cleaning tanks, performing degreasing and rust removal simultaneously, thereby shortening the production line length.

It uses a fully enclosed overflow ultrasonic cleaning system, in which the steel wire is cleaned in a completely sealed space using an environmentally friendly ultrasonic cleaning solution (mild phosphoric acid, H₃PO₄), suitable for steel wire cleaning and compatible with hot-dip galvanizing line speeds. Ultrasonic cleaning is energy-saving and environmentally friendly, producing no waste acid.

The ultrasonic cleaning tank is constructed from high-strength PP material and equipped with a corrosion-resistant circulation pump. The lower liquid reservoir is divided into two independent sections, A and B. While the liquid in Section A is circulating, Section B can be filtered, cleaned, and reused, enabling continuous cleaning of the solution without stopping the line.

A sealed cover is installed on top of the cleaning tank to prevent water and vapor from escaping. During cleaning, the steel wire is fully submerged in the cleaning solution. The tank employs a two-stage liquid reservoir system, where each stage operates independently. An external cleaning solution circulation and filtration system allows the cleaning solution to be reused, reducing consumable usage and operating costs.

Name: Online Wire Hydrochloric Acid Cleaning Tank

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:

The integrated acid cleaning tank is constructed from PP material, and the steel wire moves in a straight line during the cleaning process. The tank uses an overflow design, with the water curtains equipped with two corrosion-resistant pumps (4.0 kW). The acid cleaning tank itself is equipped with six acid-resistant pumps (0.55 kW) to provide overflow circulation for the acid solution.

The tank inlet and outlet are sealed with two water curtains each, and the sides use groove seals to prevent acid mist from escaping. To ensure rapid removal of oxides from the steel wire surface, the process is designed to meet the fast cleaning requirements of the galvanizing line.

The tank solution is circulated using the acid-resistant pumps, enabling the steel wire to achieve the required pre-galvanizing surface cleanliness under hydrochloric acid flushing. To reduce acid consumption and prevent acid carryover into the next process, the tank outlet is equipped with water interception stones and an air blow wipe system to remove residual acid from the wire surface.

Name: Online Wire Water Cleaning Tank

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:
The tank body is fabricated from acid-resistant materials. To quickly and efficiently remove residual impurities from the steel wire surface, the tank uses a two-stage overflow cleaning system with independent circulation and a counterflow water supply and drainage design.

Each tray is equipped with a corrosion-resistant vertical pump (motor power 0.55 kW) to provide overflow circulation. During the cleaning process, water enters the cleaning trays as spray jets, and the cleaning water can be recycled, reducing water consumption and minimizing wastewater discharge.

To prevent cleaning water from entering the next process, the tank outlet is equipped with water interception stones and an air knife (blower power 5.5 kW) to remove residual water from the wire surface.

The tank is designed as a fully enclosed system with an openable threading cover, and an air suction port is reserved for connection to a purification tower.

Name: Online Wire Strike Solvent Washing Tank

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:

The enclosed strike solvent washing tank is fabricated from reinforced PP material plates. During operation, a water-based ammonium chloride solution is applied to the steel wire surface to prevent secondary oxidation and improve the adhesion between the steel wire and the zinc coating.

The tank uses an overflow circulation system for continuous cleaning. A sealed cover is installed on top of the tank, and the steel wire exit is equipped with a ceramic air knife to prevent alkaline solution carryover, avoiding contamination of subsequent process steps.

Name: Online Wire Drying Equipment

Specification: Customized according to the type of wire products and the production line speed required by the user.

Overview:

The equipment is designed according to the wire diameter, DV value, and wire production output. The drying furnace is constructed with a Q235 steel welded frame, and the interior of the chamber is insulated with high-temperature aluminum silicate fiber material.

Heating is achieved through hot air circulation ducts, and an induced draft fan is installed at the end of the furnace. The operating temperature range of the furnace is 150–180°C.

Name: Metal Hot-Dip Zinc Bath

Specification: Customized according to the user's energy requirements and line speed.

Overview:

The equipment is designed based on the user's energy requirements, wire diameter, DV value, and wire production output, with a zinc capacity of 35–180 tons. The bath is made of XG08 metal or stainless steel and works in coordination with the furnace.

Heating is external, and the energy source can be electricity or natural gas. The zinc bath temperature is controlled using corrosion-resistant thermocouples, which are in direct contact with the molten zinc to ensure stable and accurate temperature control. The equipment has a service life of 5–8 years or more.

Name: Internally Heated Ceramic Zinc Bath

Specification: Customized according to the type of wire products and production line speed.

Overview:

The equipment is designed based on the wire diameter, DV value, and wire production output, with a zinc capacity of 35–180 tons. The bath features a steel shell, ceramic liner, and internal heating system, with the heating elements installed along the inner wall of the zinc bath to ensure uniform temperature in the working zone.

The zinc bath temperature is controlled using corrosion-resistant thermocouples that are in direct contact with the molten zinc, ensuring stable and accurate temperature control. The expected service life of the bath is over 10 years.

Name: Zinc Bath Gantry Frame (Vertical Steel Frame)

Specification: Customized according to the type of wire products and production line speed.

Overview:

The equipment is designed based on the wire diameter, DV value, and wire production output. A vertical steel frame is installed above the zinc bath to ensure stable operation of the equipment, preventing vibration and allowing smooth hot-dip galvanizing of the wire.

The vertical steel frame is constructed from structural steel and is equipped with wire support shafts, air and water cooling devices, guide rollers, wire directing shafts, and wiping frames as auxiliary equipment.

Name: Synthetic Silicon Nitride Ceramic Pressure Roller

Specification: Customized according to the type of wire products.

Overview:

The pressure rollers are manufactured from sintered synthetic silicon nitride ceramic. Two independent structural designs are used for high-zinc and standard-zinc wires, but the installation positions are the same, ensuring consistent zinc coating weight and reducing production costs.

The silicon nitride ceramic pressure rollers have high strength, excellent wear resistance, and corrosion resistance to molten zinc. The roller assembly adopts a two-stage gearbox flip structure, allowing the wire exit angle to be freely adjusted. The expected service life is ≥5 years.

Name: Wire Hot-Dip Galvanizing Wiping System

Specification: Customized according to the wire diameter, DV value, and wire production output.

Overview:

The wire wiping method is selected based on the required zinc coating thickness, DV value, and wire production output. Available wiping technologies include:

Fiber Pressure Block Wiping

Nitrogen Air Knife Wiping

Electromagnetic Wiping

Traditional Charcoal Wiping

These systems control the zinc coating thickness on the wire surface, with an adjustable range of 50–460 g/m².

Name: Online Zinc Coating Thickness Measurement System for Wire Hot-Dip Galvanizing

Specification: Customized according to the type of wire products and production line speed.

Overview:

This system is suitable for nitrogen wiping systems and electromagnetic wiping systems in wire hot-dip galvanizing lines.

The zinc coating is monitored online using a comparison-based detection and control method. During production, the desired zinc coating thickness is set on the HMI, typically with a tolerance of ±20 g/m².

The measurement device transmits real-time data to the PLC, which adjusts the solenoid valves in the nitrogen line as needed. By controlling the flow and pressure of the nitrogen air knives, the system ensures the zinc coating thickness is maintained accurately, making operation and adjustment simpler and more convenient.

Name: Wire Take-Up Unit For Hot dip Galvanized Low carbon Steel Wire Equipment

Specification: Customized according to the type of wire products and production line speed.

Overview:

The equipment is designed based on the wire diameter, DV value, and wire production output. It is suitable for wire take-up after hot-dip galvanizing or electro-galvanizing.

The take-up unit is selected according to the diameter, material, and intended use of the coated wire. The take-up weight range is 35–2000 kg.

Name: Wire Bundling Machine For Hot dip Galvanized Low carbon Steel Wire Equipment

Specification: Customized according to the wire product's intended use.

Overview:

The equipment is suitable for bundling large coils of wire after hot-dip galvanizing or electro-galvanizing and subsequent take-up.

The main frame of the hydraulic bundling machine is made of welded structural steel, forming a fully metal construction. The top section uses a dual hydraulic cylinder design, with cylinders screwed to the lower pressure basket for convenient transport.

A long-arm structure is used to accommodate take-up coil weights of 800–2000 kg.

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