HBFL Galfan hot dip galvanizing production line continuous galvanizing line

I. production line design and manufacturing conditions

1, low carbon steel wire: according to the corresponding low carbon steel wire hot dip galvanized and zinc aluminum alloy standard provisions.

2, product specifications: Φ 6.0 ~ 8.0 mm,

3. Tensile strength: low-carbon 450 N/mm2 ~ 550 N/mm2

4, zinc layer thickness: galvanized 40~80/150~ 300 g/m squared zinc aluminum 150~ 300 g/m squared

5. Production speed: D/V40 ~ 60 (Max. 80);

6. Number of wires: 4;

7. Wire spacing: 10 mm before treatment;Zinc aluminum 1 0 0 mm

8. Tooling length of production line: about 100m u-shaped structure;

9, heating energy: mixed gas or converter gas, electric energy

10. Power requirements: ~380V, 50Hz

II. The process flow

I wheel release line → gas open flame heat treatment annealing → steel wire air cooling → temperature-regulating cleaning → turbulent smokeless cleaning → water cleaning → coating aid → drying → hot dip galvanizing → slanting upward wiping → cooling → secondary aid plating → secondary drying →

Hot dip galvanized aluminum → nitrogen wipe → water cooling → inverted plum winding

III. Production line equipment overview:

1. Wire releasing equipment:

The pay-off device is composed of pay-off frame and pay-off frame. The rotating part of pay-off frame is designed with a tensioning straightening device to control the pay-off tension. In order to ensure the quick and continuous replacement of the pay-off frame in production, the pay-off frame is adopted

Use rotation positioning mode.Use I character wheel external dimension nanometer 800×600 mm, single axis steel wire storage 900 ~ 1000 mm

Jins, I wheel line out by the rotating arm wire out to ensure that the wire is not easy to disorderly wire, wire walking smooth and smooth.

Pay-off i-wheel has vertical and horizontal two forms, customers can choose the vertical structure or horizontal structure according to the actual production needs.

2.Open flame heat treatment furnace for heat treatment gas:

technical parameters 

1) the steel structure of the furnace body adopts the overall frame external dimension: L26000*W600*H1800 (mm)

2) net width within the furnace: 1250 (mm); steel wire spacing within the furnace;100 mm;

3) fuel type: mixed gas or converter gas (calorific value: ≥1250 KCal)

4) contact pressure: normal 0.012MPa, fluctuation ≤5% pressure value.

5) contact pipe diameter: DN80

6) four sections of counter-current furnace type assembly, direct combustion type and premixed type burner are used together to control the atmosphere and pressure in the furnace;

7) number of burners: 24 sets, maximum operating temperature: 800 ~ 1000℃

8) outdoor wall temperature ≤45℃

Technical description:

1) furnace structure: length 24m* width 1.2m * height 1.8m;

The shell of furnace body is welded with steel structure, the whole sealing performance is good, beautiful and practical;Four-stage assembly reduces the time for on-site installation and facilitates future maintenance.The column adopts square tube structure, which is not easy to deform, high strength and long service life.The furnace body is mainly composed of light and heavy insulation materials

Material insulation performance is good.Economical and reasonable furnace wall can minimize heat dissipation of furnace wall.The temperature of the outer wall of the furnace shall not exceed

45 ℃.The furnace arch adopts cast integral arch block with good sealing performance and long service life.

2) the heat treatment furnace adopts reverse flow open fire heating furnace type. The furnace body is composed of three sections. From the wire inlet, preheating section, heating section 1, heating section 2 and heating section 3 are respectively set.Each section heating is relatively independent, and mutual influence.According to the requirements of heat treatment process, the furnace temperature and atmosphere can be set in stages to meet the requirements of the process.

3) steel wire inlet and outlet furnace door of heat treatment furnace is designed with mechanical transmission device, which is easy to open and tightly structured to reduce cold air inhalation and fire.

4) heat treatment furnace adopts high efficiency and energy saving waste heat recovery device.The high temperature gas discharged from the furnace is recovered through the heat exchanger, which is used for the combustion air of the burner to improve the thermal efficiency of the furnace and save energy consumption

Increase 100℃ can save fuel 5%.

5) temperature control of heat treatment furnace

(a) the control system has manual and automatic control modes.The main control PLC adopts Siemens S300 series products to ensure accurate and stable control.

(b) the temperature and air-fuel ratio of each section can be adjusted according to the process requirements.

(c) equipment features: open flame annealing furnace adopts multi-burner heating on both sides, the heating temperature is uniform, the surface of steel wire is not easy to be damaged, the qualified rate is high, the temperature control accuracy in the furnace is high, below 1000° c, according to the steel

The actual condition of silk adjusts the temperature, stable and reliable.The two heating zones are made completely according to the heat treatment curve of steel wire, so as to ensure the complete transformation of steel wire in the furnace, stable temperature transition, pass rate of the rod up to more than 99%, oxidation burning loss rate of 0.145%, and transverse temperature difference in the furnace at ±2℃

3. Temperature adjusting cleaning tank: overflow cleaning is adopted to remove sintered dust on the steel wire surface and adjust the steel wire cleaning temperature.Material of cleaning tank: 60*60*3 stainless steel square pipe is lined with 3mm stainless steel plate. Overall dimension of tank: 1800×1000×1100 (mm)

Cleaning tank water pump: power 2.2kw *1 set

4, turbulent smokeless pickling tank: turbulent smokeless pickling is an advanced pickling technology, steel wire cleaning process is in a completely closed pickling space, suitable

The steel wire should be cleaned quickly to meet the requirement of hot dip galvanizing speed. The turbulent pickling system can ensure the reliable pickling efficiency, so that the steel wire can reach the clean surface before plating under the scouring of hydrochloric acid.Turbulent smokeless acid bath is made of high strength PP material.The upper part of the pickling tank is equipped with a sealing cover. The steel wire inlet and outlet is sealed with a water curtain to prevent acid gas leakage. Steel wire

The cleaning process is completely immersed in highly turbulent acid, using a two-stage turbulent pickling process, each stage of which is

Independent operation, acid concentration can be controlled according to process requirements.Tank dimensions: 16000×1000×1200 (mm) effective pickling length: 12000mm

5. Water cleaning tank: overflow cleaning method is adopted to clean residual impurities and acid liquid on the steel wire surface.The cleaning tank adopts 20mm

High strength PP material welding production.

Tank dimensions 1800×1000×1100 (mm) circulating pump power: 2.2KW/380V

7. Primary assisted plating solvent tank: the assisted plating solvent tank adopts overflow circulation.The gas internal heating tube is used to heat the liquid, and the tank is welded with 316L stainless steel.

The external dimension of the tank is 1600×1000×1100 (mm)

Heating energy: gas

8. Primary drying furnace: primary drying furnace adopts residual heat heating of flue of zinc pot and forced hot air circulation system to dry.Drying furnace liner

Stainless steel structure.Equipment size: 5000×1000×1200 (mm)

Control temperature: 80 ~ 100℃ control mode: PID intelligent temperature control

9. Hot-dip galvanized zinc pot:

(1) zinc pot: it adopts XG08 steel plate zinc pot with external gas heating structure. The zinc pot with heating system is installed on the top end of the zinc pot and opposite sides of the pot. The temperature of zinc liquid in the working area of the zinc pot is even

Energy.

(2) pot size: 4000×1000×750 (mm)

(3) temperature range: 440 ~ 460℃

(4) zinc pot melting amount: 10 tons;

(5) number of burners: 2 sets (diagonal layout)

(6) heating energy: mixed gas or converter gas

(7) zinc pot line pressing roller: the line pressing roller is made of nitride ceramic, the line pressing roller assembly is made of inverted structure, the line discharging Angle can be adjusted at will, the reduction ratio of reducer is 60:1

10. Coating wiping:

(1) galvanized 150 ~ 350g/m2 zinc layer, using nitrogen wipe or carbon powder wipe form.

(2) galvanized 40 ~ 80 g/m2 zinc layer, using asbestos block wipe form.

11. Cooling after plating:

Steel wire after wipe must be quickly cooled, it is the control of steel wire plating alloy layer thickness, improve the coating firmness and steel wire surface finish of the key process.Vertical plating steel wire cooling with two water spray device, oblique plating steel

Wire cooling with overflow water spray device.Cooling water adopts circulation facilities to save water resources.

12, secondary assist plating: steel wire galvanized into the zinc-aluminum pot after the second coating must be assisted to ensure the stability of zinc-aluminum alloy layer.Relief circulation is adopted in the solvent bath.The gas internal heating tube is used to heat the liquid, and the tank is welded with 316L stainless steel.

Tank dimensions 1600×1000×1100 (mm) heating energy: gas

13, secondary drying: in order to prevent steel wire into the zinc aluminum pot into the water, resulting in zinc explosion, steel wire needs to go through two drying treatment.The drying oven adopts gas heating and forced hot air circulation to improve the drying speed.

14. Zinc-aluminum pot: zinc-aluminum pot adopts ceramic zinc-aluminum pot internal heating structure. The heating system is installed on four sides of the inner wall of the pot.Zinc pot temperature control with corrosion resistance thermocouple temperature measurement, corrosion resistance thermocouple straight

Contact with zinc solution ensures stable and accurate temperature.

(1) internal size of zinc pot: 5500×1000×900 (mm)

(2) temperature range: 440 ~ 480℃

(3) capacity of zinc pot: 20 tons;

(4) heating power of zinc pot: 350KW

15, nitrogen wipe: steel wire galvanized aluminum alloy after the nitrogen wipe system, wipe off the excess zinc liquid, to ensure that

Steel wire indicates smoothness and smoothness.

16. Steel wire vertical steel frame and threading platform: steel structure portal type vertical frame and threading platform are adopted. The steel frame is provided with supporting spool, conducting shaft and steel wire guide shaft to ensure the stable operation of steel wire.

16. Winding part: it adopts the inverted type meijin-winding machine set, which adopts the variable frequency speed motor and the winding speed is adjustable. Each winding machine is equipped with a 4.0kw and a 0.75kw motor.