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Hot dipped Steel Wire Galvanizing Line

  • Hot dipped wire galvanizing Line

  • Pulley Type Wire Drawing Line

  • Pulley Type Wire Drawing Machine

  • Pulley Type Wire Drawing Plant

  • Cooling bath of wire galvanizing line

  • Wire galvanizing bath

Hot Dip Galvanizing Line Process Flow:
Pay off → lead annealing bath → water quench → Fumeless pickle → "Flash" pre-flux→ Drying → Hot-dip galvanizing → Wiping → Cooling → Vertical take up
Equipment component
Take the following specification as example: wire dia. Is 1.8-5.0mm, line number is 24, wire spacing is 35mm, zinc layer thickness: 60-120g/㎡
1) Pay-off equipment:
The pay-off equipment is comprised of pay-off trays and pay off frames. A tension device is installed on the pay off tray to control pay-off tension. The pay-off tray and pay off frame can be changed freely. There are 24 pay-off trays and pay-off frames to give 4 spares to ensure that exchanging of empty frames does not delay production. Each pay-off tray can comfortably hold 400-600 Kgs steel wire. The coiled wire runs can be paid off smoothly without tangles and snags.
2) Lead annealing bath:
This bath is made of stainless steel, gas fired. The internal size is 8000× 1200×1200mm.
3) Water quench bath:
The tank is made of GRP. Internal dimensions are 2000×1200×1100mm. Two corrosion resistant pumps total rating 30m3/hr are employed to give the required overflow volume.
4) Fume free rinsing-pickling-rinsing tank:
This tank system is made of glass fiber and is of overflow design. The internal size is 11800×1200×1200 mm. The tank is comprised of three parts: rinse, pickle and rinse. The entry rinse bath has 2 centrifugal pumps with total rating of 20m3/h. The pickling bath has 2 corrosion resistant pumps with total rating of 30m3/hr. The rinse bath has 2 corrosion resistant centrifugal pumps with total rating of 20m3/hr. There are two water curtains at the entrance to the bath to prevent escape of acid fumes. The final rinse section has three water curtains to remove acid from the wire and to prevent escape of acid fumes. Rinse water is recycled to reduce water consumption and reduce discharge to waste.
5) Overflow flash pre-flux bath:
This bath is made of GRP. The internal dimensions are 4000×1200×1200 mm. Two Corrosion resistant pumps with total rating of 25 m3 are employed to give the required overflow volume. The power supply is rated 1500A.
6) Overflow coating pre-flux bath:
The bath is made of glass fiber. The internal size is 2000×1200×1200mm. Heating is by electric immersion heaters rated at 30 KW. The temperature is controlled in the range 60-80°C. Two Corrosion resistant pumps with total rating of 25m3/hr are employed to give the required overflow volume.
7) Drying furnace:
The drying furnace is electrically heated with forced air circulation. The temperature range is automatically controlled in the range 100℃ and 150℃. Furnace size is 4000×1450×2000 mm
8) Hot-dip galvanizing:
Zinc kettle: The kettle is comprised of kettle body, gas fired immersion heaters and a temperature and electric control system. K-type corrosion resistant thermocouples are employed to test temperature and allow control to ±3℃.
Kettle working dimensions: 4000×1600(400)×900 mm (L×W×H)
Kettle exterior dimensions: 5200×2800×1500 mm (L×W×H)
Temperature range of molten zinc: 420~480°C
Capacity of molten zinc: 38 tons
Heating power of zinc kettle: 360 Kw (9 heater, each of 40 Kw)
Width of working area: 1200 mm
Characteristic of immersion heated ceramic kettle:
Reduced zinc consumption:
Using a ceramic zinc kettle avoids the dross created by a steel kettle.
Zinc consumption can be reduced by between 10% and 15% compared with a normal steel kettle and pre-flux system.
The high fluidity of the molten zinc resulting from the low amount of iron entering the galvanizing process promotes accurate and concentric coating to reduce zinc consumption
Long working life: The working life of a ceramic kettle is at least ten years and may be as great as 20 years.
High production efficiency: No lost time for dross removal when a ceramic kettle is used in conjunction with “flash” pre-flux
Improved working conditions – lower temperatures in the work place
Sink roller: 24 channel sintered Alumina ceramic material sinker with a pitch of 40 mm. The sinker has high strength and good wear and corrosion resistance to molten zinc.
Thick ceramic liner which ensures that in the unlikely event of a crack developing in the liner the zinc will freeze before it travels through the wall
9. Vertical steel frame:
The frame is of robust construction to assist in eliminating wire vibration and is fitted with wire support and wire guide axes. Adjustments can be made to wire tension to ensure vibration free wire travel.
10. Wiping system:
Thin coatings: Kevlar type pads above and below the wire to wipe off excess zinc as the wire exits the molten zinc.
Thick coatings above 80 g/m2 coating: Nitrogen protection. Source of nitrogen can be from a generator or bottle. This quotation does not include for nitrogen gas supply. This quotation includes for all nitrogen gas flow and pressure control equipment.
11. Cooling:
The steel wire must be cooled quickly after being wiped. This is a key process in controlling consistency of the coating weight and improving the firmness and smoothness of coating surface. Our cooling system has the dual function of air and water cooling. The wire is cooled in minimum time. Cooling water is recycled to reduce consumption.
12. Take up:
Vertical, pattern laid take-up units are specified. The speed of each steel wire can be independently controlled. Each take-up has a variable-frequency motor (5.5KW and 0.75KW) for speed adjustment. The wire runs free of vibration.. Different diameters of wire can be galvanized at the same time. Coil weight to 1000 Kgs. Exchange of coils is simple and easy.
The Finished Products (Wire):
Glavanized wire Hot dipped galvanized wire