WD-MLG-24 Wire Hot-Dip Galvanizing and Lead Bath Heat Treatment Production Line
1| Design Basis
Product: High-carbon steel wire (42B-82B)
DV Value: 80-100 mm·m/min
Zinc Coating Thickness: (See table below)
Diameter (mm) |
Pure Zinc High Zinc Layer Control Range (g/m2) |
Zinc Layer Control Precision (g/m2) |
| 1.3-1.8 |
130-200 |
±20 |
| 2.0-2.4 |
200-250 |
±20 |
| 2.5-3.0 |
250-260 |
±20 |
| 3.0-4.0 |
260-280 |
±20 |
| Wire Strength: 1200-2200 MPa
| Wire Diameter: Ø1.3 - Ø4.0 mm
| Number of Wires: 24 | 24 pure zinc wires
| Representative Size: Ø2.6 mm
| Wire Space:
| Heat treatment wire spacing: 30±1 mm
| Total spacing: 690 mm
| Hot-dip galvanizing wire spacing: 38±1 mm
| Total spacing: 874 mm
| Travel Elevation:
Heat treatment: +900 mm
| Pre-treatment and galvanizing: +900 mm
| Travel Mode: | Straight-through type
| Production Capacity:
1438.56 t/month (Ф2.5mm,DV=90mm·m/min,24h/d,47.95 t/d,30d)
90%,43.16 t/d,1290 t/month
Considering production efficiency (including wire hanging and breakage), actual capacity is 43.16 t/d, 1290 t/month
1150.8 t/month (Ф1.8mm,DV=90mm·m/min,24h/d,34.5 t/d,30d)
90%,31 t/d,930 t/month | Considering production efficiency (including wire hanging and breakage), actual capacity is 31 t/d, 930 t/month
| Heating Method:Tank solution: Electric heating
Heat treatment furnace and lead bath: Natural gas heating:Zinc bath: Electric heating
| Production Line Equipment Length: 159m(2,2)
Actual length: 159 m (Pay-off units arranged in two rows, take-up units in double rows)
| Required Workshop Length: >170m
| Required Workshop Width: >9m
| Required Workshop Height: >8 m
, | Temperature Monitoring and Control: | Automatic digital display
, | Concentration Monitoring and Control: | Manual
| Energy Supply: 380V 50Hz
2- Production Process Flow
2.1
Pay-off Machine Passive Pay-off Unit Process Flow
I-shaped spool vertical active pay-off (double-row pay-off) → Idle → Open flame furnace → Lead bath → Air cooling → Two-stage water cleaning → Idle → Smokeless pickling tank → Idle → Three-stage water cleaning → Idle → Fluxing → Idle → Drying → Idle → Hot-dip galvanizing → Guide roller set → Idle → Water cooling tank → Idle → Inverted plum blossom take-up unit (double-row take-up)
Production Line Length: 160m | Approx. 160m
3- | Process Description
I-shaped Spool Active Pay-off Unit
Using SF950 accumulator pay-off machine for 24-wire active pay-off (Φ1.3-Φ4.0mm low-carbon steel wire), suitable for Φ950 I-shaped spool (specific drawing provided by the customer, see Appendix 1). Adjustable tension ensures smooth pay-off without slack. Accumulation time is no less than 3 minutes, allowing spool replacement without stopping. Spool replacement is simple and easy to operate. Inovance inverters and Siemens S7 PLCs are used. Electrical equipment is housed in an independent cabinet with the take-up machine's electrical system. The pay-off and take-up are interlocked for control, automatically adjusting tension tracking.
Φ950 I-shaped spool horizontal-axis rotating pay-off device with independent automatic dual-drum traction wheel (24 wires).
Spool model: Φ950 (See customer's attached drawing).
Spool frame: Pneumatic top center, top plate fixed method.
Wire diameter range: Φ1.3mm-Φ4.0mm.
Traction motor: 4kW.
Accumulator motor: 3kW.
Dual drum diameter: Φ550mm.
Accumulation time: ≤3 min (Accumulation specification: Φ2.5mm, speed: 40m/min).
Spool braking: Mechanical braking with sensing arm.
Operating speed range: DV=100.
Compressed air: 3-5 bar; each row is equipped with an automatic drainage oil-water separator to ensure proper operation.
Noise level: ≤83 dB.
The pay-off maintains synchronized operation during normal operation, ensuring no wire pressing, no wire breakage, and no wire tangling.
Wire passing components are made of alloy steel with quenching treatment.
Natural Gas Open Flame Furnace + Lead Bath Furnace
2.1 | Open Flame Furnace
1- | Main Technical Parameters
| Material: ,(42B-82B) | High-carbon steel wire, carbon content (42B-82B).
| Wire Diameter Range: φ1.3~φ4.0mm
| Average Diameter: φ2.5mm
| Wire Elevation in Furnace: 900mm | Approx. 900mm
| Number of Wires: 24 | 24 wires
| Wire Spacing: 30±1mm
| Total Wire Spacing: 690mm
| Wire Speed: (DV=mm×m/min) 100
| Maximum Speed: 50m/min(≤φ2.0mm) | 50m/min (for ≤φ2.0mm)
| Production Capacity:
| Minimum Furnace Production Capacity: 1136.6kg/h (φ1.6,DV=80) | Approx. 1136.6kg/h (φ1.6, DV=80)
| Maximum Furnace Production Capacity: 2664kg/h (φ3.0mm, DV=100) | Approx. 2664kg/h (φ3.0mm, DV=100)
| Average Furnace Processing Capacity: 1598.4t/month(φ2.5mm,DV=100) | Approx. 1598.4t/month (φ2.5mm, DV=100)
| Designed Production Capacity: 2220kg/h(φ2.6mm) | Approx. 2220kg/h (φ2.6mm)
| Oxidation Loss: ≤0.2%
| Energy Supply:
| Fuel Type: , | Natural gas, calorific value ≥8000KCal/Nm³
| Pipeline Pressure: 30-40kPa
| Connection Pressure: 5-10kPa
| Maximum Heating Capacity: 145.5×10×4.18kJ/h
| Designed Heating Capacity: 121.2×10×4.18kJ/h
| Connection Pipe Diameter: DN60
| Power Supply Requirements: AC380V±5%, | AC380V ±5%, three-phase four-wire system
2.2 / Detailed Description of Open Flame Heating Furnace
Construction Materials: High-temperature resistant stainless steel, Q235A plates, Q235A profiles, refractory materials, etc.
Front Wire Separation Nozzle: 1 set
Furnace Internal Wire Elevation: +915mm
Furnace Length: Preheating section 3.7m + Heating section 28.3m = Approximately 32m
Furnace Internal Net Width: Approximately 1150mm (External Net Dimension: 2300mm)
Number of Heating Sections: 5 sections
Number of Burners: 38
Maximum Operating Temperature: 1150ºC
Main Structural Design Features of the Furnace:
Furnace Type and Structure
The furnace adopts a counter-flow direct-fired heating design with multi-section configuration. The preheating section is non-heated, while each of the remaining sections is equipped with multiple high-speed mixed-gas burners installed laterally on both sides.
From the wire entrance, the furnace consists sequentially of a preheating zone, heating zone 1, heating zone 2, heating zone 3, and heating zone 4 (soaking zone).
Each heating zone operates independently yet interactively. Temperature and atmosphere can be zone-specified per heat treatment requirements.
Ceramic wire supports are installed in each zone to elevate the wires, maintaining clearance from the furnace chamber.
Hermetic access doors are provided on both sides before/after supports for oxide removal and wire entanglement resolution.
Retractable sealed covers with fiber wool curtains are installed at both ends to minimize oxidation and heat loss while preventing wire scratches.
A wire comb at the exit ensures even distribution into the lead bath without tangling. Dedicated wire channels are incorporated.
The direct-fired furnace features four zones: hot-air combustion in low-temperature zones and premixed combustion in high-temperature zones.
Zones 1-2 use conventional high-speed burners; zones 3-4 employ premixed burners.
An exhaust heat exchanger recovers thermal energy to preheat combustion air for zones 1-2, enabling self-recirculation and energy savings.
Furnace Construction
Walls: High-strength lightweight brick + low-thermal-conductivity brick + insulation board + ceramic fiber + steel casing.
Roof: High-temp ceramic fiber modules + insulation blanket + steel cover plate.
Floor: Heavy-duty castable + high-strength lightweight brick + low-thermal-conductivity brick + insulation board + steel baseplate.
1.3Combustion System & Burners
The furnace employs zone-specific heating with independent temperature/atmosphere control.
Multiple premix burners are installed per zone.
The system includes pressure regulators, motorized butterfly valves, digital actuators/controllers, premix burners, pressure switches, piping, and gas explosion-proof devices.
Gas/air are proportionally premixed via digital actuators/controllers prior to combustion
High-velocity combustion generates chamber circulation, while cross-arranged burners ensure uniform heating without hotspots.
Precise zone control prevents wire decarburization and oxidation.
Forced Draft System
A dedicated blower supplies air (typical specs, subject to design):
Pressure: 9,800-8,500 Pa
Flow rate: 1,800-2,300 m³/h
Power: 12.5 kW
Exhaust System
Flue gas exits at the wire entrance, passing through a heat exchanger and pressure valve before natural draft emission via steel stack.
Stack flange is provided; height (recommended 18m) and DN550+ outlet to be determined by buyer.
Gas Supply & Safety
The gas main includes pressure regulators, safety shutoff valves, and vent valves (no S-filter required). All valves must be horizontally mounted.
System operation requires stable air/gas pressure.
Emergency gas cutoff triggers upon pressure deviation or power failure.
Safety valves only open when power and pressure meet specifications.
7Control System
PLC1200 regulates each zone's temperature via real-time measurement vs. setpoint calculations.
Adjusted signals actuate zone air valves to maintain fixed gas/air ratios for stable combustion and temperature control.
Optimal atmosphere settings are locked during commissioning for consistent operation.
The HMI displays real-time data, alarms, parameters, and temperature trends.
Dual master/slave interfaces feature PID tuning and zone-specific air/fuel ratio adjustment.
2.3 / Lead Bath Furnace
/ Production Line Orientation
Complies with overall equipment layout direction
/ Steel Grade & Wire Diameter
High-carbon steel wire: 0.60%-0.93%C, Φ1.3-Φ2.2mm
/ Internal Dimensions : 8000mm (L) × 1200mm (W) × 500mm (H)
/ Wire Spacing : 23×30mm=690mm
/ Wire Entry Groups
2,12(12)
2 groups, 12 wires per group (12-wire group on operator side)
/ Heating Method
Natural gas bottom heating: 4×70kW = 280kW
/ Processing Capacity
2.5mm,DV100mm*m/min
Example for 2.5mm wire: DV value 100mm·m/min
/ Wire Elevation : 900mm(ground reference)
/ Operating Temperature
560±20,600°C
Standard: 560±20°C | Max withstand: 600°C
/ Dust Control Design
Lead bath covered with steel plate over flux agent, plus protective hood
/ Thermocouples
1 each at front/rear of lead pot, measuring points aligned with wire level
/ Furnace Structure
/ External dimensions: 9500×2700×1500mm
/ Construction:60ºC. Welded steel frame with high-temperature refractory lining and insulation (wall temp rise ≤60°C)
/ Lead pot: 40mmQ235(),, 40mm thick Q235 steel plate (flat bottom/corners) for strength, corrosion/heat resistance
/ Reinforcement: , Steel framework to prevent deformation
/ Insulation:Bottom: High-alumina insulation material
Sides: Aluminum silicate fiber blankets
/ Lead capacity: ~67.5 tons
/ Heating System
4 Natural gas bottom heating (4 burners)
Automatic flame detection, flameout protection, gas cutoff
Remote PLC records flameout/alarms; local audible/visual alarms
70,280kw 70kW per burner (total 280kW)
PLC,±3ºC PLC auto-control (±3°C accuracy)
/ Cooling System:,
Air-cooled heat exchangers for lead temperature regulation
Activated when temperature exceeds setpoint (controlled by thermocouples)
Dedicated solenoid valves/dampers per cooling group
Removable cooling pipes at pot bottom (independent airflow control for front/rear zones)
/ Lead Pumps & Thermocouple
Ensure uniform lead temperature (±3°C variation)
circulation pumps installed at low-temperature exit zone
lead circulation pumps (mounted on both sides of pot)
Water connections per final drawings; slag-proof circulation channels
/ Sink Rolls & Guide Wheels
6000mm immersion length; 1 sink roll at entrance/exit
Alloy steel semicircular heat-resistant rolls (fixed/passive)
Water-cooled single guide wheel at exit
Cooling water connections per final layout
/ Sand Hoppers & Boxes
Sand hopper, wire comb, and support roller at exit,Dedicated sand box to prevent lead adhesion,1m length; ash collection box with casters
/ Cover
Steel plate over flux agent + protective hood
/ Equipment Cooling
Water cooling for guide wheels and lead pumps
Buyer to connect cooling system
Connections per final drawings
" pipes, 0.4MPa, 15-20m³/h flow
Recommend outdoor recirculation tank
/ Exhaust System
Flange provided for connection to buyer's existing duct
/ Lead Control Measures
Minimize lead carryover: wire surface must be smooth, unscratched, oxidation-free
No rust from rain/sandblasting
Special flux agent required at exit sand bath
Direct-fired furnace must adjust reducing atmosphere to minimize oxidation
/ Water Cooling (Quench Tank)
Supplier provides drawings; buyer fabricates/installs
/ Overflow-type Water Cleaning
The tank is welded and manufactured using reinforced 304 stainless steel, with a length of 3000 mm. To quickly and efficiently remove residual impurities from the surface of the steel wire, the tank adopts a two-stage overflow cleaning system with separate circulation and reverse inflow and drainage configuration. Each tray is equipped with a lifting pump (motor power: 0.55 kW) to provide the driving force for overflow cleaning. During the overflow cleaning process, the water supply to the cleaning tray uses a jet flow pattern. The cleaning water can be recycled and reused, thereby conserving water usage and reducing wastewater discharge. To prevent cleaning water from entering the subsequent processing stage, the outlet of the cleaning tank is equipped with interception stone bars and back-blow air knives (supplied with a 5.5 kW blower) to intercept residual water on the steel wire surface.
Tank material: 304 stainless steel
Number of trays: 2-stage overflow trays
Liquid supply: 2 lifting pumps
Residual liquid wiping: 1 set of interception stone bars + 1 set of back-blow air knives (equipped with one 5.5 kW blower)
/ Overflow-type Closed Acid Pickling
An integrated acid pickling tank is manufactured using PP material, with a length of 19,000 mm. During the cleaning process, the steel wire runs linearly through the integrated tank, which employs an overflow system. The tank is equipped with two corrosion-resistant pumps (motor power: 2.2 kW) for water curtain circulation, and three acid-resistant pumps (motor power: 0.55 kW) to provide the overflow for the pickling solution. Both the inlet and outlet of the tank are sealed with dual water curtains, while the sides are protected by groove seals to prevent acid mist leakage. To ensure rapid removal of oxides from the steel wire surface, adapting to the high-speed cleaning requirements and meeting galvanizing process specifications, the pickling solution is circulated reciprocally by acid-resistant pumps. This enables the steel wire to achieve pre-plating surface cleanliness through hydrochloric acid rinsing. To reduce acid consumption and prevent residual acid from entering subsequent processes, the tank outlet is equipped with interception stone bars and a back-blow wiping system to remove leftover acid from the steel wire surface.
Tank material: PP plate
Number of trays: 3-stage overflow trays
Liquid supply: 2 corrosion-resistant pumps, 3 lifting pumps
Residual liquid wiping: 1 set of interception stone bars + 1 set of back-blow air knives (equipped with one 5.5 kW blower)
| Six-stage Overflow Water Cleaning
The tank is welded and manufactured using reinforced PP material, with a length of 3,300 mm. To rapidly and efficiently remove residual acid from the steel wire surface, the tank employs a six-stage overflow cleaning system with separate circulation and reverse inflow/outflow configuration. Each tray is equipped with six corrosion-resistant vertical pumps (motor power: 0.55 kW) to provide overflow driving force. During the overflow cleaning process, the water supply to the cleaning tray uses a jet flow pattern. The cleaning water can be recycled and reused, thereby conserving water usage and reducing wastewater discharge. To prevent cleaning water from entering subsequent processes, the tank outlet is equipped with interception stones and back-blow systems to trap residual water on the steel wire surface.
| Tank material: PP material
| Number of trays: 6-stage overflow trays
| Stone bars: 6 sets
| Liquid supply: 6 lifting pumps (ABB)
| Residual liquid wiping: 1 set of interception stone bars + 1 set of back-blow air knives (equipped with one 5.5 kW blower)
| Overflow Assisting Plating
The total length of the tank is 2.5 meters. The tank consists of a storage tank and an upper tank, where circulating pumps extract assisting plating solution from the storage tank to the upper tank for overflow plating of the steel wire. The storage tank is equipped with inlet, drainage, and overflow ports. A digital temperature controller on the instrument panel regulates the submerged heater to control temperature. At the steel wire outlet, high-efficiency air knives are installed. Two-stage interception stones and back-blow systems are equipped at the exit, blowed by a single fan through the pipeline to return excess liquid to the assisting plating tank.
Technical parameters of zinc-aluminum alloy assisting plating tank are identical to those of galvanizing assisting plating tank.
| Tank material: PP plate
| Splitter plate: Granite, quantity 2 sets
| Solution heating: Corrosion-resistant electric hybrid heating, temperature range 50-75ºC, auto-adjustable
| Temperature control: Digital temperature display with automatic regulation
| Circulation pumps: Quantity 2
| Piping & valves: PP pipes with ball valves (PP material)
| Air blowers: Quantity 2
| Drying Furnace
The drying furnace uses direct electric heating for heat supply. The frame is welded with Q235 steel, while the inner chamber lining is made of 304 stainless steel to resist assisting plating solution corrosion. The bottom of the chamber uses steel plates as heat storage medium, and the insulation layer employs high-temperature aluminum silicate fiber materials. Heat is circulated through hot air ducts. Operating temperature ranges from 150~250ºC, with a total length of 8,000 mm. To prevent rusting of the zinc coating during storage, post-plating steel wires must be dried.
| Furnace material: Q235 frame, steel plate, alumina-silica fiber insulation
| Heating method: Electric heating, manual temperature control
| Temperature range: 150-250ºC
| Empty Gear: For operational convenience;
| Electric Internal Heating Ceramic Zinc Pot
The zinc pot utilizes ceramic tube internal heating technology. It consists of a pot body, ceramic tube heaters, and a temperature control system. The heating elements are installed inside the pot wall to ensure uniform zinc liquid temperature. Corrosion-resistant K-type thermocouples measure the temperature directly in contact with the zinc liquid, ensuring stable performance with a service life of over 1 year.
Install differential temperature alarm device
Install two comparison thermocouples (one at midpoint, one at pressure axis position)
Design parameters of galvanizing pot:
Internal dimensions: 6,500×1,120×900 mm (L×W×D)
External dimensions: 8,900×2,500×1,500 mm (L×W×H)
Zinc melting capacity: ~45 tons
Pot weight: ~75 tons
Installed power: 540 kW (three-side heating, 108 sets of ceramic heaters, 5 kW/set)
| Pure Zinc Vertical Steel Frame
The vertical steel frame for wire extraction uses thickened steel beams and structural steel design to ensure stability and anti-vibration performance. The upper platform is made of slip-resistant steel plate with continuous welding, surrounded by protective railings for worker safety. The tensioner and guide shafts adopt single-pulley transmission to accommodate wire tension and ensure smooth operation.
| Frame material: Q235 reinforced steel
| Pure zinc transmission system: 2 zinc tensioner rollers + 1 guide roller (single-pulley design)
| Alloy traditional system: 2 alloy tensioner rollers + 1 guide roller (single-pulley design)
| Safety protection: Guardrails around platform and ladder
| Pressure Roller
11.1
The pressure roller is made of SiC-SiN composite material sintered. With a sector arc radius R≥300 mm, it features high strength, wear resistance, high-temperature resistance, and zinc liquid corrosion resistance. The flip-type mechanism allows angle adjustment via hand wheel operation (reducer ratio 50:1), with a service life of ≥2 years.
| Roller material: SiC+SiN
| Sector radius: R≥300 mm
| Transmission: 50:1 reducer with manual control
| Wiping System
Nitrogen gas wiping system is a contact-type device for controlling zinc layer thickness through air knives. Each air knife independently adjusts nitrogen flow rate, pressure, and temperature via automatic flow valves and meters. Zinc layer thickness is controlled by modifying gas parameters and wire speed. Designed for high-speed galvanizing lines (1.3-4.0 mm wire diameter), maximum DV value 100 mm·m/min. The online detection & control system includes four components:
Zinc layer sensor
Gas flow/pressure control actuator
Air knife actuator
PLC central controller
Principle: Real-time thickness measurement → feedback to PLC → adjustment of gas parameters → precise thickness control.
Gas source requirement: ~400 m³/h nitrogen (customer-supplied nitrogen generator/tank).
Control modes:
Manual: ±45 g/ precision
Automatic: ±20 g/ precision
Key requirements:
Constant tension control for wire payoff/reel
No wire twists or joints (welding required)
Technical specifications:
Zinc layer thickness: 150-330 g/
Wiping method: Air knife
Air knife material: Stainless steel, precision-machined
Control mode: PLC automatic control
| Cooling System
13.1
Rapid cooling after wiping is essential for controlling zinc-iron alloy thickness, improving coating adhesion, and surface finish. The system features 3 water cooling stages and 1 air cooling stage. Cooling water flows through distribution manifolds with adjustable valves for precise flow control. Water recycling facilities (customer-provided) are required to conserve resources.
| Cooling method: 3-stage water cooling + 1-stage air cooling
| Control mode: Manual with individual control systems
| Supply: 2 combination pumps (7.5 kW each) + 1 blower
| Pure Zinc Water Cooling Tank
The tank is welded with reinforced 304 stainless steel, measuring 2,400 mm. It features a single-stage overflow washing tray for efficient cooling of hot-dip galvanized wires. The overflow system operates with independent water circulation per stage. Washed water is recycled to save resources and reduce pollution. At the outlet, back-blow air knives (equipped with a 3.7 kW turbine blower) trap residual water. A corrosion-resistant pump (0.55 kW) supplies overflow.
| Tank material: 304 plate
| Number of trays: 1-stage overflow tray
| Liquid supply: 1 corrosion-resistant lifting pump (0.55 kW)
| Residual liquid wiping: 2 sets of back-blow air knives + 2 turbo blowers
| Wire Coiling Unit (2 Groups)
24 Inverted Wire Coiling Machines
SL 625 inverted coiling units with 24 lines are adopted, featuring traction wheel diameter of 625 mm, suitable for wire diameters Φ1.3-4.0 mm, equipped with 5.5 kW motors and reducers.
Coiling dimensions: Inner diameter 450 mm, outer diameter 800 mm, coiling weight 500-800 kg.
Coiling speed range: DV=120 (for materials Q195/Q235 low-carbon steel wires after hot-dip galvanizing).
The coiling system is equipped with pneumatic accumulation arms and ground-mounted carts (0.55 kW motors, sliding rails). Party A is responsible for installing floor plates and welding cart tracks on the ground. Frequency converters, touchscreens, and Huichuan PLCs are installed in independent control cabinets for individual line control.
The bottom cart automatically tracks the traction drum speed and can be manually adjusted. (Party A manufactures the inner drop-off frame for finished coils; Party B manufactures the outer wire rack with guide rollers.) Suitable for two outer diameter specifications.
Straightening devices (3 sets per line, each containing 5-wheel units) are installed at the traction drum, covering Φ1.6-4.0 mm wires.
All coiled products must meet quality requirements:
Vertical coil expansion/contraction ≤±40 mm
Lift height ≤40 mm
Smooth surface without defects
Oil/wax coating lines prevent slippage and twisting
Ensures smooth payoff and includes a length counter with alarm function
| Additional Specifications
Lighting for inverted coiling units is installed on central pedal platforms to meet production requirements.
Dual-wire systems share frames (two heads per frame); inverted coilers use 2-head-per-frame design.
Bearings, belts, and pulleys for payoff and coiling use domestic premium brands.
Drum material: 45 steel with tungsten carbide coating (HRC55-60). Inverted V-groove drums are heat-treated (HRC45-50).
The take-up and pay-off systems use AC variable frequency motors manufactured by Wannan Motor Company and are controlled by Inovance PLC frequency inverters. The take-up and pay-off electrical cabinets are placed independently and utilize Inovance grouped control to meet the user's process requirements, ensuring individual control for each wire.
Paint color: Sky blue (to be confirmed by client).
Equipment is arranged in back-to-back (optional face-to-face) configuration, including splitting and threading devices.
Subsystems:
24-line splitting device
24-line portal frame
Coiling units with 24-line design
| Wire Spacing & Elevation
Wire height at furnace inlet: 900 mm (determined by furnace manufacturer).
Wire spacing at payoff station: 38 mm (determined by furnace manufacturer).
Wire spacing at coiling station: 38 mm (determined by furnace manufacturer).
| Acid Mist Tower (Indoor, Integral)
The entire acid mist dust collection system is comprehensively planned and designed, involving re-selection of fans, customization of pipeline layouts and dimensions based on practical conditions, installation of dust covers at all steam generation points and acid mist emission sources for one-time setup, ensuring neatness, aesthetic appeal, and operational convenience. The system is equipped with one acid mist purification tower that absorbs and neutralizes HCl gas overflow from pickling tanks through three-stage NaOH solution spraying, while discharging residual hydrogen gas from tanks to outside the workshop via fan ducts.
| Centralized Control System
According to production line operation and control requirements, Siemens PLC with custom programming is adopted to control production processes and equipment. The zinc pot (high-power high-temperature special equipment) only participates in display functions of the centralized control system, not in centralized control. The human-machine interface uses Kunlun Touch 15-inch touchscreen (model/specification customized according to production and equipment control needs), installed on the main console. The software uses simplified Chinese interface, configured according to client-specific requirements. Operators/engineers can perform simple and intuitive operations to achieve terminal centralized control.
| Main Control System for Entire Line:
PLC with custom programming controls production processes and equipment.
| Integrated Display and Operation:
Operate production line settings, display status, adjust monitoring, and view I/O point statuses on the touchscreen.
| Key Functions Include:
1. Displays working status of all major devices on the production line.
2. Sets control modes.
3. Configures operating parameters.
4. Displays all critical real-time parameters.
Nitrogen Generator (Client-supplied),200Nm³/≥99.99%,,,,.,,,,..
To meet the nitrogen requirements of the production line's nitrogen wiping system, the production line is equipped with a nitrogen generator (200 Nm³/h flow rate, purity ≥99.99%) that employs nitrogen molecular sieves as adsorbents and utilizes the pressure swing adsorption principle to produce nitrogen from atmospheric air under normal temperature and low pressure conditions. The nitrogen generator consists of an air compressor, compressed air purification system, oxygen-nitrogen separation unit, nitrogen buffer system, nitrogen purification system, and other components.
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