Process flow
I-wheel pay-off→gas open flame heat treatment furnace→lead bath treatment→temperature adjustment cleaning→smokeless pickling→water cleaning→assisting plating→drying treatment→hot-dip galvanizing→wiping cooling→inverted winding
Overview of process equipment
1. Pay off the spool
2. Steel wire open flame heat treatment furnace:
3. Lead bath treatment
The lead bath is made of 50mm thick steel plate and welded by steam protection, and the lead bath boiler body is welded by steel plate and section steel. The overall performance is good, beautiful and practical. The furnace body adopts an integral structure, which reduces on-site installation time and facilitates future maintenance; the outer column adopts a square tube structure, which is not easy to deform and has high strength. Lead bath furnace body insulation is mainly composed of light fiber felt and heavy insulation and load-bearing materials, which have good insulation performance. The furnace wall with composite insulation structure can minimize the heat dissipation of the furnace wall.
4. Temperature adjustment cleaning tank
The overflow cleaning method is used to remove residual impurities and oxides on the surface of the steel wire. The cleaning tank is made of stainless steel welding.
5. Turbulent smokeless pickling tank
6. Water cleaning tank
The overflow two-stage flushing cleaning method is used to clean the residual impurities and residual acid on the surface of the steel wire. The cleaning tank is made of 20mm thick, high-strength PP material plate welding.
7.plating aid solvent tank
The steel wire is washed with water and enters the plating aid solvent tank. The plating aid solvent tank adopts overflow circulation method. The tank body is made of reinforced PP plate welding. The heating adopts electric internal heating or PPE steam heater heating. The temperature control adopts intelligent instrument PID to automatically control the temperature. .
8. Steel wire drying furnace
The drying furnace adopts box-type steel structure, which is beautiful and durable. The inner tank of the drying furnace is made of stainless steel to prevent corrosion of the plating solution. The heating adopts the heat source of the exhaust gas of the zinc boiler to heat the drying furnace, and an external circulating fan is installed for forced circulation.
9. Hot-dip galvanized zinc pot
The zinc pot is made by welding of XG08 zinc pot special wide steel plate produced by Anshan Iron and Steel, with a thickness of 60mm. The zinc pot adopts a round bottom and rounded structure. The XG08 zinc pot special wide steel plate produced by Anshan Iron and Steel has the characteristics of no deformation and long service life. Use high-quality refractory fiber and other materials as heat insulation layer. The heating adopts 4 high-speed burners, and the total power of gas heating is 920KW. The heating burners are arranged diagonally in the zinc pot to ensure uniform and stable heating of the zinc liquid. Using intelligent instrument PID to automatically control the temperature of zinc liquid.
10. Zinc pot steel wire pressing roller
11. Wipe the coating
150g/square meter≤plating layer≤350g/square meter; adopt vertical nitrogen protection wiping technology. The nitrogen wiping system consists of a gas distribution bag, flow control, nitrogen heating, a split wiping tube and a gas supply pipeline. The nitrogen enters the independent flow controller after passing through the gas distribution bag, and the flow controller sends the nitrogen into the nitrogen heating furnace to be heated to 80~150°C and then through the gas pipeline into the annular chamber of the wiper pipe to achieve the purpose of wiping.
12. Cooling after plating
The steel wire must be quickly cooled after being wiped. It is a key process to control the thickness of the alloy layer after the steel wire is plated, and to improve the firmness of the coating and the surface finish of the steel wire. The steel wire cooling water has recycling facilities to save water resources.
13. Steel wire vertical plating steel frame and threading platform
The vertical plated steel frame adopts a steel structure frame. The steel frame is equipped with a support spool, a vertical plated steel wire cooling device, a wire shaft and a steel wire guide shaft. The vertical plated steel frame is designed to be firm and the steel wire runs smoothly.
14. Steel wire take-up equipment
The production line adopts 48 sets of V-shaped disc inverted plum blossom take-up unit, and the surface of the V-shaped groove is sprayed with tungsten carbide treatment. The unit adopts a single-reel independent transmission system. The single-reel take-up speed can be adjusted arbitrarily according to the wire specifications. The wire take-up has good flatness and stable wire routing. The reel weight meets the requirements of 800~1000kg, which is convenient for workers to operate.
