Galvanized Production Line

Electric Galvanized production line

We will customize the elctric galvanized production line according to your detailed request.

Such as, we need to know what the raw material is, what the zinc coating thickness, what the fuel is , what the capacity is, what the inlet wire dia is, what the capacity is. Etc.
Then i will make a complete offer for you.

Flow Chart


Pay-off wires by a spool→annealing by heat treatment→air cooling→washing and
temperature adjustment→smokeless pickling→washing→galvanization→washing→
washing by hot water→drying→inverted take up wires

The following is a detailed program for inlet wire 1.8-4.0mm


1. Designing and manufacturing conditions in the production line

1.1Requirement on products:meeting standard technical requirement on galvanizing mild steel wires;

1.2. Specification of products:Φ1.8~4.0mm;

1.3. Zinc coating thickness:20~30g/m2

1.4. Speed of galvanization:DV value is 120;

1.5. 60 wires,elevation of the central wire is 900mm,distance of steel wires in the plating tank is 35mm

1.6. Making 2.2mm, steel wires as the example,we can get the daily output up to 130 ton;

1.7. Temperature of sulfate liquor for galvanization:30~40ºC;

1.8. Voltage and frequency:380V,50Hz,total power is about 850KW;

1.9. Length of production line occupied is about 180m;

1.10. There's advanced technology and good appearance in the production line and it adopts overflow wash for galvanization and preliminary treatment.



2. Flow processes

Pay-off wires by a spool→annealing by heat treatment→

air cooling→washing and temperature adjustment→

smokeless pickling→washing→galvanization→washing→washing by hot water→drying→inverted take up wires

3. General situation of equipment in the production line:

3.1Equipment for paying off wires:

A spool is used for paying off wires and it is composed of a pay-off frame and a bobbin. There's a regulating device installed on the rotating part of the pay-off frame in order to control the tension of paying off wires. To ensure the quick and continuous replacement of bobbins,we apply rotational positioning to pay-off frames.External dimension of each bobbin is 800×600mm.Reserve steel wire volume of single spindle is 900~1000kg.Whirling arms are used to extract steel wires and ensure that wires are not easy to be out of order and go smoothly.

3.2 The annealing furnace for steel wire heat treatment:

To ensure stable mechanical property of wires in operation,we adopt a gas flame heat treatment furnace,whose shell is welded as a steel structure,so it is attractive and durable with good whole sealing. We can make the temperature and atmosphere inside the furnace under the accuracy control by Math model method.30 direct-fired gas burners are installed on both sides of the furnace body.It adopts counter current flame for heating inside the furnace body and the control includes four periods.Period 1:preheating period for inlet wires;Period 2:heating period;Period 3:stable heating period;Period 4:heat treatment of steel wires.It is not only independent but also interactive among four periods.We can set the temperature and atmosphere inside the furnace according to each period to meet the technical requirement on heat treatment of steel wires.

External dimension of the furnace:24000×2800×1900mm.

Distance among wires inside the furnace is 30mm, width inside the furnace is 1900mm,standard height of wires is 900mm.

Temperature inside the furnace:1050~1100ºC

Energy consumption :gas consumption is 35~40m³/t when DV value is 120

Accuracy of temperature :±2ºC

3.3. Air cooling of steel wires:

To ensure the uniform cooling of wires after heat treatment in the air and prevent wires from hardening because of air cooling,it adopts tray type cooling way to make wires cooled uniformly in the cooling tray.Specification of the cooling tray:(L)8000×1300×900mm,There is a wire comb distributing wires.

3.4. Air-conditioning purge tank:

According to the technological requirement,current efficiency must be distributed evenly when electroplating each wire.It is easy to thread.This production adopts 60 lines shunt type pretreatment and the electric galvanization adopts double-groove production technology.That is to say,it adopts the shunt5 cleaning process of 30 wires after the cooling of wires. The purge tank in the front adopts double-groove and overflow type to remove sinter dust on the surface of wires and adjust the temperature of wire cleaning.The purge tank is welded by stainless steel plates.

-External dimensions of the purge tank2500×1400×1100mm,2 sets

-Each purge tank is equipped with a set of corrosion resistant vertical centrifugal pump of which the power is 2.2KW;1 set for each tank

-Brushes at the exit of the purge tank for wires are used to wipe for bring the washing water out.



3.5.Smokeless pickling tank:

The smokeless pickling tank adopts environmentally friendly steel pickling technology and works in completely sealed space for pickling.Acid turbulence resulting from acid circulation improve the efficiency of pickling,which makes wires get clean surface quickly before galvanization by the hydrochloric acid wash,so it meets the speed requirement of galvanization.The smokeless pickling tank is welded by PP material with the thickness of 20mm, effective cleaning length of pickling is 16000mm,a sealed cowling is equipped above the pickling tank.It adopts the water seal to prevent acid gas going out.It adopts three-lever turbulence in the pickling process and each lever runs dependently.The threading method is threading lines lengthwise along the pickling tank by gliding lead plate on both sides of the acid tank.It is easy to thread and distance among wires is 35mm,the height of central wires is 900mm.

-External dimension of the tank:20000×1600×1200mm, 2 sets

-The acid circulating system adopts corrosion resistant vertical centrifugal pumps whose size is 3 cun,power is 5.5 KW. 6 sets for each tank

-The water seal circulation adopts corrosion resistant vertical centrifugal pumps whose size is 2 cun, power is 2.2KW. 2 sets for each tank

3.6.The purge tank:adopting overflow wash,cleaning out and removing residual liquid and sundries on the surface when pickling wires. The purge tank is welded by PP plates with the thickness of 20mm.

-External dimension of the tank:2500×1400×1100mm, 2 sets

-The tank is equipped with a corrosion resistant vertical centrifugal pump,whose size is 2 cun and power is 2.2KW.1 set for each tank

-Rubber brushes are used to wipe and bring water out at the exit of the tank for wires.



3.7 The tank for electric galvanization:

To ensure the speed and surface quality of galvanization,we adopts two sets of plating tanks,each of that contains 8 plating tanks.The plating tanks are welded by PP plates with the thickness of 20mm.Inner dimension of each tank is(L×W×H)3500×1160×30mm.Length of 8 connected plating tanks is 30m.Effective length of galvanization is 28m.

The positive and negative electrodes of the tank adopt the copper bar,whose specification is 100×10mm.The anode uses a plumbum plate and its specification is 100×10mm.The cathode uses a current-carrying plate made of antifriction alloy.Power supply of each tank adopts adjustable voltage and range of power is 0~12V.It uses eliminator supply and the electric current is 4000A.

Steel wire rollers of the tank adopts abrasion-proof engineering plastics. Structure of rollers adopts single chip transmission.Diameter of rollers is 200mm.

It uses brushes at the exit of plating tanks for wires to wipe and prevent electroplate liquid being brought out.

Electric galvanization solution is sulfate added brightener.Sulfate plating solution is stable.Electric current density is 40~50A/cm2,temperature is 30~40ºC,PH value is 3~4.5. Filter the solution regularly according to the output.

3.8 Wire cleaning trough:

It adopts overflow wash.When cleaning galvanized Zn,there is residual plating solution on the surface of wires.The cleaning trough is made of PP material with the thickness of 20mm.

-External dimension of the trough:2500×1400×1100mm,2 sets

-A corrosion resistant vertical centrifugal pump is installed in the trough and its power is 2.2KW. 1 set for each

Brushes at the exit of the trough for outlet wires are used to wipe and prevent washing water being brought out.

3.9 Hot water cleaning tank:

It adopts overflow hot water to further wash the residual plating solution on the surface on steel wires.Oxidation of the wire surface is avoided in the process of storage and transportation.The cleaning tank is welded by PP material with the thickness of 20mm and uses resistance wire heating tubes for hot water heating.The temperature is controlled in the range of 60~80ºC.

External dimension of the tank:2000×1800×1100mm,2 sets

A centrifugal pump under corrosion fluid is installed in the tank and its power is 2.2KW.1 set for each

Power of each tank is 27KW.9 heating pipes,power of each pipe is 3 KW.1 set of electric control cabinet.

Brushes at the exit of the trough for outlet wires are used to wipe and prevent washing water being brought out.

3.10The baking furnace:

The furnace adopts pass-type electric heating with hot air drying equipment.The inner shell is made of stainless steel.The temperature can be adjusted according to the moving speed and diameter of steel wires. -External dimension of the furnace:5000×1300×1050mm, 2 sets

-The heating power of the furnace is 36KW,Power of each heating pipe is 1.5KW. 24 heating pipes in total.

-Adjustable range of temperature:80~200ºC

3.11 Part of taking up wires:

It adopts inverted plum blossom type take-up units and the take-up unit adopts the independent single plate driving system.Take-up speed of a single plate can be adjusted at will.Each take-up unit is equipped with a variable frequency motor of 4 KW and another one of 0.75KW.The take-up machine has a function of centralizing wires to ensure constant take-up speed,good flatness and stable move of wires.It can meet requirement on taking up wires of 600~800kg.

4.Traits of this production line

4.1The plating tanks of the production line are controlled by segmented power supply to ensure stable current density in the plating tanks every period.There are two designs in the plating tanks and the effective length of galvanization is 18m,which ensures that it can meet the requirement on speed and thickness of galvanization.The plating solution inside tanks can recycle outside tanks.Adjusting temperature of plating solution when recycling.

4.2 It adopts overflow to wash as the preliminary treatment of the production line,improving the washing speed,making steel wires move straightforwards and reducing the bend of wires to keep their physical properties. Wire washing speed is improved by using turbulent acid in smokeless acid pickling tanks,which is suitable for washing wires quickly and improves the quality of steel wires' surface.Acid frog is condensate recycled in the sealed space,which saves the pickling cost and improves the workshop production environment.

4.3 The furnace for heat treatment uses counter-current flame to heat and it is composed by several sections.The preheating section doesn't supply heat. Both of the sides of each section are equipped with many high-speed fuel gas nozzles in side direction.There are preheating section,heating section 1,heating section 2 and heating section 3. Each heating supply section is relatively independent and mutually influence.According to the requirements of heat treatment process,we can set the furnace temperature and atmosphere during each section.Wires inside the furnace are hold up by combs in order to keep a certain distance away from the hearth.Before and after combs,one side of the heating furnace is equipped with an air tightness door in order to clean furnace oxidation slag and deal with the accidents(such as wires gather together,unequal distribution).It is equipped with combs at the entrance and exit of wires to prevent from winding.We can open the doors at the entrance and exit to process in the furnace at will.