PROCESSING LINES FOR HOT-DIP GALVANIZING

PROCESSING LINES FOR HOT-DIP GALVANIZING

Konsorcjum REMIX offers comprehensive service of HDG plants concerning consultation, design and manufacture of equipment contained in hot-dip galvanizing process lines. We offer complete HDG lines based on electrical heated or gas-fired furnaces with steel kettles or ceramic baths for both low temperature and high temperature hot-dip galvanizing. Being experts of longstanding experience, we provide comprehensive solutions suited to individual requirements of our Customers. With the help of our expertise we can provide professional support in design of complete processing lines for hot-dip galvanizing. Our offer comprises: A local inspection at the Customer's facility. Consultations concerning selection of technology and equipment for a HDG plant under construction. Design of complete HDG processing lines. Manufacturing and assembly of equipment incorporated in a given HDG processing line: Hoists for charge moulding and demoulding of charges and stockpoints. Transport systems for HDG plant (rope overhead cranes, rope hoits, industrial truck cars) Complete lines for surface preparation before galvanizing (system of processing tanks with ventilation, utility installations, storage containers, flux regeneration units, waste neutralization systems Electrical heated and gas-fired chamber driers using the heat of exhaust gases leaving the galvanizing furnace HDG furnaces with steel kettles and ceramic baths Steel galvanizing kettles Water tanks Slotted and cabin vapour extraction systems Exhaust gas extracting and pollutants filtering systems Transport, unloading and positioning Service, overhauls and modernization of HDG plants Control, monitoring and process visualization systems for HDG plant Spare parts Draft of a HDG processing line 1. Charge moulding area 2. Charge degreasing tank 3. Rinsing tank 4. Charge etching tank 5. Rinsing tank 6. Etching-out tank 7. Fluxing tank 8. Charge dryer 9. Galvanizing furnace 10. Water tank 11. Charge demoulding area

Surface preparation Chemical surface processing lines An etching line (preliminary processing before hot-dip galvanizing) is a key segment of every HDG plant and has a major impact on the operation of the entire galvanizing plant. As experts of longstanding experience, we offer comprehensive solutions to our Customers. For new investments in the area of surface preparation prior to galvanizing we provide: Manufacture and assembly of etching tanks A system of storage tanks for new and used chemicals Transport system for chemicals within the plant Ventilation system with absorption of acid fumes Neutralization of liquid waste and used acids Assembly, start-up, training Etching tank 3D

Surface preparation Our etching tanks feature exceptional durability and solidity of construction. Each tank is designed in accordance with PN-EN 12573 standards and DVS 2205 parts 1 5 guidelines. Apart from that we can provide testing strength calculations with MES method. A process tank consists of a steel supporting structure (protected with chemo-resistant coating) which holds supports for handling traverses. Etching tanks may be equipped with movable covers, which significantly decreases evaporation of acids. The following can be used to heat up the baths: electric heaters, plastic immersion heaters or external heat exchangers. Air cleaning systems, flux regeneration units and liquid waste neutralization systems In order to be considerate of the environment and to comply with environmental standards, the users of HDG plants are committed to clean the air of noxious substances and provide flux regeneration units as well as liquid waste neutralization systems. Manufactured by IMFITEX absorbers and droplet eliminators, together with ventilators and other elements of the system provide a reliable and efficient air cleaning system to be used at the stage of chemical surface preparation before galvanizing.

Dryers Chamber dryers are designed to dry up and heat the charge up to the temperature of 120 C (measured inside the chamber) prior to galvanizing process. To suit our Customer's needs we provide dryers with either electric or gas heating systems. Charges inside a dryer are heated with air which uses the thermal energy from the exhausts leaving the HDG furnace. An additional gas burner may be provided to support the heat exchanger to heat up the drying air. Charge transport inside a dryer may be effected in one of the following ways: Push-through system Chain-driven mobile system Truck system. Photo acknowledgments: MEPROZET, JAMALEX, LEGIPOL, POLIMEX Furnaces with ceramic baths Galvanizing furnaces with ceramic baths are designed for high temperature HDG processes run at the temperature up to 600 C. Most often they are used for galvanizing of small elements. Bath volume up to 100 ton Bath capacity (for galvanizing) up to 4 ton/h Heating system electric or gas

Furnaces with steel kettles Galvanizing furnaces with steel kettles are designed for low temperature HDG processes run at the temperature up to 450 C. Most often they are used for galvanizing of large elements. Modular thermal insulation of furnace walls is made of top quality fibrous ceramic materials. Appropriately selected thickness of insulation layer and the type and quality of materials applied in its construction ensure low idle power of the furnace and external temperature of its casing walls not exceeding the ambient temperature by more than 40 C. Depending on the individual needs of our Customer, we can provide furnaces with either electric or gas heating systems, suitable for high temperature operations in industrial conditions. The heating systems ensures such a temperature gradient that prevents rising of hard zinc from the bottom of the galvanizing kettle. Bath volume up to 450 ton Bath capacity (for galvanizing) up to 15 ton/h Heating system electric or gas Exhaust extraction system slot or chamber Photo acknowledgments: MEPROZET, JAMALEX, LEGIPOL, POLIMEX

Filtering systems Exhaust extraction and filtering systems In order to be considerate of the environment and to comply with environmental standards, the users of HDG plants are committed to clean the exhausts and waste released in the course of galvanizing. Our exhaust extraction and waste filtering systems are provided by Nederman Polska. Our quotation on exhaust extraction and filtering systems comprises the following: industrial dust extractors industrial fans screw conveyors collection and transport units for filtered waste pipes and pipelines, filtering bags service of dust extraction systems.

Additional products for hdg plants Electric screw elevators to operate at charged moulding and demoulding areas. Charged stockpoints (waiting areas). Process transport including: rope cranes, electric rope hoists and rail platforms to carry galvanized workpieces. Cooling and galvanizing baths Tooling (traverses, zinc pumps, hard zinc scoops, etc.) Spare parts Control, monitoring and process visualization systems for HDG plant Stacks (emittors) Spinning machines Cabins and suction for galvanizing fumes All equipment is manufactured in compliance with basic requirements of applicable EU directives and has the CE compliance mark @ 6.2016