CN112941447A - Batch hot dip high-efficiency environment-friendly continuous walking plating process and equipment - Google Patents
Batch hot dip high-efficiency environment-friendly continuous walking plating process and equipment Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 106
- 230000008569 process Effects 0.000 title claims abstract description 90
- 239000000463 material Substances 0.000 claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 claims abstract description 33
- 238000007599 discharging Methods 0.000 claims abstract description 16
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 81
- 239000011701 zinc Substances 0.000 claims description 81
- 229910052725 zinc Inorganic materials 0.000 claims description 81
- 238000005554 pickling Methods 0.000 claims description 41
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- 238000007598 dipping method Methods 0.000 claims description 23
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 23
- 239000002253 acid Substances 0.000 claims description 21
- 238000002161 passivation Methods 0.000 claims description 17
- 238000001816 cooling Methods 0.000 claims description 15
- 238000005238 degreasing Methods 0.000 claims description 13
- 238000007602 hot air drying Methods 0.000 claims description 13
- 239000003795 chemical substances by application Substances 0.000 claims description 12
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 12
- 239000003595 mist Substances 0.000 claims description 12
- 238000007789 sealing Methods 0.000 claims description 12
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- 239000000956 alloy Substances 0.000 claims description 11
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- 238000011068 loading method Methods 0.000 claims description 10
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- 238000002203 pretreatment Methods 0.000 claims description 5
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- IMQLKJBTEOYOSI-UHFFFAOYSA-N Phytic acid Natural products OP(O)(=O)OC1C(OP(O)(O)=O)C(OP(O)(O)=O)C(OP(O)(O)=O)C(OP(O)(O)=O)C1OP(O)(O)=O IMQLKJBTEOYOSI-UHFFFAOYSA-N 0.000 claims description 4
- 239000000654 additive Substances 0.000 claims description 4
- BJEPYKJPYRNKOW-UHFFFAOYSA-N alpha-hydroxysuccinic acid Natural products OC(=O)C(O)CC(O)=O BJEPYKJPYRNKOW-UHFFFAOYSA-N 0.000 claims description 4
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- 229940068041 phytic acid Drugs 0.000 claims description 4
- 235000002949 phytic acid Nutrition 0.000 claims description 4
- KDYFGRWQOYBRFD-UHFFFAOYSA-N Succinic acid Natural products OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 claims description 3
- 229910000611 Zinc aluminium Inorganic materials 0.000 claims description 2
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 238000012805 post-processing Methods 0.000 claims description 2
- 238000007781 pre-processing Methods 0.000 claims description 2
- 229910000838 Al alloy Inorganic materials 0.000 claims 1
- 230000000996 additive effect Effects 0.000 claims 1
- 238000005246 galvanizing Methods 0.000 abstract description 53
- 230000008901 benefit Effects 0.000 abstract description 15
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- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 8
- 238000005516 engineering process Methods 0.000 description 7
- 238000003618 dip coating Methods 0.000 description 5
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 4
- 239000002920 hazardous waste Substances 0.000 description 4
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- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
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- 238000005265 energy consumption Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 description 2
- 229910001335 Galvanized steel Inorganic materials 0.000 description 1
- NSEQHAPSDIEVCD-UHFFFAOYSA-N N.[Zn+2] Chemical compound N.[Zn+2] NSEQHAPSDIEVCD-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/003—Apparatus
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
- C23C2/06—Zinc or cadmium or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/26—After-treatment
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating With Molten Metal (AREA)
Abstract
The invention relates to a batch hot plating high-efficiency environment-friendly continuous plating process and equipment, wherein the process comprises a feeding area, a pretreatment area, a dip plating area, a post-treatment area and a discharging area in sequence according to a process flow, the continuous plating process adopts an annular rail, the annular rail is provided with an electric conveying device, the whole process flow does not need transfer, the material conveying of all areas is completed on the same annular rail, the feeding area is provided with a plurality of groups of electric hoists with different starting moments, so that the materials on different electric hoists enter the annular rail according to time difference, and the continuous circulating plating of batch parts is realized. The invention adopts the annular plating process to realize continuous operation without stopping and turning back, simplifies the operation process, reduces the waiting time of batch galvanizing, realizes continuous production from feeding to discharging, greatly improves the production efficiency, has the characteristics of energy conservation, consumption reduction, high production efficiency, less occupied area, energy conservation, emission reduction, environmental protection and the like, and improves the production benefits of enterprises.
Description
Technical Field
The invention relates to the technical field of batch hot dipping in the metallurgical industry, in particular to a batch hot dipping efficient environment-friendly continuous walking plating process and equipment.
Background
Galvanization on steel surfaces is one of the steel corrosion prevention technologies which are commonly used worldwide, and can provide physical barrier protection and sacrificial anode protection for steel substrates at the same time. Along with the development of national economy, the requirement of hot galvanizing on some important steel structural parts is increasing day by day, and the hot galvanizing has incomparable advantages compared with electrogalvanizing, so that the hot galvanizing is not only applied to continuous hot galvanizing of automobiles, civil galvanized steel plates, steel pipes, steel wires and the like; the proportion of the batch hot-dip galvanized structural members in the fields of electric power, traffic, photovoltaic supports, communication, municipal engineering, marine structures, bridges, buildings and the like is greatly increased. The hot galvanizing technology is also developed towards the times of environmental protection, low energy consumption, low pollution, high quality and mechanization; the traditional old technology is gradually eliminated, and the development and popularization period of the new hot galvanizing technology is gradually shortened.
Compared with continuous galvanizing, the batch hot galvanizing technology in China is relatively lagged behind, and the batch hot galvanizing process in the prior art adopts a more traditional linear walking plating process: degreasing → water washing → acid washing → water washing → plating assistant → drying → hot dipping → zinc extraction → water cooling → passivation → finished product. The process has the advantages of low production efficiency, relatively slow pace and low productivity, is difficult to meet the industrialized pace, and wastes energy in the process of workpiece pretreatment waiting. Therefore, the development of a novel environment-friendly batch continuous hot-dip plating process and the reduction of the production cost have important significance for improving the production efficiency of batch zinc plating and improving the enterprise benefit. The patent (CN203700474U) discloses a hot galvanizing annular production line, which is characterized in that a hanging part area, a pickling area, a galvanizing area, a cooling area, a passivation area and a part unloading area are sequentially distributed in an annular arrangement mode, galvanized parts are conveyed to the pickling area through a ground rail vehicle, then are subjected to pickling by a lifting device of the pickling area, then the workpieces subjected to pretreatment such as pickling are placed in a conversion pit, are subjected to galvanizing, cooling and passivation by a lifting device on an annular monorail and then are conveyed to a material unloading area through a ground rail; although the zones are distributed annularly, each zone is independently mobile, and the middle part needs to be transferred by a plurality of workpieces, so that the method is improved compared with a linear arrangement, but the operation is complicated, the working efficiency is relatively low, and continuous and efficient production is difficult to realize.
Aiming at the defects, the invention further improves and provides a batch hot dip high-efficiency continuous plating process and equipment so as to change the current situation of batch zinc plating production.
Disclosure of Invention
The invention provides a batch hot galvanizing efficient environment-friendly continuous walking plating process and equipment, aiming at the problems of low production efficiency, long waiting time of batch hot galvanizing, complex operation, relatively low working efficiency and difficulty in realizing continuous high-efficiency production in the prior art. Meanwhile, aiming at the current pollution situation of dust, acid mist and the like in the existing production process, the environmental-friendly rust remover is adopted to replace the traditional acid washing in the pretreatment process, the method has the advantages that no hazardous waste is generated in the whole process flow, the closed environment is adopted to prevent corrosion to workshop equipment due to corrosive atmosphere generated by volatilization on one hand, and the workshop working environment is improved on the other hand.
In order to achieve the purpose, the invention provides the following technical scheme:
the efficient environment-friendly continuous walking plating process for batch hot plating comprises a feeding area, a pre-processing area, a dip plating area, a post-processing area and a discharging area which are sequentially included according to a process flow.
The loading area and the unloading area comprise an electric track terrace car, an electric hoist and a lifting appliance, and a workpiece is hung below the lifting appliance to realize the conveying and hanging of the material; the number of the electric hoists and the corresponding lifting appliances is not less than four, the first group of electric hoists carry materials which are just coming out from the pickling process in the front treatment area, the second group of electric hoists carry materials which enter the pickling process from the washing process in the front treatment area, and so on, when the first group of materials come out from the front treatment area and enter the dip-plating area, the length of the zinc pot can accommodate two batches of materials, the materials move forwards along the annular guide rail in the zinc pot and then enter the post-treatment area and the unloading area in sequence, and the electric hoists after unloading continue to hang the materials for the next cycle; the four groups of electric hoists can realize continuous and cyclic hot dipping of batch components;
or every two groups of electric hoists are a unit, the time interval of the two groups of electric hoists in the same unit is smaller than the time interval of the starting of the two groups of electric hoists in different units, the first group of electric hoists carry materials to enter the pickling process in the pretreatment area, the second group of electric hoists start to enter the degreasing process in the pretreatment area, the third group of electric hoists is started when the first group of electric hoists goes out of the pickling process, and the fourth group of electric hoists is started when the third group of electric hoists goes.
The efficient environment-friendly continuous batch hot plating equipment comprises a degreasing treatment tank, a first water washing tank, a pickling tank, a second water washing tank, a plating assisting tank, a drying device, a zinc pot, a water cooling tank and a passivation tank, and is characterized in that the degreasing treatment tank, the first water washing tank, the pickling tank, the second water washing tank, the plating assisting tank and the drying device belong to a pre-treatment area, the zinc pot is a dip plating area, the water cooling tank and the passivation tank belong to a post-treatment area, a feeding area is arranged in front of the pre-treatment area, a discharging area is arranged behind the post-treatment area, the discharging area is connected with the feeding area to form an annular route, and all the areas carry out material conveying through the same annular track; a rail electric terrace car, an electric hoist and a lifting appliance are arranged in the feeding area, materials are fixed on the electric hoist by the lifting appliance and sequentially pass through the areas, and after the materials are unloaded from the unloading area, the electric hoist enters the feeding area again to wait for the next circulation; the equipment of each area is positioned below the annular track, the zinc pot is positioned in the closed chamber, the top of the closed chamber is provided with a smoke dust absorption device, and the pretreatment area is also positioned in the closed acid mist room.
The pickling tank is internally provided with an environment-friendly rust remover instead of the traditional pickling, wherein the environment-friendly rust remover mainly comprises carboxythiosuccinic acid, phytic acid, malic acid, citric acid and additives, such as GD-X201 environment-friendly rust remover, and is used for continuous batch hot dipping. The organic weak acid is adopted to replace traditional inorganic acids such as hydrochloric acid, sulfuric acid and the like which are seriously polluted, the method can be added and used circularly, so that no hazardous waste is discharged in the whole production process, and the method has the advantages of high rust removal speed, high efficiency, environmental protection, energy conservation, consumption reduction, low cost and the like, and has wide market prospect.
In the plating assistant procedure, the traditional plating assistant agent is replaced by the less-smoke plating assistant agent, the types of hot-dip coatings are increased, the hot-dip coating can be used for galvanizing, hot-dip coating of Galfan alloy and the like, and the emission of hot-dip galvanizing smoke dust is reduced.
The drying device is in a hanging type drying mode (currently, pit type drying mode) or a hot air drying mode, automatic doors are arranged at two ends of the drying device along a plating direction, a scale-shaped sealing device is arranged at the upper part of the drying device and can carry out hot plating and routing, the automatic doors can be opened or closed when workpieces pass in and out, and drying operation is achieved in the drying device. The hot air drying box and the production line (namely the operation heights of other devices in the pretreatment area are the same) are at the same horizontal height, and the box-type hot air drying device with the hanging parts can be selected for drying, so that the drying operation in the conveying process is realized, the long-time stop in a certain process is not needed, and the working efficiency is improved.
The zinc pot is an internal heating ceramic zinc pot, a smoke dust collecting device is installed on a closed chamber at the upper part of the zinc pot, the smoke dust collecting device is a top suction type device, suction ports are formed in two sides of a hanger channel above the zinc pot in an immersion plating area, the smoke dust collecting device is arranged outside the suction ports, smoke dust which can escape upwards in a hot plating process of the zinc pot can be effectively collected, and the dust removing effect is better than that of a side suction type device which is formed in two sides of the zinc pot port and is sucked by the existing smoke dust suction ports.
All processes of pretreatment are carried out in a closed acid mist room, and can form annular symmetrical arrangement, the degreasing treatment tank, the first water washing tank, the pickling tank and the second water washing tank are located on one side, the plating assisting tank and the hot air drying box are located on the other side, the plating assisting tank and the hot air drying box adopt two sets of parallel equipment, and materials are driven by an electric hoist to sequentially pass through the equipment along an annular track.
The environment-friendly continuous plating process is an annular plating process, continuous operation can be realized, and after one batch of workpieces are subjected to loading, pretreatment and galvanizing, the next batch of workpieces can be subjected to continuous plating; after the last batch of workpieces are subjected to the post-treatment process and unloaded, the unloaded electric hoist can rush to the loading area for continuous operation immediately.
Compared with the traditional linear process, the method has the beneficial effects that:
the invention provides an annular high-efficiency environment-friendly continuous plating process and equipment aiming at the environment-friendly pressure faced by a hot galvanizing enterprise, the process connects the whole process flow end to end through an annular rail, a feeding area, a pretreatment area, a galvanizing area, a post-treatment area and a discharging area are tightly connected in sequence by adopting the annular rail, and the time intervals of the pretreatment area and a dip plating area are adjusted through four groups of electric hoists, so that the continuous production of batch galvanizing is realized, the continuous plating can be realized like long material galvanizing, and the production efficiency of the enterprise is greatly improved. The invention adopts the annular walking plating process to realize continuous operation without stopping and turning back, simplifies the operation process, reduces the waiting time of batch galvanizing, realizes continuous production from feeding to discharging, greatly improves the production efficiency, improves the production benefits of enterprises, reduces the standby time of equipment such as drying and zinc dipping, and has the characteristics of energy conservation, consumption reduction, high production efficiency, less occupied area, energy conservation, emission reduction, environmental protection and the like.
The size of the zinc pot can be adjusted according to the size of a single batch of structural members, the zinc pot can simultaneously accommodate two batches of workpieces for simultaneous operation, the zinc pot is an internal heating ceramic zinc pot, supplies heat through an internal heater, has the advantages of fast heat supply, less zinc slag and the like, and can realize sufficient heat supply.
The annular design in this application only sets up an annular track, does not need the transfer in the middle of the work piece, adopts the annular to walk and plates the technology and has avoided turning back and the transfer of overhead traveling crane in batch hot dipping, has realized the continuous hot dipping operation of circulating streamlined of batch piece, shortens operating time, improves production efficiency.
Compared with the traditional pretreatment process, the invention adopts the environment-friendly rust remover to replace the traditional inorganic acid such as hydrochloric acid which is seriously polluted and easily generates acid mist to carry out rust removal operation, has the advantages of high efficiency, environmental protection, high rust removal speed, cyclic addition and use, no any hazardous waste discharge and the like, can still maintain higher rust removal efficiency through component supply after being used for a period of time, and reduces the problem of water pollution.
Drawings
FIG. 1 is a schematic flow diagram of the batch hot-dip high-efficiency environment-friendly continuous plating process of the invention.
FIG. 2 is a schematic diagram of a layout three-dimensional structure of the batch hot-dip high-efficiency environment-friendly continuous plating process of the invention.
FIG. 3 is a schematic diagram of a three-dimensional simulation of a zinc pot closed chamber in the batch hot-dip high-efficiency environment-friendly continuous plating process.
In the figure, a feeding area 1, a degreasing treatment pool 2, a water washing pool 3, a pickling pool 4 (environment-friendly rust remover), a water washing pool 5, a plating assisting pool 6, an acid mist room 7, a hot air drying box 8, a zinc pot 9, a closed chamber 10, a water cooling pool 11, a passivation pool 12, a discharging area 13, an annular rail 14 (comprising an electric conveying device), an electric terrace car 15, a heat-insulating sealing strip 16, a smoke dust absorbing device 17, an automatic door 18, an electric hoist 19 and a workpiece 20 are arranged.
Detailed Description
The present invention is further explained with reference to the following examples and drawings, but the scope of the present invention is not limited thereto.
The invention relates to a batch hot plating high-efficiency environment-friendly continuous plating process and equipment (shown in figure 1), wherein the continuous plating process is realized by adopting an annular track (provided with an electric conveying device), the annular plating process sequentially comprises a feeding area, a pre-treatment area, a dip plating area, a post-treatment area and a discharging area according to the process flow, the whole process flow does not need transfer, and the plating can be continuously and circularly carried out; the loading area and the unloading area comprise an electric track terrace car, an electric hoist and a lifting appliance (a workpiece is hung below the lifting appliance), and the material is conveyed and hung; the pretreatment area comprises a pickling tank, a water washing tank, a plating assisting tank, a drying device and the like, the traditional pickling is replaced by an environment-friendly rust remover for continuous batch hot plating, all pretreatment equipment is arranged below the annular rail, and the electric hoist always drives a workpiece to enter the other equipment from one equipment along the annular rail; the novel less-smoke plating assistant agent is adopted to replace the traditional plating assistant agent, the types of hot-dip coatings (namely, zinc can be plated, Galfan alloy can be plated) are increased, the emission of hot-dip galvanizing smoke dust is reduced, a zinc pot in a dip plating area is arranged in a closed chamber, the zinc pot is arranged in the closed chamber, the tops of two sides of the closed chamber are provided with suction ports, the closed chamber is arranged at the lower part of an annular rail, a workpiece is hung on the zinc pot in the closed chamber by an electric hoist and a lifting appliance for hot plating, the workpiece also moves forwards along the annular rail in the hot plating process, automatic doors are arranged on two sides of the closed chamber, the workpiece leaves the closed chamber, the automatic doors are closed, an absorption port is arranged at the top of the closed chamber above the zinc pot, and the floating smoke dust. The drying device and the production line are at the same horizontal height and are driven by the electric hoist all the time, the height does not need to be adjusted, the use is convenient, the box type hot air drying device capable of hanging is selected, and the workpiece passes through the heating box; the pretreatment process is carried out in a closed acid mist room; the dip coating area comprises a zinc pot and a smoke dust absorption device; the post-treatment zone comprises a water-cooling pool and a passivation pool.
In the embodiment, the pickling process time is 5-10min, the plating assisting time is 20-50s, the hot dip plating time is 40-60s, the zinc pot is large and contains two batches of parts at the same time, the blending time is reserved for the next group, after the former group of workpieces are immersed in the zinc pot, the zinc liquid is not discharged and is moved to the other side of the zinc pot to be discharged from the zinc pot, and a space is reserved for the next group of workpieces; the time of the passivation process is 10-30 s.
The efficient continuous plating process is characterized in that continuous plating operation is realized through an annular track with an electric device, workpieces hung from a loading area are subjected to pretreatment, plating-assisting and drying, and then enter a zinc pot area for zinc dipping, the zinc dipping temperature is kept at 420-470 ℃, and the zinc dipping time is 30-60 s; after one batch of workpieces are immersed into the zinc liquid from one side of the zinc pot, the workpieces are moved from the zinc liquid to the other side of the zinc pot to discharge zinc, and meanwhile, the zinc immersion process can be repeated for another batch of workpieces, so that continuous plating is realized; and directly conveying the cooled and passivated finished product to an unloading area for unloading, and enabling the unloaded electric hoist to enter a circulating plating process from a hanging piece in the loading area.
The pickling rust removal in the pretreatment is a GD-X201 environment-friendly rust remover which mainly comprises carboxythio succinic acid, phytic acid, malic acid, citric acid and additives, the environment-friendly rust remover adopts organic weak acid to replace traditional inorganic acids such as hydrochloric acid, sulfuric acid and the like which cause serious pollution, and has the advantages of high efficiency, environmental protection, high rust removal speed, no discharge of any hazardous waste, cyclic addition and use, low price and the like. The quantity of pickling bath can be a plurality of, and a plurality of pickling baths arrange in proper order, also can be a bulky pickling bath, makes it can hold two batches of work pieces at least and carry out the pickling, realizes that in long-time pickling process, the work piece of wholesale has certain time difference and carries out the pickling simultaneously, goes out the pickling bath according to this time difference, gets into next process, realizes the continuous hot dipping of batch piece, improves production efficiency.
Further, drying device is for the suspension type stoving (current for pit type stoving), and the hot-blast drying mode, the inside both sides of drying device body are provided with hot-blast mouthful, and the line department of walking is equipped with scale form sealing device in the top of drying device body, all is equipped with the automatically-controlled door at drying device both ends along walking the direction of plating.
Furthermore, the zinc pot is an internal heating ceramic zinc pot, the upper part of the zinc pot is provided with a smoke dust collecting device, the smoke dust collecting device is a top suction type device, suction ports are arranged on two sides of a lifting appliance moving plating channel above the zinc pot in the dip plating area, and the smoke dust collecting device 17 is arranged on the outer side of the lifting appliance moving plating channel.
Furthermore, the size of the zinc pot can be adjusted according to the size of a single batch of structural members, the zinc pot can simultaneously accommodate two batches of workpieces for simultaneous operation, the zinc pot is an internal heating ceramic zinc pot, supplies heat through an internal heater, has the advantages of fast heat supply, less zinc slag and the like, and can realize sufficient heat supply.
The electric device is characterized in that the electric device is provided with at least four groups of electric hoists and lifting appliances, and the electric hoists can drive workpieces to rise or fall to assist the workpieces to complete corresponding processes. The two groups of electric hoists are one unit, and the time difference of the two groups of electric hoists in one unit is smaller than the time difference of the electric hoists of the adjacent starting time of different units; when the electric block is provided with six groups, a standby group can exist according to the actual production condition, and the electric block is started when a certain electric block breaks down, so that the production efficiency is ensured.
The zinc pot is an internal heating ceramic zinc pot, and a smoke dust collecting device is arranged at the upper part of the zinc pot;
the size of the zinc pot can be adjusted according to the size of a single batch of structural members, and the zinc pot can simultaneously accommodate two batches of workpieces for simultaneous operation;
the drying device adopts a hot air drying mode, and the upper part of the drying box is provided with a scaly automatic rebounding heat-insulating sealing gasket, so that the drying device can be rapidly sealed after the plating device passes through the drying box, and the heat loss is reduced.
The invention is further characterized in that the hot dip galvanizing Galfan alloy and other zinc-aluminum alloy products can be produced by adjusting the components of the plating assistant agent under the condition of not changing production equipment.
Before the invention is made, the overhead traveling crane linear reciprocating plating process adopted by the batch galvanizing of the structural part is generally adopted; unloading is needed after galvanization, and then returning to the feeding area for next batch of rack plating.
The present invention will be further described with reference to the following specific examples.
Example 1
The hot-dip plated product is a scaffold for construction in the embodiment, and the grade of the product is Q235 (chemical composition: C0.14-0.22% Mn0.30-0.65% Si is less than or equal to 0.30% S is less than or equal to 0.050P is less than or equal to 0.045).
Before the invention is made, the overhead traveling crane linear reciprocating plating process adopted by the batch galvanizing of the structural part is generally adopted; unloading the workpiece after the pretreatment process of galvanizing, and then returning the crown block to the starting area for feeding for the next batch of hot dipping; the scaffold is subjected to acid cleaning and rust removal by using inorganic acid such as hydrochloric acid, acid mist and the like generated in the pretreatment process pollute the environment, and waste acid needs further post-treatment; therefore, the environment-friendly organic acid rust remover is imperative to replace the traditional acid washing, and in addition, compared with a linear reciprocating plating process, the annular continuous plating process can greatly improve the production efficiency, reduce the waiting time of batch galvanizing, and has great significance for improving the production benefit of enterprises, reducing the energy consumption and the comprehensive cost of products.
In this embodiment, as shown in fig. 1, according to a process flow, a raw material blank is loaded on an electric floor vehicle 15 in a loading area 1 in a batch manner by a scaffold, a loaded workpiece is conveyed to a position below an annular rail 14 where the loading area is located by the electric floor vehicle, and is hung by an electric hoist on the annular rail, and operations such as degreasing (degreasing treatment tank 2) → washing (water washing tank 3) → pickling (pickling tank 4) → washing (tank water washing 5) → plating aid (plating aid tank 6) → drying (hot air drying box 8) → hot dip galvanizing (zinc pot 9) → water cooling (water cooling tank 11) → passivation (passivation tank 12) → discharging (discharging area 13) are sequentially performed;
four groups of electric hoists are arranged on the annular track, after pretreatment, galvanizing is carried out, the next group of electric hoists is pretreated, after the last group of electric hoists is loaded and enters the next procedure, the next group of electric hoists automatically enter the hanging piece of the feeding area, then the last group of workpieces are followed, and the process steps are repeated to achieve the purpose of continuous work without stopping. The pretreatment and plating assisting procedures are realized in a closed acid mist room 7; specifically, after the first group of electric hoists drive the workpieces to carry out the pickling process, the next group of electric hoists drive the workpieces to enter the pretreatment, the pretreatment enters the hot-dipping process, in the process of transferring from the pretreatment to the hot-dipping process, no large pause occurs, the zinc pot can simultaneously carry out two batches of workpieces, the last group of electric hoists directly hang the materials from the material loading area to enter the pretreatment area after unloading, the time difference between the plating assisting, the drying, the zinc dipping, the cooling and the passivation is utilized to make up the time of the pickling process, and further, the continuous gapless production is realized.
A closed chamber 10 (see figure 3, figure 3 only shows the installation relative position of related equipment, the specific equipment structure can be obtained commercially, and is mature technology) is arranged outside a zinc pot in the hot-dip galvanizing process, automatic doors 18 are arranged at two ends of the closed chamber 10 along the galvanizing direction, a heat-insulating sealing strip 16 is arranged at the top of the closed chamber along the galvanizing direction, suction ports are arranged at two sides of the heat-insulating sealing strip at the top of the closed chamber, a smoke dust absorption device 17 is arranged at the outer side of the top of the closed chamber, and the smoke dust absorption device is communicated with the suction ports to absorb smoke gas in the closed chamber. One side of the closed chamber is provided with an observation door capable of lifting or an observation door made of transparent glass for observing the galvanizing condition, the observation door capable of lifting is closed when beginning galvanizing, and is opened after galvanizing, so that the dip-plating condition is conveniently observed. The annular track is positioned above the closed chamber, when a plating device (an electric hoist drives a workpiece 20 to move along the annular track) on the annular track enters a plating area, an automatic door 18 on the entering side of the closed chamber is opened, the automatic door is closed after the workpiece enters the closed chamber, a heat insulation sealing strip 16 is arranged on a central axis at the top of the closed chamber, the part of the electric hoist connected with the workpiece moves forwards along the central axis, the sealing strip is opened when passing through the heat insulation sealing strip, and is closed after passing through the central axis, the closed state is kept, the electric hoist electric workpiece in the closed chamber slowly descends into the zinc pot and is plated to the other side of the zinc pot, the electric hoist drives the workpiece to slowly ascend away from the zinc pot after the zinc pot is plated, along with the plating, the workpiece is opened through the automatic door on the outlet side of the smoke dust collecting device after exiting; after water cooling passivation, the hot galvanizing scaffold with good appearance quality (the thickness of the coating is about 50 microns) can be obtained.
The internal heating ceramic zinc pot adopted in the hot dip galvanizing in the embodiment has the advantages of high heat utilization rate, less zinc slag generation and the like; furthermore, the environment-friendly rust remover adopted in the embodiment is a GD-X201 environment-friendly rust remover which mainly comprises carboxythio succinic acid, phytic acid, malic acid, citric acid and additives, and the environment-friendly rust remover is a composite rust remover taking the organic weak acids as main components, and has the advantages of high efficiency, environmental friendliness, high rust removing speed, cyclic addition and use and the like. In the embodiment, the hot dipping temperature is maintained at 450 ℃; the immersion plating time is 40-60 s; the hot galvanizing plating assistant agent adopted by the process is common zinc ammonium plating assistant agent (zinc chloride: ammonium chloride is 1: 1); plating assisting time is 30s, and plating assisting temperature is 60-70 ℃; the drying temperature is 150 ℃.
Example 2
The workpiece used in this example is still a scaffold for construction, and unlike example 1, the plating material of this example is not pure zinc but Galfan alloy (Zn-5 Al% -Re), but the embodiment is the same as example 1.
According to the process flow, the raw material blanks are loaded on the electric floor vehicle in the feeding area in batches, the loaded workpieces are conveyed to the lower part of the annular track of the feeding area by the electric floor vehicle and are hung and loaded by the electric hoist on the annular track, and operations such as degreasing → washing → acid washing → plating assistance → drying → hot dipping zinc → water cooling → passivation → discharging are sequentially carried out; the method is characterized in that four groups of electric hoists are arranged on the annular track, after the previous group of electric hoists are loaded and enter the next procedure, the next group of electric hoists automatically enter the hanging part of the feeding area, then the next group of electric hoists follow the previous group of workpieces, and the process steps are repeated; the purpose of continuous work without stopping the vehicle is achieved; the pretreatment and plating assisting procedures are realized in a closed acid mist room; a smoke dust collecting device is arranged above the zinc pot in the hot-dip galvanizing process; after water-cooling passivation, a hot-dip Galfan scaffold (the thickness of the plating layer is about 20 microns) with good appearance quality can be obtained.
The thickness of the Galfan alloy coating is about half of that of hot galvanizing, but the corrosion resistance of the Galfan alloy coating is 2-8 times that of a hot galvanizing scaffold, so that the zinc consumption can be saved by more than 50%, the plating cost is greatly reduced, and the production benefit and profit margin are improved;
the plating assistant agent adopted in the embodiment is a special plating assistant agent for hot-dip Galfan (patent number: 201810612609.2), and the plating assistant agent is a special plating assistant agent for hot-dip Galfan alloy, so that the single plating of Galfan alloy by a solvent method can be realized, and the plating layer is bright and beautiful and has no plating leakage;
the hot dipping temperature in the embodiment is 420-440 ℃; the plating assisting temperature can be room temperature or 60-70 ℃; the plating assisting time is 30s, the drying temperature is less than 150 ℃, and the scaffold product obtained by the embodiment has beautiful appearance, bright and uniform plating layer and excellent corrosion resistance.
The core of the invention is to provide an annular efficient continuous plating process, and the continuous production of batch hot galvanizing is realized by controlling the plating time and improving each procedure. Batch galvanization is typically for discrete structural members (e.g., scaffolding, hardware, steel grating, fencing panels, etc.); continuous galvanizing aims at continuous long materials (such as steel wires, steel strips, wire rods and the like), the application aims at the defects of low production efficiency, long interval waiting time and the like in batch galvanizing, an independent annular single rail is adopted to connect the whole production process, the pretreatment process and the hot dipping process are improved according to the environmental protection pressure faced by a hot galvanizing enterprise, a feeding area, a pretreatment area, a galvanizing area, a post-treatment area and a discharging area are tightly connected in sequence by adopting an annular rail, the time intervals of the pretreatment area and the galvanizing area are adjusted by four groups of electric hoists, workpiece transfer is not needed, pause is reduced, batch galvanizing is enabled to realize continuous production, and therefore the continuous production of the batch galvanizing can be realized like continuous galvanizing similar to long material galvanizing, and the production efficiency of the enterprise is greatly improved.
The present invention is further explained by the above embodiments, and modifications made without departing from the core content of the present invention are within the scope of the present invention.
Nothing in this specification is said to apply to the prior art.
Claims (10)
1. The efficient environment-friendly continuous walking plating process for batch hot plating comprises a feeding area, a pre-processing area, a dip plating area, a post-processing area and a discharging area which are sequentially included according to a process flow.
2. The plating process according to claim 1, wherein the loading area and the unloading area comprise an electric track floor vehicle, an electric hoist and a lifting appliance, and a workpiece is hung under the lifting appliance to realize the conveying and hanging of the material; the number of the electric hoists and the corresponding lifting appliances is not less than four, the first group of electric hoists carry materials which are just coming out from the pickling process in the front treatment area, the second group of electric hoists carry materials which enter the pickling process from the washing process in the front treatment area, and so on, when the first group of materials come out from the front treatment area and enter the dip-plating area, the length of the zinc pot can accommodate two batches of materials, the materials move forwards along the annular guide rail in the zinc pot and then enter the post-treatment area and the unloading area in sequence, and the electric hoists after unloading continue to hang the materials for the next cycle; the four groups of electric hoists can realize continuous and cyclic hot dipping of batch components;
or every two groups of electric hoists are a unit, the time interval of the two groups of electric hoists in the same unit is smaller than the time interval of the starting of the two groups of electric hoists in different units, the first group of electric hoists carry materials to enter the pickling process in the pretreatment area, the second group of electric hoists start to enter the degreasing process in the pretreatment area, the third group of electric hoists is started when the first group of electric hoists goes out of the pickling process, and the fourth group of electric hoists is started when the third group of electric hoists goes.
3. The efficient environment-friendly continuous batch hot plating equipment comprises a degreasing treatment tank, a first water washing tank, a pickling tank, a second water washing tank, a plating assisting tank, a drying device, a zinc pot, a water cooling tank and a passivation tank, and is characterized in that the degreasing treatment tank, the first water washing tank, the pickling tank, the second water washing tank, the plating assisting tank and the drying device belong to a pre-treatment area, the zinc pot is a dip plating area, the water cooling tank and the passivation tank belong to a post-treatment area, a feeding area is arranged in front of the pre-treatment area, a discharging area is arranged behind the post-treatment area, the discharging area is connected with the feeding area to form an annular route, and all the areas carry out material conveying through the same annular track; a rail electric terrace car, an electric hoist and a lifting appliance are arranged in the feeding area, materials are fixed on the electric hoist by the lifting appliance and sequentially pass through the areas, and after the materials are unloaded from the unloading area, the electric hoist enters the feeding area again to wait for the next circulation; the equipment of each zone is positioned below the circular track.
4. The plating equipment of claim 3, wherein an environment-friendly rust remover is adopted in the pickling tank, and mainly comprises carboxythio succinic acid, phytic acid, malic acid, citric acid and an additive; the pickling tank can at least accommodate two batches of workpieces for pickling; the zinc pot is an internal heating ceramic zinc pot, and a smoke dust collecting device is arranged on a closed chamber at the upper part of the zinc pot.
5. The plating equipment of claim 3, wherein all the procedures of the pretreatment are carried out in a closed acid mist room to form an annular symmetrical arrangement, the degreasing treatment tank, the first water washing tank, the pickling tank and the second water washing tank are positioned on one side, the plating assisting tank and the drying device are positioned on the other side, the plating assisting tank and the drying device adopt two sets of parallel equipment, and the materials are driven by the electric hoist to sequentially pass through the equipment along an annular track.
6. The plating equipment as claimed in claim 3, wherein the drying device is in a hanging type drying or hot air drying mode, the drying device is located outside the acid mist room, and all other pretreatment processes are performed in a closed acid mist room; the automatic doors are arranged at two ends of the drying device along the plating direction, the upper part of the drying device is provided with a scale-shaped sealing device which can carry out hot-plating wiring, and the automatic doors can be opened or closed when a workpiece enters or exits, so that the drying operation is realized in the drying device; the drying device adopting the hot air drying mode is a hot air drying box, the hot air drying box and the production line are at the same horizontal height, and the drying operation in the conveying process is realized.
7. The plating equipment of claim 3, wherein the zinc pot is arranged in a closed chamber, automatic doors are arranged at two ends of the closed chamber along the plating direction, a heat insulation sealing strip is arranged at the top of the closed chamber along the plating direction, suction ports are arranged at two sides of the heat insulation sealing strip at the top of the closed chamber, a smoke dust absorption device is arranged at the outer side of the top of the closed chamber, and the smoke dust absorption device is communicated with the suction ports and absorbs smoke gas in the closed chamber; one side of the closed chamber is provided with a lifting observation door or an observation door made of transparent glass.
8. The plating equipment as claimed in claim 3, wherein the pickling process time is 5-10min, the plating assisting time is 20-50s, the hot dip plating time is 40-60s, and the passivation process time is 10-30 s; the zinc dipping temperature is kept between 420 and 470 ℃, and the zinc dipping time is 30 to 60 seconds.
9. The plating equipment of claim 3, wherein the zinc-plated aluminum alloy is zinc-dipped and galvanized by the process of claim 1 or 2 by adjusting the components of the plating assistant agent without changing the production equipment, and the zinc-aluminum alloy comprises Galfan alloy.
10. The plating assembly of claim 1, wherein the batch of parts are discrete structural members, the discrete structural members comprising scaffolding, hardware, steel grating, and fence panels.
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Application publication date: 20210611 |