Galvanizing:

Custom engineered Galvanizing System - most advanced in North America  Bath dimensions - 12.5m x 1.6m x 3.0m.

Driving Principles - Emission Controls and Automation   Achieved through complete enclosure of the galvanizing process – pre-treatment area, drying chamber and galvanizing furnace. Suitable suction and drainage mechanism to extract solid, liquid and air emissions and route them through treatment processes.

The best standards of emission controls that can meet the most stringent regulations. Acid fumes from the enclosed pre-treatment plant are extracted by negative pressure and taken to an acid fume scrubber to be re-liquified. This is then taken to a water-recycling unit. The clean water of the effluent treatment plant is recycled in the pre-treatment plant. The separated acid is recycled back after being reconcentrated to the correct level.

The galvanizing bath is covered with a white fume enclosure. White fumes arising from the zinc bath are collected by an exhaust unit that routes to a bag house filter. The zinc powder settles down & cleaned air moves through the exhaust chimney. The enclosed dryer ensures efficient utilization of the heat generated in the furnace.

Automation

Automation is achieved through PLC controls and software programs that help operate the entire process. Fabricated black steel is transported to a jiigging area where steel is hooked on to a jig. The Jig is then transported into the enclosed pretreatment area on rails. In the pre-treatment area, Once the process parameters for a jig are fed into a computer, PLC controls take over the process.

Two suspended monorails with hoists pick up the jigged steel and take it through the sequence of degreasing, rinsing, fluxing, pickling and rinsing. The monorails have sensors to track distance and sense the position of the jigs for lifting and dropping them into the pre-treatment tanks. There is no human element of variation and this ensures a consistent process.

A viewing gallery along the length of the pre-treatment is available area for observation. The pre-treatment enclosure restricts the acid fumes to within the enclosure and prevents impacting the workforce in the vicinity.

After pre-treatment, the jigged material is moved into a dryer using PLC controls with the help of a third monorail. After drying, the doors of the galvanizing enclosure open and the monorail moves in with the jigged steel. The doors then close and steel is dipped into the furnace containing high purity molten zinc for a pre-defined process time.

The exit door of the galvanizing enclosure opens up to allow the monorail to move the galvanized steel out. Finally, the galvanized jigged material is moved through to the post-treatment processes like quenching, dulling and passivation.