A steel structure manufacturer planned to build a natural gas heated linear hot dip galvanizing line for processing steel components up to 8.6 meters in length, including transmission towers, highway guardrails, and building embedments.
Customer requirements:
Zinc pot size: 8.6m × 1.0m × 1.6m
Zinc capacity: 75 tons
Hourly output: 3 tons
Must meet emission standards for acid mist and zinc fumes
WUXI WONDERY INDUSTRY EQUIPMENT CO., LTD. was responsible for process design and equipment integration.
Operating conditions:
Three pickling tanks, each 8.6m × 1.0m × 1.6m
Immersion time: 6 minutes per tank (adjustable)
High acid mist generation requiring complete containment
Design solution:
Fully enclosed acid mist chamber: 11m × 10.6m × 4.0m, flame-retardant fiberglass panels
Negative pressure maintenance: 11kW variable frequency fan
Two-stage scrubber tower:
Tower size: φ1800mm × 6500mm, PP material (10mm thickness)
Filler: PP wreath (3.5 inches diameter), two layers
Defogging layer: PP spheres (2.0 inches diameter), one layer
Spray layer: PP-1/2 spiral nozzles, two layers
Circulating pump: 5.5kW vertical acid/alkali resistant pump
Automatic pH control: Dual pH probes (inlet/outlet) with automatic dosing
Technical conclusion:
The combination of enclosed structure + negative pressure exhaust + two-stage spray neutralization effectively controls acid mist escape. Online pH monitoring ensures accurate chemical dosing, suitable for continuous pickling of 8.6-meter long tanks.
Operating conditions:
Zinc pot size: 8.6m × 1.0m × 1.6m
Zinc bath temperature: 438–450℃ (PLC controlled)
High volume of zinc particulate fume during immersion
Design solution:
Double-sided suction ducts:
Side ducts: 8600mm × 2500mm × 250mm, two sets
End duct: 6000mm × 3000mm × 250mm, one set
With deflectors, flanges, and sealing strips
Bag filter system:
Main unit size: 5540mm × 3000mm × 6500mm
Filtration area: 640m²
Filter bags: φ133mm × L3500mm, 426 sets
Filter material: waxed nylon needle-punched (service life ≥2 years)
Fan: 55kW double-sided suction variable frequency fan
Water curtain deodorization tower:
Tower size: φ2800mm × 6500mm, PP material (12mm thickness)
Circulating pump: 7.5kW vertical acid/alkali resistant pump
Operation strategy:
Variable frequency fan runs only 2–3 minutes per zinc pot loading
Bag filter collects zinc particles; water curtain removes odors
Technical conclusion:
For an 8.6-meter long zinc pot, double-sided suction covers the entire fume generation area. The 640m² filtration area meets the 3 tons/hour production requirement. The VFD control strategy reduces continuous power consumption.
| Module | Technical Parameters | Function |
|---|---|---|
| Combustion air preheating | Alloy tube heat exchanger, 50–150℃ air preheat | Reduces natural gas consumption |
| Sludge drying box | 304 stainless steel, 5500×750×375mm | Reduces filter cake moisture from 80% to 10% |
| Pot edge heat recovery | Double-layer stainless steel coil, pot edge temp ~200℃ | Heats water for acid preheating or workshop heating |
Responsibilities in this case:
Supplier: Equipment supply, internal piping, control cabinet & internal cables, installation guidance, commissioning guidance, training materials
Buyer: Civil work, plant building, external utilities (water/electricity/gas), compressed air, hoisting equipment, scaffolding, meals/accommodation for technicians, fire protection, lightning protection
For this 8.6m hot dip galvanizing line, the following fume treatment solutions were implemented:
Acid mist: Sealed negative pressure chamber + two-stage spray neutralization
Zinc fume: Double-sided suction + bag filter + water curtain deodorization
All equipment parameters match the 8.6m × 1.0m × 1.6m tank dimensions and 3 tons/hour capacity. The waste heat recovery modules further reduce operating energy costs.
A steel structure manufacturer planned to build a natural gas heated linear hot dip galvanizing line for processing steel components up to 8.6 meters in length, including transmission towers, highway guardrails, and building embedments.
Customer requirements:
Zinc pot size: 8.6m × 1.0m × 1.6m
Zinc capacity: 75 tons
Hourly output: 3 tons
Must meet emission standards for acid mist and zinc fumes
WUXI WONDERY INDUSTRY EQUIPMENT CO., LTD. was responsible for process design and equipment integration.
Operating conditions:
Three pickling tanks, each 8.6m × 1.0m × 1.6m
Immersion time: 6 minutes per tank (adjustable)
High acid mist generation requiring complete containment
Design solution:
Fully enclosed acid mist chamber: 11m × 10.6m × 4.0m, flame-retardant fiberglass panels
Negative pressure maintenance: 11kW variable frequency fan
Two-stage scrubber tower:
Tower size: φ1800mm × 6500mm, PP material (10mm thickness)
Filler: PP wreath (3.5 inches diameter), two layers
Defogging layer: PP spheres (2.0 inches diameter), one layer
Spray layer: PP-1/2 spiral nozzles, two layers
Circulating pump: 5.5kW vertical acid/alkali resistant pump
Automatic pH control: Dual pH probes (inlet/outlet) with automatic dosing
Technical conclusion:
The combination of enclosed structure + negative pressure exhaust + two-stage spray neutralization effectively controls acid mist escape. Online pH monitoring ensures accurate chemical dosing, suitable for continuous pickling of 8.6-meter long tanks.
Operating conditions:
Zinc pot size: 8.6m × 1.0m × 1.6m
Zinc bath temperature: 438–450℃ (PLC controlled)
High volume of zinc particulate fume during immersion
Design solution:
Double-sided suction ducts:
Side ducts: 8600mm × 2500mm × 250mm, two sets
End duct: 6000mm × 3000mm × 250mm, one set
With deflectors, flanges, and sealing strips
Bag filter system:
Main unit size: 5540mm × 3000mm × 6500mm
Filtration area: 640m²
Filter bags: φ133mm × L3500mm, 426 sets
Filter material: waxed nylon needle-punched (service life ≥2 years)
Fan: 55kW double-sided suction variable frequency fan
Water curtain deodorization tower:
Tower size: φ2800mm × 6500mm, PP material (12mm thickness)
Circulating pump: 7.5kW vertical acid/alkali resistant pump
Operation strategy:
Variable frequency fan runs only 2–3 minutes per zinc pot loading
Bag filter collects zinc particles; water curtain removes odors
Technical conclusion:
For an 8.6-meter long zinc pot, double-sided suction covers the entire fume generation area. The 640m² filtration area meets the 3 tons/hour production requirement. The VFD control strategy reduces continuous power consumption.
| Module | Technical Parameters | Function |
|---|---|---|
| Combustion air preheating | Alloy tube heat exchanger, 50–150℃ air preheat | Reduces natural gas consumption |
| Sludge drying box | 304 stainless steel, 5500×750×375mm | Reduces filter cake moisture from 80% to 10% |
| Pot edge heat recovery | Double-layer stainless steel coil, pot edge temp ~200℃ | Heats water for acid preheating or workshop heating |
Responsibilities in this case:
Supplier: Equipment supply, internal piping, control cabinet & internal cables, installation guidance, commissioning guidance, training materials
Buyer: Civil work, plant building, external utilities (water/electricity/gas), compressed air, hoisting equipment, scaffolding, meals/accommodation for technicians, fire protection, lightning protection
For this 8.6m hot dip galvanizing line, the following fume treatment solutions were implemented:
Acid mist: Sealed negative pressure chamber + two-stage spray neutralization
Zinc fume: Double-sided suction + bag filter + water curtain deodorization
All equipment parameters match the 8.6m × 1.0m × 1.6m tank dimensions and 3 tons/hour capacity. The waste heat recovery modules further reduce operating energy costs.
