镀锌车间工艺操作规程

目 录 Contents第一部分 生产概况2 Section one General description of the production line一、生产工艺流程图2 Process flow diagram二、工艺平面布置示意图2 Layout sketch三、原料规格及执行标准2 Specification of material and its criteria四、试生产说明3 Starting-up illustration第二部分 设备的主要技术性能 5 Section two Main technical characteristics of the equipments一、钢管前处理段4 Pre-treatment of steel pipes二、烘干炉5 Drying oven三、入料辊道6 Feeding rollers四、镀锌炉6 Galvanizing furnace五、镀锌锅8 Galvanizing vat六、浸锌机构8 Dipping unit七、拨料机构8 Kick out unit八、提升机构8 Lifting unit九、磁力辊8 Magnetic roller十、外吹8 External blowing十一、磁力辊升降机构9 Elevation device of magnetic roller十二、曳出辊道9 Pulling out roller十三、猫头叉横移机构9 Fork-shaped transverse moving device十四、内吹和升降机构9 Internal blowing and elevation device十五、冷却水槽9 Cooling water tank十六、检查台架10 Check table十七、钝化辊道10 Passivation roller十八、钝化喷淋站10 Spraying station for passivation十九、烘干台架10 Drying table二十、打印辊道10 Stamp roller二一、打印机10 Stamp machine二二、六角打包设备10 Packaging tools二三、除尘器10 Cleaner二四、电器设备10 Electrical device第三部分 镀锌车间技术操作规程11 Section three Operating instruction of galvanizing workshop一、 目的11 Purposes二、 使用范围11 Applying scope三、 工作程序11 Working procedures 3.1、酸洗工序11 Acid cleaning3.2、火炕工序11 Heating 3.3、锌锅工序11 Dipping3.4、内外吹工序12 Blowing3.5、钝化水洗工序12 Passivation and wash3.6、检验工序12 Check 3.7、司炉工12 Operators 修订状况记录12 Record of revision12第一部分 生产概况 Section one General description of the production line一 生产工艺流程图 Process flow diagram钢管热镀锌生产线是将成品黑管经过表面处理后自动侵锌，在钢管内外表面镀一层耐腐蚀、表面光洁锌层的生产设备。Steel pipe hot-dip galvanizing line is the automatic equipments to produce resistant and smooth layer on the surface of raw pipes after cleaning.黑管raw pipes涂溶剂 applying impregnant空冷natural cooling烘干 drying水冷 cooling with water碱洗脱脂alkali cleaning热浸锌 hot-dipping检验 check盐酸洗 acid treatment外吹 external blowing打印 stamp漂洗 water cleaning内吹 internal blowing入库 entering warehouse二工艺平面布置示意图（附）Layout sketch (enclosed)三原料规格及执行标准Specification of material and its criteria 114生产线 产品大纲 main parameters of 114 production line 序号number规格 specification壁厚mmThickness单重kg/mUnit weight6m重 kgWeight per 6m小时 产量 支/时Yield by pieces小时产量公斤/时Yield by weight面积产量m2/时yield by area所占 比例%Proportion年工作 时间 小时Running time per year年产量吨Yearly yield by weight年面积 产量 m2Yearly yield by area10.52.65 1.22 7.32110080007704018001440020.252.65 1.58 9.488448000770313.25 2.44 14.6454680006283013501080041.253.25 3.14 18.84424800062851.53.25 3.61 21.653688000628623.55.130.6261800058210450360072.53.756.5139.062058000544104503600834.058.4750.82157800050352251800944.6512.172.610980004385225180098550计 100450036000执行标准：（GB3091-93）Designed according to criteria (GB3091-93) 注：支重及产量均以黑管计算。因酸、熔剂及锌的消耗与镀管的内外表面积有关，故生产统计除统计重量产量外，还需统计镀锌表面积产量，上述消耗也以表面积为基数进行考核。 Note: statistics of single pipe weight and yield based on raw pipes. Because consumption of acid, solvent and zinc is related to and calculated by pipes surface area, production data should include both weight yield and area yield.四试生产说明 Starting-up illustration4.1镀锌炉的点火与升温 Galvanizing furnace ignition and heating up 4.1.1 在锌锅内码放好锌锭与铅锭后可进行点火,高炉煤气热值极低,续燃能力差,较难点火. 经商议确定用液化气罐胶管及1.5米长的1/2”（？）钢管组成的燃烧器作为辅助火源进行点火。Piled zinc and lead ingots, and use a piece of rubber tube and 1.5 meter long steel pipe as a auxiliary burning device to ignite the main fire, because blast-furnace gas has low calorific value and is hard to light up. 点火前应准备8套燃烧器对8套烧嘴同时进行强迫点火。Prepare 8 sets of burning device to light 8 burners simultaneously. 由于镀锌炉在此之前曾经过水，但时间已过去4-5个月估计已自然风干。但为保险起见，升温时拟适当延缓升温梯度，并适当增加110区（显含水的蒸发）及300区（结晶水的去除）的保温时间以期炉体安全渡过升温期。The furnace might have been contacted with water and got dry after 4-5 months exposure to air. But still for sake of safety, laggard and placid heating speed is recommended, elongate time at temperature of 110(flowing water evaporation) and 300(crystal water evaporation).4.2.试生产用料准备 Raw pipes preparation for start-up4.2.1炉料 furnace material: 1#锌锭 155吨 zinc ingot 155 ton 铅锭 15吨 lead ingot 15 ton4.2.2.盐酸:37%盐酸比重为1.19，试生产时一条线先配2槽酸按17%浓度配制约需浓盐酸20吨. 正常生产时每日约消耗2(8”)-7(1/2”)吨不等的浓酸,根据供货条件与生产计划可确定维持生产必要的储备量. Hydrochloric aid: its solution of 37% concentration has specific gravity of 1.19. Confect two tanks of 17% hydrochloric acid for one production line before start-up, and around 20 ton of high-concentration hydrochloric acid may be needed. In normal production, 2(8”)-7(1/2”) ton of 37% acid are consumed per day, so some stock of it is necessary to maintain continuous production with respect to delivery and production plan.4.2.3 熔剂的铵锌比按1.6:1，浓度按450克/升配制，一槽熔剂需用氯化铵4.7吨，氯化锌2.9吨。Proportion for ammonium and zinc in solvent is 1.6:1, almost 450g per liter. One tank of solvent needs 4.7 ton of ammonium chloride and 2.9 ton of zinc chloride.4.2.4 锌铝合金：含10%的锌铝合金100公斤，在生产过程逐渐加入，锌液中铝含量为50g/吨。添加铝的目的一为防止锌液的氧化，二为增加镀锌管表面的亮度，三为增加镀层表面的均匀性，防止由于锌层表面产生过大晶花而出现鼓棱。Zinc and aluminum alloy: 100kg of zinc-aluminum alloy with 10% of zinc is added into solvent, keeping aluminum content of 50g per ton in solvent. The function of aluminum is: 1. prevent oxidation to zinc solvent; 2. increase brightness of galvanized pipes surface; 3. improve uniformity of galvanizing coat; reduce protuberance caused by uneven zinc distribution.铝过多会阻碍合金层的形成而出现漏镀现象。Excessive aluminum may impede form of alloy coat, and the result is that the coat may not be integral. 4.2.5 钝化剂的准备：钝化箱一次投放量为350升，其消耗与配制请与供应厂家联系。Prepare passivation additives: adds 350L of it to passivation case for one time, and consult supplier for its consumption and confecting method. 4.3.工艺参数 process parameters 4.3.1 产品基本参数与设备运行参数 equipments and operation parameters 114生产线 114 production line序号规格壁厚mm单重kg/m6m重 kg小时 产量 支/时小时产量公斤/时面积产量m2/时生产节奏秒螺旋转速/调频Rpm/ Hz曳出速度 m/s大磁辊电机频率Hz小磁辊电机频率Hz内吹时间s浸锌时间s所用螺旋生产方式10.52.65 1.22 7.32110080007706.59.2/91 1.194831491#双管20.252.65 1.58 9.4884480007708.5 7/69 0.8270621641#双管313.25 2.44 14.64546800062813.24.55/450.543382732#双管41.253.25 3.14 18.844248000628173.5/35 0.4034303942#双管51.53.25 3.61 21.65368800062819.6 3/300.35302631082#双管623.65 5.1030.6260800055827.72.2/220.2521194623#双管72.53.656.5139.06205800055817.63.4/340.434304793#单管834.058.4750.821578000503232.6/260.326234804#单管944.6512.273.21098000438331.8/180.21181651164#单管114线小磁辊电机 114 line small magnetic roller motor n=1460rpm i=23 r=100mm 大磁辊电机 large magnetic roller motor n=1460rpm i=59 r=225mm 4.3.2 温度参数：temperature parameters 4.3.2.1 烘干炉温度：120-200（热电偶显示）drying oven temperature: 120-200 (measured with TC) 4.3.2.2 熔剂温度：70-80（温度计人工测量）flux temperature: 70-80 (measured with thermometer manually) 4.3.2.3 锌液温度：4505（热电偶测量或手持高温温度计人工测量）zinc pool temperature: 4505 (measured with TC or thermometer manually) 4.3.2.4 水冷槽水温：70-80（温度计人工测量）temperature of cooling water tank 70-80 （measured with thermometer）4.3.3 前处理操作与管理：pre-treatment and regulation 4.3.3.1 酸洗液检测制度：rules on check pickling liquid 1）检测内容 a)HCl 浓度 check items: a) HCI concentration b)铁离子浓度 b) iron ion concentration 2）检测频度：4小时/次 check frequency: every 4 hours 3）酸浓度不足可通过添加新酸予以调整以提高酸洗速度。When acid concentration gets below the required level, add some new to maintain acid washing efficiency. 4）铁盐浓度操标时应予排放。Expel pickling liquid when iron ion exceed requirements排放标准：铁离子浓度200g/升 expel standard: iron ion concentration over 200g/liter 或FeCl2浓度450g/升 or FeCl2 over 450g/liter HCl浓度4% HCI concentration less than 4% 4.3.3.2 酸洗操作：acid washing operation酸洗使用天车成捆进行移位与翻动，每个酸槽中均置放有3个梯形石，酸洗时通过天车吊带的收放与梯形石的散捆作用，使钢管表面相互磨擦，促进除锈。在整个酸洗过程，这种吊带收放的操作最少需进行4-5次。There are 3 ladder-shaped stones in each acid-washing tank, and use crane to move and rotate bundles of pipes. Through cranes motion of raise and drop, friction among the pipes can helpful with removing rust on pipes surface. During whole acid washing process, raise-and-drop motion should be performed for 4-5 times.钢管表面油污阻碍除锈并造成漏镀，为此钢管的运输移位严禁使用钢丝绳（包括焊管车间），应改用尼龙吊带。Oil stain on pipes surface impede removing rust and cause incompletion of galvanizing, so steel wire rope can not be applied when transferring the steel pipes(including the welding workshop), only nylon belt is acceptable.盐酸酸洗除化学作用外，它对氧化铁皮还有机械剥离作用使氧化铁皮积存在槽底，为阻断积存的氧化皮继续消耗盐酸，建议建立倒槽操作制度，每班应进行一次倒槽操作，将槽底积存的含大量氧化铁皮的污泥冲洗干净。Apart from chemical reaction, pickling with HCL can have mechanical effect on oxidation scale. To prevent stocking oxidation scale continually consume HCL, Trough operating system should be regulated. 4.3.3.3 漂洗操作：漂洗应在流动的水中进行，并进行两次漂洗，漂洗水可通过再生处理后循环使用，但处理站需对回流使用水的铁盐含量与游离酸含量进行测控，回用水的盐酸浓度不得高于4g/升，铁盐浓度不得大于3g/升。4.3.3.3 Rinsing operation: rinsing is carried out in the flowing water and proceeds twice rinsing. Rinsing water can be reused through regeneration. But processing plant can track to iron salt and free acid of recycled water, and the HCL concentration must less than 4g/liter, iron salt concentration less than 3g/liter 4.3.3.4 熔剂检测制度：flux test and inspection system 1）检测内容：a)游离HCl 浓度 free HCL concentration b)铁离子浓度 iron ion concentration c) PH值 PH value 2）检测频度：4小时/次 4 hour/time 3）要求：PH值需控制在3.5-4.5范围内，一般情况下，由于酸洗残留物的缘故，熔剂液多少含有游离酸，PH值均较低。PH值大于4.5将引起ZnCl2析出，降低溶剂的效用，应加HCl予以调整；PH值小于3.2或游离HCl 浓度大于2g/升时，熔剂作用将降低，需加NH4OH 或 加入锌灰予以调整。3) Requirements: PH value must be controlled in the range of 3.5-4.5. generally speaking, due to pickling residue resistance, flux contain suitable free acid which cause PH in a low valve, PH value is more than 4.5, which cause ZnCl2 salted out. In order to lower flux influence, HCL should be adjusted properly. PH value less than 3.2 or free HCL concentration more than 2g/liter, flux effect will be lower and more NH4OH should be added or add zinc ash. 4.3.3.5 涂熔剂操作： Flux operation熔剂须经过连续过滤与加热，过滤机每班最少进行一次反冲清洗，滤芯需定期更新。Flux need continually filtering and heating, filter should be flushing each work, and filter core should be changed regularly 熔剂的洁净与否对锌耗有很大的影响，通过试生产应建立一套严格的熔剂管理制度。The clean of flux have a great influence on zinc consumption. Through trial production, one set of flux management regulation should be set.4.4成品质量检验： finished product quality inspection 4.4.1 外观漏镀检验。 4.4.2 镀层均匀性检验：硫酸铜腐蚀试验。Coating uniformity inspection: copper sulfate test 4.4.3 镀层厚度检验：超声测厚仪。 Coating thickness inspection: ultrasonic thickness measurement instrument 4.4.4 镀层重量检验：氯化锑置换试验。Coating weight inspection: butter of antimony4.5.热调试规格： 1/2”双管生产（114线）；hot testing specification: 1/2”double pipe production 4”单管生产（114线）；4”single pipe production第二部分 设备的主要技术性能 一 钢管前处理段 Pretreatment1.1Hcl酸洗槽5个：HCL pickling bath 5 尺寸：长宽深=7.6m1.5m1.5m Dimension: lengthwidthdepth=7.6m1.5m1.5m结构：玻璃钢夹层结构，槽壁与槽底用钢结构框架加固，槽低用花岗岩块铺垫。Structure: FRP sandwich structure, bath wall and bath base are strengthened by constructed steel structure, and base used in moonstone 酸洗槽之间用衬塑钢管连接在一起，并配有耐酸泵管路系统又与贮酸罐及排污沟连接，可实现酸洗槽加酸、排污、以及酸槽之间的“倒槽”操作。1.2清洗水槽2个：cleaning water tank:2 尺寸：长宽深=7.6m1.5m1.5m Dimension: lengthwidthdepth=7.6m1.5m1.5m 结构：与1.1相同。Structure: same as 1.11.3熔剂槽2个：Flux bath:2尺寸：长宽深=7.6m1.5m1.5m Dimension: lengthwidthdepth=7.6m1.5m1.5m 结构：与1.1相同。配有熔剂过滤机一台，利用过滤机的泵将熔剂槽的槽液连续抽出、过滤，并通过一个换热面积为3m2的石墨热交换器，将熔剂加热到80左右，加热介质为蒸气，温度利用温度调节阀控制。Equipped with 1 set flux filter, which draw out solution in flux bath through pump of filter, and then fliter by graphite heat exchanger in exchange area of 3 m2. When flux is warming-up to 80 , that is flux has become steam. At that time, temperature is controlled by adjusting valve.二烘干炉 drying furnace 尺寸：长宽=8m7mDimension: lengthwidth= 8m7m传动：制动电机：YEJ100L3，n=1500 r.p.m， N=3kw；Diving: driving motor: YEJ100L3，n=1500 r.p.m， N=3kw；行星摆线减速器：XWEDE3-4P-74-289，I=289，n=5 r.p.m；Planetary cycloid reducer: XWEDE3-4P-74-289，I=289，n=5 r.p.m；链轮：t=391.9，Z=8，每步2齿需3秒。Sprocket: t=391.9，Z=8，每步2齿需3秒烘干炉底板为铸铁双面肋板，下部为烘干炉的烟道，烟道内敷设有114钢管换热器，换热气面积为20m2，利用烟气余热加热筋板以烘干钢管，此外有一台循环风机，风量为6600NM3/h，N=5.5Kw，将烘干炉膛内的空气引入烟道内的换热器，经加热后又喷入炉膛内，以增强钢管的加热效果，烟道入口温度约600，出口温度约200，烟气量约为1200NM3/h，每小时的供热量约为大卡。 Drying furnace setting is made of double cast iron ribbed plate and flue below it. 114 pipe heat exchanger inside the flue with exchange area of 20m2. The working principle is drying pipes through waste gases warming up stiffened plates. Except for heat exchanger, circulator with air-volume 6600NM3/h，N=5.5Kw draw air in the drying furnace chamber into heat exchanger in the flue, and then puff into chamber after heating to strengthen heat effect of pipes. Inlet temperature of flue is about 600, and 200 for outlet, flux 1200NM3/h, supplying caloric each hour.烘干炉的产量最大以8吨/时计，入料温度设为20，出料温度设为70，其吸热量为： 8000（70 - 20）0.111=44400大卡，利用系数为0.28。The maximum capacity of drying furnace is 8 ton/hour, feeding temperature is 20, out-feeding temperature is 70, heat-absorbing is 8000（70 - 20）0.111=44400 caloric, coefficient is 0.28. 钢管在烘干炉内的输送依靠链条步进驱动，输送链的移位步距为304.8mm，7m炉长可移动22步，不同规格的钢管在烘干炉内的停留时间为表1-7所示。The transmission of pipe in drying furnace is driven by step chain, and transmission chain displacing step distance is 304.8mm, that is furnace of 7m length displace 22 step. Below 1-7 are retention time of pipes in the drying furnace with different specification. 烘 干 炉 内 钢 管 的 加 热 时 间 表1-7Heating time of pipes in drying furnace 规格 specification产量 output（支/时）节奏（秒）rhythm 总加热时间 total heating time （秒）烘干炉内容纳钢管的数量为Pipes quantity in drying furnace n=7000/304.8 =22 0.511006.52210.758448.5289154613.24491.25424175781.536819.6666224514.75002.520517.6598315723506/782410933726/1122三 入料辊道 feeding roller 114入料辊道长28m，辊间距1.43m，共20套辊，输送速度2.78m/s，组合传动，电机 N=4Kw，i=3.7 t=140mm。端部设定位挡板，电机转动拨料。Length of Roller is 28m, roller distance 1.43m, and total 20 sets roller. The transmission speed is 2.78m/s and combined driving. Motor parameters is N=4Kw，i=3.7 t=140mm. Position plate is in the front part of roller with motor rotating to kick out.辊道连续运行，端部设定位挡板。四镀锌炉Galvanizing furnace4.1加热方式：heating method两侧长焰烧嘴加热，两端有循环风机，风机流量约为燃气排出量的10倍左右，形成循环再加热的方式，使炉内温度分布均匀，见图示。Heat by burner, circulator in both ends of furnace with air flow 10 times is of combustion gas, which forms circulation heating to distribute temperature asymmetry. 4.2技术数据：（以下所列为一条线的参数）Technical Data: 燃料：煤制气，热值1200-1350Kcal/m3 Fuels: coal gas, heat value 1200-1350Kcal/m3燃气烧嘴：供气压力为1000-1500pa， 气量：50万大卡/h 2个，25大卡/h 2个；Combustion gas burner: Pressure: 1000-1500pa flow of gas:鼓风机：全风压 400-500mm水柱，流量 2000NM3/h，电机11Kw；Blower: wind pressure steam: 400-500mm volume: 2000NM3/h Motor: 11kw循环风机：2台，作温度700，最高温度800。 流量：Q=13000NM3/h，全压：30mm水柱，电机：5.5/4Kw双速电机；Circulator: 2 set working temperature: 700 max tem: 800 Flow: Q=13000NM3/h pressure: steam: 30mm Motor: 5.5/4Kw double-speed 引风机：一台，流量：Q=2400NM3/h，全压：50mm水柱，电机：2.2kw（变频调速）；Draft fun: 1 set, flow: Q=2400NM3/h pressure steam: 50mm, Motor: 2.2kw (VVVF)烟囱：直径720，高度18m；Chimney: diameter: 720 Height:18m尾气引风机采用变频调速电机，用于调节炉压，以保证镀锌炉在微负压下工作。Exhaust draft fun adopt VVVF motor to adjust furnace pressure to ensure galvanizing work under negative pressure condition. 4.3镀锌炉的热负荷计算： Thermo-load calculation4.3.1最大产量C=8000kg/h。 Max output: C=8000kg/h 4.3.2加热镀件的热量：每公斤钢升温1，需0.111Kcal，钢管入锅温度设为50，则Q1=0.1114008000=Kcal/h Works heat: 4.3.3熔化锌的热量：每公斤钢大致最多消耗0.085kg锌，锌的比热为0.093Kcal/kg锌的熔化潜热为27.17Kcal/kg，则Q2