Environmental protection intelligent hot-dip galvanizing production line: intelligent technology, reuse of waste acid containing zinc, etc. [hot-dip galvanizing Development Forum]

SMM Sept. 14: at the 2021 China International Hot galvanizing Technology and Market Application Development Forum held by SMM, Li Shimin, a software engineer of Xuzhou Ruima Intelligent Technology Co., Ltd., introduced in detail the related technology and application of the environmental protection intelligent hot dip galvanizing production line.

Environmental protection intelligent hot-dip galvanizing production line

General situation of L-type transition automatic production line

Control system overview:

The environmental protection intelligent hot-dip galvanizing production line is equipped with eight subsystems: automatic loading and unloading system, RGV transfer system, process slot management system, energy management system, environmental protection system, automatic detection system, automatic control system, MES information management system and so on. The subsystems work together to realize the automatic control of the whole production line and the whole network communication.

Automation technology:

The logistics and process system of the galvanizing production line is centrally controlled by the central control unit Siemens S70001500 series PLC, and has an industrial network communication interface in line with industrial 4.0. the real-time control information of the whole system is transmitted by Profinet industrial network communication protocol.

Wireless communication, using Siemens industrial AP and client, using industrial 5G band;

RGV trolley motion control: the application of speed closed-loop and position closed-loop double closed-loop control technology, can simultaneously adjust the speed and actual position of the PID, through the unique "anti-sway" technology, to achieve accurate positioning of materials, steady-state transport.

The RGV car frequency converter uses the message control mode, which has the advantages of simple external wiring, reliable signal and large amount of control information. it can feedback all the operation and fault information of the frequency converter remotely and monitor the operation safety in an all-round way.

The remote communication module of "Tianyu couplet" can remotely visit each field PLC, in the office to monitor, optimize and update the on-site program, which greatly improves the work efficiency.

Hot-dip galvanizing automation is not only the automation of logistics system, but also serves the automation of hot-dip galvanizing production process requirements based on hot-dip galvanizing process.

Information, digital and intelligent technology:

The intelligence of the environment-friendly intelligent hot-dip galvanizing production line is reflected in its data analysis, data model, intelligent algorithm, situation awareness, machine vision and other systems.

Intelligent environmental protection equipment:

The all-in-one machine of auxiliaries can automatically analyze the content of zinc chloride and ammonium chloride, automatically match the concentration and proportion, and automatically circulate the auxiliaries to reduce the adhesion of precipitation and mud, so as to avoid galvanizing leakage; the acid mist spray tower equipment adopts a micro negative pressure control design to maintain a micro negative pressure of-10-0Pa in the closed room, and the acid fog is collected to the spray tower for spray treatment under low power consumption to meet the secondary discharge standard of environmental protection.

The pipe system of the pump room can independently monitor the liquid level of acid pool and pool, rinse the pool and cool the pool automatically; in the zinc smoke dedusting system, the hot-dip galvanized smoke is collected by the way of "lifting closed zinc pot cover + side suction and top suction". And the use of patented technology pulse bag dust collector. The frequency can be adjusted automatically according to the working condition to save energy and reduce consumption.

The integrated function of rinsing water treatment can automatically analyze the composition of rinsing water, start the rinsing water circulation machine to deal with the rinse water exceeding the control standard, and recycle it in rinsing, acid distribution and so on after treatment.

Regeneration and utilization of waste acid containing zinc

The necessity of waste hydrochloric acid regeneration treatment: at present, hot-dip galvanizing enterprises use a large amount of acid, hidden dangers are inevitable in the process of transportation of new acid and waste acid, and the state is also carrying out strong control over acid-related enterprises, and the future direction of waste acid will be controlled by the process and terminal. once there is a problem in a certain link, the corresponding enterprises will bear joint and several liability. Moreover, there have been some local requirements that the total amount of acid waste from acid-related enterprises reaches 1000 tons or more than 5000 tons per year, which needs to be treated and disposed by themselves, which has a trend. in addition, the external treatment of waste acid is limited by hazardous waste disposal centers and environmental protection policies. there is the possibility of restricting production in the future, while hot-dip galvanizing (hanging plating), the zinc content in the waste acid solution is higher, and the outsourcing price is positively related to the zinc content, and the enterprise cost increases.

Therefore, there is no doubt that in the waste acid standard of hot-dip galvanizing industry in the future, the control of zinc content will be more stringent.

Process:

Product advantage

According to the characteristics of this product, we can roughly list 10 product advantages:

1. Ensure quality: based on automation, information, intelligent system, eliminate the influence of human factors, make the quality more stable; ensure quality: based on automation, information, intelligent system, eliminate the influence of human factors, make the quality more stable

2. Intelligent manufacturing system: through data modeling and analysis, the use of machine depth learning algorithm, intelligent adjustment of production line operation parameters. The cost of zinc ingot is reduced by more than 10%, and the annual production line with an annual output of 100000 tons saves more than 10 million yuan.

3. Solve the difficult problems of the industry: advanced design concept, end-in and side-out, solve the problem of color difference in the industry, and at the same time ensure stable operation with original invention patent technology.

4. Improve production efficiency: ensure that there is no sluggish time in key processes through intelligent manufacturing systems, and the output is increased by more than 50% compared with traditional production lines.

5. Improve the management level: through the intelligent management system to achieve real-time data collection and timely early warning, to provide data support for management to make corresponding decisions.

6. Ensure environmental protection standards: provide EPC (Engineering General contract) project construction, from the design link to ensure that all environmental protection equipment and automatic production line seamless docking, to ensure that customers successfully pass the EIA acceptance

7. Circular economy: the design follows the balanced design concept of circular economy utilization, minimum environmental output and resource reuse, and the balanced design of input and output, so as to ensure that environmental indicators meet the requirements of environmental protection control at the same time, treatment and operating costs reach the optimal level of the same industry.

8. Shorten the construction cycle: product modular design, factory pre-production, rapid installation, rapid production, shorten the production line construction cycle

9. Reduce labor costs: reduce the number of workers and the requirements for workers' skills through automation and informationization, and reduce labor costs by more than 20%.

10. Production safety: improve production safety through automation and information, real-time monitoring and control of equipment operation.