Project Background and Core Process Requirements

WONDERY recently delivered a custom Electric Heating Linear Environmentally Friendly Hot-Dip Galvanizing (HDG) Production Line. The project features a massive zinc pot (11m x 1.5m x 2.0m) with a 200-ton capacity. Unlike gas-fired alternatives, the client opted for an all-electric solution due to energy accessibility and strict carbon emission regulations. The core objectives were to ensure thermal balance for 200 tons of molten zinc while achieving exceptional energy conversion efficiency and temperature precision.

Technical Solutions and Parameterized Evidence

1. High-Power Precision Electric Heating System

To maintain the 200-ton zinc melt at a constant temperature, WONDERY engineered a high-capacity heating array:

• Heating Power: A total installed capacity of 1200 kW, utilizing zoned control logic to balance the thermal field across the 11-meter pot.

• Control Architecture: Managed by a segmented PLC system with large-screen displays for real-time temperature monitoring. The micro-positive pressure heating environment ensures uniform heat transfer to the pot walls.

• Safety & Detection: The system features automatic and manual high-low power switching and integrates ultraviolet (UV) sensors for flame/heat source detection in auxiliary systems to ensure operational safety.

2. Structural Integrity and Zinc Pot Longevity

• Pot Specifications: To withstand the pressure of 200 tons of zinc, the pot is fabricated from 60mm thick specialized XG08 low-carbon, low-silicon steel, significantly reducing erosion caused by the molten metal.

• Logistics Support: Equipped with four sets of 5t + 5t dual-hook hoists with wireless remote control. These cover pickling, fluxing, dipping, and trimming, ensuring stable transport of large workpieces and minimizing mechanical damage to the pot.

3. Intelligent Energy Management

• Production Capacity: Supported by the 1200 kW heating system, the line achieves a maximum hourly output of 6.7 tons.

• Efficiency Logic: The system automatically adjusts the number of active heating elements based on production load. During standby, a low-power maintenance mode (High-Low switching) is used to minimize heat loss.

4. Environmental and Logistics Optimization

• Linear Layout: The straight-line production design, paired with railcar transport, optimizes the workflow between pre-treatment and the dipping stage.

• Centralized Control: All control cabinets are interlinked for centralized load balancing and feature over-temperature alarm logic to prevent localized overheating, protecting both the zinc coating quality and the pot's structural safety.

Delivery Specifications and Key Parameters

• Zinc Pot Dimensions: 11 (L) x 1.5 (W) x 2.0 (H) m.

• Zinc Capacity: 200 tons.

• Energy Source: Electricity (380V/50Hz).

• Included Components: 1200kW heating system, PLC automated control cabinets, 5t-grade hoisting matrix, and all necessary internal cabling.