Turnkey Hot Dip Galvanizing Plants
We provide end-to-end engineering solutions, taking a project from a greenfield site to a fully operational facility. Our turnkey services encompass feasibility studies, custom engineering, manufacturing, logistics, and onsite commissioning. We ensure that every component—from the pickling line to the furnace—is synchronized for maximum throughput and minimum waste.
Our furnaces are the heart of the plant, engineered for extreme thermal efficiency.
- Technology: We utilize Pulse Firing, where burners operate at high velocity “on/off” cycles. This maintains a constant high-velocity flow of combustion gases even at low heat demands.
- Benefits: This turbulence eliminates vertical temperature gradients (hot spots) on the kettle wall, drastically extending Zinc Kettle life and reducing fuel consumption by up to 15-20%.
- Fuel Options: Versatile designs for Natural Gas (PNG), LPG, LDO, or Dual-Fuel configurations.
To prevent “splashing” and zinc explosions, our dryers use waste heat from the furnace flue gases to preheat and dry the fluxed material.
• Feature: A high-volume re-circulating air system ensures the workpieces reach an optimal temperature (approx. 80°C–120°C) before dipping, which also improves zinc flow and coating finish.
Encapsulated Pretreatment Room
- Heating: Keeps the flux solution at an optimal 50°C–60°C to speed up the drying process and improve chemical action.
- Filtration: An automated system that removes iron (Fe) contamination from the flux bath. Lower iron levels in the flux lead to significantly less dross formation in the zinc kettle.
After galvanizing, products are cooled in water (Quench) and then treated in a Passivation tank (typically chromate or chrome-free) to prevent the formation of “white rust” during storage and transport
We transition your plant from manual labour to Industry 4.0 standards:
- Fully Automatic Operations: PLC-controlled dipping cycles for consistent coating thickness.
- SCADA Systems: A centralized “brain” for the plant, offering real-time data on furnace temperature, fuel levels, and chemical concentrations.
- Remote Access: Monitor your plant’s performance via smartphone or PC from anywhere in the world.
- Production Data Management: Automated logging of every “heat” or batch, providing detailed reports on zinc consumption per ton of steel.
- Plant Layout: Optimizing the “U-shape” or “Straight-line” flow to minimize material handling time.
- Foundation Designs: Specialized civil engineering drawings for the furnace pit and heavy tank foundations.
- Process Optimization: We analyze your product mix (pipes, structures, small parts) to calibrate the chemistry and heat settings for maximum profit.
We provide specialized logistics for the harsh galvanizing environment:
- Monorail & Semi-Auto Cranes: Designed for precision dipping with “slow withdrawal” capabilities to ensure smooth zinc drainage.
- Fully Automatic Crane System: Uses laser-positioning to move jigs through the entire pretreatment and dipping process without manual intervention.
- Transfer Trolleys & Conveyors: Hydraulic loading stations and chain conveyors that move heavy jigs between the pickling room and the furnace area safely.
Our relationship doesn’t end at delivery. We provide:
- Turnkey Installation: Our engineers stay on-site until the first batch of high-quality galvanized steel is produced.
- AMC (Annual Maintenance Contracts): Regular health checks for the furnace, burners, and kettles to prevent unplanned downtime.
- Operator Training: Comprehensive training for your staff on safety, chemical management, and zinc saving techniques.
Start your Galvanizing Journey with
Our Team of Experts!
If you have any questions please contact us.
Send Mail: info@qtechengineering.in or Call Us: (+91) 9949-321087 / (+91) 9959-152246