CN115247248A - Hot galvanizing automatic treatment process based on online detection system - Google Patents
Hot galvanizing automatic treatment process based on online detection system Download PDFInfo
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- CN115247248A CN115247248A CN202111503527.2A CN202111503527A CN115247248A CN 115247248 A CN115247248 A CN 115247248A CN 202111503527 A CN202111503527 A CN 202111503527A CN 115247248 A CN115247248 A CN 115247248A
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- 238000001514 detection method Methods 0.000 title claims abstract description 100
- 238000005246 galvanizing Methods 0.000 title claims abstract description 47
- 238000000034 method Methods 0.000 title claims abstract description 33
- 230000008569 process Effects 0.000 title claims abstract description 29
- JIAARYAFYJHUJI-UHFFFAOYSA-L zinc dichloride Chemical compound [Cl-].[Cl-].[Zn+2] JIAARYAFYJHUJI-UHFFFAOYSA-L 0.000 claims abstract description 78
- 238000005554 pickling Methods 0.000 claims abstract description 73
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 claims abstract description 60
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 51
- 238000007747 plating Methods 0.000 claims abstract description 44
- 235000005074 zinc chloride Nutrition 0.000 claims abstract description 39
- 239000011592 zinc chloride Substances 0.000 claims abstract description 39
- 235000019270 ammonium chloride Nutrition 0.000 claims abstract description 30
- 229960002089 ferrous chloride Drugs 0.000 claims abstract description 28
- NMCUIPGRVMDVDB-UHFFFAOYSA-L iron dichloride Chemical compound Cl[Fe]Cl NMCUIPGRVMDVDB-UHFFFAOYSA-L 0.000 claims abstract description 28
- 239000008237 rinsing water Substances 0.000 claims abstract description 24
- 239000012752 auxiliary agent Substances 0.000 claims abstract description 19
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 12
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims abstract description 11
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims abstract description 10
- 229910000041 hydrogen chloride Inorganic materials 0.000 claims abstract description 10
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 claims abstract description 10
- 238000004140 cleaning Methods 0.000 claims abstract description 5
- 229910001448 ferrous ion Inorganic materials 0.000 claims abstract description 5
- 238000007667 floating Methods 0.000 claims abstract description 5
- 229910052739 hydrogen Inorganic materials 0.000 claims abstract description 5
- 239000001257 hydrogen Substances 0.000 claims abstract description 5
- -1 hydrogen ions Chemical class 0.000 claims abstract description 5
- 238000012544 monitoring process Methods 0.000 claims abstract description 5
- 230000001172 regenerating effect Effects 0.000 claims abstract description 5
- 239000007788 liquid Substances 0.000 claims description 68
- 239000002253 acid Substances 0.000 claims description 41
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 claims description 18
- 238000001816 cooling Methods 0.000 claims description 13
- 230000008929 regeneration Effects 0.000 claims description 13
- 238000011069 regeneration method Methods 0.000 claims description 13
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 12
- 239000002699 waste material Substances 0.000 claims description 12
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 238000005406 washing Methods 0.000 claims description 10
- VTLYFUHAOXGGBS-UHFFFAOYSA-N Fe3+ Chemical compound [Fe+3] VTLYFUHAOXGGBS-UHFFFAOYSA-N 0.000 claims description 6
- 238000001704 evaporation Methods 0.000 claims description 6
- 230000008020 evaporation Effects 0.000 claims description 6
- 230000009467 reduction Effects 0.000 claims description 6
- 239000002994 raw material Substances 0.000 claims description 5
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 claims description 4
- 235000011114 ammonium hydroxide Nutrition 0.000 claims description 4
- 238000006243 chemical reaction Methods 0.000 claims description 4
- 238000001914 filtration Methods 0.000 claims description 4
- 239000000203 mixture Substances 0.000 claims description 4
- 235000011121 sodium hydroxide Nutrition 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 claims description 3
- 230000003203 everyday effect Effects 0.000 claims description 3
- 238000006386 neutralization reaction Methods 0.000 claims description 3
- 238000005086 pumping Methods 0.000 claims description 3
- 230000007704 transition Effects 0.000 claims description 3
- 238000005273 aeration Methods 0.000 claims description 2
- 230000001590 oxidative effect Effects 0.000 claims description 2
- 239000013589 supplement Substances 0.000 claims description 2
- 238000005097 cold rolling Methods 0.000 claims 1
- 238000005098 hot rolling Methods 0.000 claims 1
- 230000000694 effects Effects 0.000 abstract description 2
- 239000003344 environmental pollutant Substances 0.000 abstract description 2
- 231100000719 pollutant Toxicity 0.000 abstract description 2
- 239000002184 metal Substances 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 9
- 230000001276 controlling effect Effects 0.000 description 7
- 230000007613 environmental effect Effects 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 230000003749 cleanliness Effects 0.000 description 2
- 238000005536 corrosion prevention Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 230000035484 reaction time Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 238000010025 steaming Methods 0.000 description 1
- 230000001502 supplementing effect Effects 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
- C23C2/06—Zinc or cadmium or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/26—After-treatment
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating With Molten Metal (AREA)
Abstract
The invention discloses a hot galvanizing automatic treatment process based on an online detection system, and relates to the technical field of hot galvanizing treatment processes; in order to improve the hot galvanizing effect and ensure the product quality; the method comprises the following steps: pickling the qualified workpiece, removing oxide skin and floating rust on the surface of the workpiece, detecting the concentration of hydrogen ions and the concentration of ferrous ions in the pickling solution by using an online detection system, and monitoring and adjusting the parameter data of the solution in the pickling tank and the pickling time in real time; rinsing the workpiece with hydrogen chloride and ferrous chloride adhered to the surface by using water, detecting the concentrations of the hydrogen chloride and the ferrous chloride in the water by using an online detection system, and regenerating the rinsing water when the cleaning capacity of the rinsing water is weakened. The rinsed workpiece enters the plating assisting tank, the concentration of effective components zinc chloride and ammonium chloride is detected by using an online detection system, the concentration of ferrous chloride serving as a pollutant is detected, the zinc chloride and the ammonium chloride are automatically added, and an auxiliary agent is regenerated to reduce the concentration of the ferrous chloride.
Description
Technical Field
The invention relates to the technical field of hot galvanizing treatment processes, in particular to a hot galvanizing automatic treatment process based on an online detection system.
Background
The hot dip galvanizing, also called hot dip galvanizing and hot dip galvanizing, is an effective metal corrosion prevention mode, is mainly used for metal structure facilities in various industries, and is characterized in that a steel member after rust removal is immersed into molten zinc liquid at about 450 ℃ to enable a zinc layer to be attached to the surface of the steel member, so that the purpose of corrosion prevention is achieved. The automation degree is a great obstacle to the automation and digital promotion of the industry.
Through retrieval, the Chinese patent with the application number of CN202011303957.5 discloses a galvanizing treatment process for a metal workpiece; relates to the technical field of metal workpiece treatment, and comprises the following steps: (1) Steaming and boiling the metal workpiece for 40-50min by adopting a hot sodium hydroxide solution, then filtering, washing to be neutral, and drying to be constant weight; (2) Placing the metal workpiece into a surfactant solution, performing immersion treatment for 1-2 hours, then filtering, and drying to constant weight to obtain a treated metal workpiece; (3) And (3) placing the treated metal workpiece in a galvanizing solution, carrying out galvanizing treatment, then taking out, and cooling to room temperature to obtain a galvanized workpiece.
The galvanizing treatment process for the metal workpiece in the patent has the following defects: in the process of treatment, various parameters of the treated liquid cannot be detected in real time, so that the use amount and concentration of various liquids cannot be adjusted in time, and the production cost is increased.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides an automatic hot galvanizing treatment process based on an online detection system.
In order to achieve the purpose, the invention adopts the following technical scheme:
a hot galvanizing automatic treatment process based on an online detection system comprises the following steps:
s1: pickling the qualified workpiece, removing oxide skin and floating rust on the surface of the workpiece, detecting the concentration of hydrogen ions and the concentration of ferrous ions in the pickling solution by using an online detection system, and monitoring and adjusting the parameter data of the solution in the pickling tank and the pickling time in real time;
s2: rinsing the workpiece with hydrogen chloride and ferrous chloride adhered on the surface by using water, detecting the concentration of the hydrogen chloride and the ferrous chloride in the water by using an online detection system, and regenerating the rinsing water when the cleaning capacity of the rinsing water is weakened;
s3: putting the rinsed workpiece into a plating assistant solution consisting of zinc chloride and ammonium chloride, detecting the concentrations of the zinc chloride and the ammonium chloride, the concentration of ferrous chloride and the pH value by using an online detection system, controlling the concentration of each parameter of the plating assistant solution, performing regeneration treatment on the plating assistant solution to remove the ferrous chloride and adjust the pH value, and simultaneously adding the zinc chloride and the ammonium chloride to maintain the concentrations of the zinc chloride and the ammonium chloride;
s4: controlling the galvanizing solution at 445-450 ℃, and placing the workpiece in the galvanizing solution for 40-50s to perform galvanizing operation;
s5: and (3) cooling the hot-dip galvanized workpiece by air, and then placing the hot-dip galvanized workpiece in a water cooling tank for water cooling.
Preferably, the following components: and S4, controlling the temperature of the galvanizing liquid at 450-460 ℃, and placing the workpiece in the galvanizing liquid for 50-60S to perform galvanizing operation.
Preferably: the adjustment of the pickling time in the S1 comprises the following steps:
s11: during the production process of a workpiece, dividing a batch of workpieces to be pickled into a plurality of stages according to the hot-rolled and cold-rolled oxide skin composition and thickness parameters of the production process, the different specifications of the oxide skin thicknesses of the same type of workpieces and the grade parameters of the workpieces according to the pickling duration by workers according to experience, inputting the batch into an online detection system, judging the pickling duration according to the acidity of an acid pool to be entered, automatically feeding, and automatically discharging after pickling at regular time;
s12: after the liquid level in the acid tank is reduced due to evaporation and workpiece bringing-out factors, adding new acid into the tank to replenish the liquid level to a normal height, and immediately detecting acidity to avoid transition pickling;
s13: when the acidity is detected to reach the waste acid degree, the waste acid is automatically pumped into a waste acid tank, fresh acid and water are conveyed into an acid tank in proportion, the acidity of the prepared acid liquor is detected to reach the acidity, the waste acid is automatically discharged, and the fresh acid is automatically prepared.
Preferred for the present invention are: the rinsing water regeneration treatment in the S2 comprises the following steps:
s21: when the online detection system detects that the concentration of the washing water reaches a set value, part of rinsing water is pumped out of the rinsing pool;
s22: according to the liquid level reduction amount, clean water is used for automatic replenishment until a liquid level set value is reached;
s23: pumping the rinsing water into a rinsing water treatment device, adding an alkaline agent into the water for neutralization after the treatment device receives an incoming water signal, and oxidizing ferrous iron into ferric iron by aeration;
s24: and reusing the filtered rinsing water into a water washing tank, and carrying out online detection and online treatment to ensure that the water in the water washing tank is always in a qualified state.
As a preferable aspect of the present invention: the concentration adjustment of the plating assistant solution in the step S3 comprises the following steps:
s31: when the online detection system detects that ferrous chloride or the PH value in the auxiliary agent liquid reaches a set value, part of the plating assistant liquid is pumped out of the plating assistant pool, and the reserved qualified plating assistant liquid is automatically replenished according to the liquid level reduction amount until the liquid level set value is reached;
s32: the pumped plating assistant solution enters plating assistant solution regeneration treatment equipment, hydrogen peroxide and liquid caustic soda are sequentially added into water for reaction after the treatment equipment receives an incoming liquid signal, ferrous iron is oxidized into ferric iron, the adding amount of the hydrogen peroxide is adjusted according to the concentration of ferrous chloride in the incoming liquid and the feed liquid amount, and the phenomenon that excessive hydrogen peroxide is added to return to an auxiliary agent tank is avoided;
s33: according to the pH value, ammonia water is added into the auxiliary agent liquid, and the ammonia water is filtered and stored for supplementing the reduced liquid level of the auxiliary agent tank;
s34: when the concentration of the zinc chloride reaches a set low value, automatically calculating the adding amount, automatically starting a zinc chloride adding pump, stopping adding when the flow reaches the calculated value, and detecting the concentration of the zinc chloride on line;
s35: when the concentration of the ammonium chloride is detected to reach a set low value, the online adjustment is carried out by adopting the same adjustment method as the zinc chloride;
s36: the detection and adjustment are carried out for multiple times every day, and the fluctuation amount of the components of the auxiliary agent is reduced;
s37: the liquid temperature in the plating-assisting tank is maintained at 60-65 ℃, the evaporation speed is increased, and when the zinc chloride or ammonium chloride solution is supplemented, if the liquid level is still lower than a set value, clean water can be automatically supplemented.
As a preferable aspect of the present invention: on-line measuring system, including central controller, pickling bath concentration detection module and pickling bath pickling time detection module and central controller electric connection, pickling bath concentration detection module and pickling bath pickling time detection module detect concentration and pickling time in the pickling bath, and central controller carries out automatic control according to the concentration and the pickling time that detect data in to the pickling bath and adjusts.
Further: on-line measuring system includes rinsing pond concentration detection module, and rinsing pond concentration detection module electric connection between central controller, rinsing liquid concentration in rinsing pond of rinsing pond concentration detection module pair detects, and central controller carries out automatically regulated according to detected data to rinsing liquid concentration.
As a further scheme of the invention: the on-line detection system comprises a plating assisting pool concentration detection module, the plating assisting pool concentration detection module is electrically connected with the central controller, and the plating assisting pool concentration detection module detects the usage amount of zinc chloride and ammonium chloride raw materials.
The invention has the beneficial effects that:
1: the rinsed workpiece enters the plating assisting tank, the concentration of effective components zinc chloride and ammonium chloride is detected by using an online detection system, the concentration of ferrous chloride serving as a pollutant is detected, the zinc chloride and the ammonium chloride are automatically added, and the auxiliary agent is regenerated to reduce the concentration of the ferrous chloride.
2. The workload of a laboratory worker is reduced, the sampling by an acid pool with poor environment in public is not needed, and the random error of manual detection is reduced; the detection frequency is increased, so that indexes in the process tank can be obtained at high frequency, and various parameter values in the process tank can be automatically adjusted; the reaction time was automatically adjusted.
3. The whole galvanizing pretreatment production line can automatically run; the matched environmental protection equipment or regeneration equipment can automatically operate; the use amount of acid, zinc chloride and ammonium chloride raw materials is saved; the cleanliness of the auxiliary agent pool is maintained, and no sludge exists in the pool; the liquid components in the process tank are stable and qualified, and the product quality is stable.
Drawings
FIG. 1 is a schematic overall flow chart of an automatic hot galvanizing treatment process based on an online detection system according to the present invention;
fig. 2 is a schematic structural diagram of an on-line detection system of a hot galvanizing automatic processing technology based on the on-line detection system.
Detailed Description
The technical solution of the present patent will be described in further detail with reference to the following embodiments.
Reference will now be made in detail to embodiments of the present patent, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary only for the purpose of explaining the present patent and are not to be construed as limiting the present patent.
In the description of this patent, it is to be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and "outer" refer to an orientation or positional relationship relative to one another as illustrated in the figures, which are used for convenience in describing the patent and for simplicity of description, and are not to be construed as limiting the referenced devices, structures, or elements to a particular orientation, configuration, or operation as long as they are in a particular orientation.
In the description of this patent, it is noted that unless otherwise specifically stated or limited, the terms "mounted," "connected," and "disposed" are to be construed broadly and can include, for example, fixedly connected, disposed, detachably connected, disposed, or integrally connected and disposed. The specific meaning of the above terms in this patent may be understood by those of ordinary skill in the art as appropriate.
Example 1:
an automatic hot galvanizing treatment process based on an online detection system is shown in figure 1 and comprises the following steps:
s1: pickling the qualified workpiece, removing oxide skin and floating rust on the surface of the workpiece, detecting the concentration of hydrogen ions and the concentration of ferrous ions in the pickling solution by using an online detection system, and monitoring and adjusting the parameter data of the solution in the pickling tank and the pickling time in real time;
s2: rinsing the workpiece with hydrogen chloride and ferrous chloride adhered on the surface by using water, detecting the concentration of the hydrogen chloride and the ferrous chloride in the water by using an online detection system, and regenerating the rinsing water when the cleaning capacity of the rinsing water is weakened;
s3: putting the rinsed workpiece into a plating assistant solution consisting of zinc chloride and ammonium chloride, detecting the concentrations of the zinc chloride and the ammonium chloride, the concentration of ferrous chloride and the pH value by using an online detection system, controlling the concentration of each parameter of the plating assistant solution, performing regeneration treatment on the plating assistant solution to remove the ferrous chloride and adjust the pH value, and simultaneously adding the zinc chloride and the ammonium chloride to maintain the concentrations of the zinc chloride and the ammonium chloride;
s4: controlling the galvanizing solution at 445-450 ℃, and placing the workpiece in the galvanizing solution for 40-50s to perform galvanizing operation;
s5: and (3) cooling the hot-dip galvanized workpiece by air, and then placing the hot-dip galvanized workpiece in a water cooling tank for water cooling.
Example 2:
an automatic hot galvanizing treatment process based on an online detection system is shown in figure 1 and comprises the following steps:
s1: pickling the qualified workpiece, removing oxide skin and floating rust on the surface of the workpiece, detecting the concentration of hydrogen ions and the concentration of ferrous ions in the pickling solution by using an online detection system, and monitoring and adjusting the parameter data of the solution in the pickling tank and the pickling time in real time;
s2: rinsing the workpiece with hydrogen chloride and ferrous chloride adhered on the surface by using water, detecting the concentrations of the hydrogen chloride and the ferrous chloride in the water by using an online detection system, and regenerating the rinsing water when the cleaning capacity of the rinsing water is weakened;
s3: putting the rinsed workpiece into a plating assistant solution consisting of zinc chloride and ammonium chloride, detecting the concentrations of the zinc chloride and the ammonium chloride, the concentration of ferrous chloride and the pH value by using an online detection system, controlling the concentration of each parameter of the plating assistant solution, performing regeneration treatment on the plating assistant solution to remove the ferrous chloride and adjust the pH value, and adding the zinc chloride and the ammonium chloride to maintain the concentrations of the zinc chloride and the ammonium chloride;
s4: controlling the galvanizing solution at 450-460 ℃, and placing the workpiece in the galvanizing solution for 40-50s to perform galvanizing operation;
s5: and (3) cooling the hot-dip galvanized workpiece by air, and then placing the hot-dip galvanized workpiece in a water cooling tank for water cooling.
The adjustment of the pickling time in the S1 comprises the following steps:
s11: during the production process of a workpiece, dividing a batch of workpieces to be pickled into a plurality of stages according to the hot-rolled and cold-rolled oxide skin composition and thickness parameters of the production process, the different specifications of the oxide skin thicknesses of the same type of workpieces and the grade parameters of the workpieces according to the pickling duration by workers according to experience, inputting the batch into an online detection system, judging the pickling duration according to the acidity of an acid pool to be entered, automatically feeding, and automatically discharging after pickling at regular time;
s12: after the liquid level in the acid tank is reduced due to evaporation and workpiece bringing-out factors, adding new acid into the tank to replenish the liquid level to a normal height, and immediately detecting acidity to avoid transition pickling;
s13: when the acidity is detected to reach the waste acid degree, the waste acid is automatically pumped into a waste acid tank, fresh acid and water are conveyed into an acid tank in proportion, and the acidity of the prepared acid liquor is detected to reach the acidity, so that the waste acid is automatically discharged, and the fresh acid is automatically prepared.
The rinsing water regeneration treatment in the S2 comprises the following steps:
s21: when the online detection system detects that the concentration of the washing water reaches a set value, part of rinsing water is pumped out of the rinsing pool;
s22: according to the liquid level reduction amount, clean water is used for automatic replenishment until a liquid level set value is reached;
s23: pumping the rinsing water into a rinsing water treatment device, adding an alkaline agent into the water for neutralization after the treatment device receives an incoming water signal, and aerating to oxidize ferrous iron into ferric iron;
s24: and reusing the filtered rinsing water into a water washing tank, and carrying out online detection and online treatment to ensure that the water in the water washing tank is always in a qualified state.
The concentration adjustment of the plating assistant solution in the step S3 comprises the following steps:
s31: when the online detection system detects that ferrous chloride or the PH value in the auxiliary agent liquid reaches a set value, part of the plating assistant liquid is pumped out of the plating assistant pool, and the reserved qualified plating assistant liquid is automatically replenished according to the liquid level reduction amount until the liquid level set value is reached;
s32: the pumped plating assistant solution enters plating assistant solution regeneration treatment equipment, hydrogen peroxide and liquid caustic soda are sequentially added into water for reaction after the treatment equipment receives an incoming liquid signal, ferrous iron is oxidized into ferric iron, the adding amount of the hydrogen peroxide is adjusted according to the concentration of ferrous chloride in the incoming liquid and the feed liquid amount, and the phenomenon that excessive hydrogen peroxide is added to return to an auxiliary agent tank is avoided;
s33: adding ammonia water into the auxiliary agent liquid according to the pH value, filtering, and storing to supplement the reduced liquid level of the auxiliary agent pool;
s34: when the concentration of the zinc chloride reaches a set low value, automatically calculating the adding amount, automatically starting a zinc chloride adding pump, stopping adding when the flow reaches the calculated value, and detecting the concentration of the zinc chloride on line;
s35: when the concentration of the ammonium chloride is detected to reach a set low value, the online adjustment is carried out by adopting the same adjustment method as the zinc chloride;
s36: the detection and adjustment are carried out for multiple times every day, and the fluctuation amount of the auxiliary agent components is reduced;
s37: the liquid temperature in the plating-assisting tank is maintained at 60-65 ℃, the evaporation speed is increased, and when the zinc chloride or ammonium chloride solution is supplemented, if the liquid level is still lower than a set value, clean water can be automatically supplemented.
In this embodiment: the parameters of the process liquid can be automatically adjusted in each process section of the pretreatment, so that after the workpiece enters each process pool, the reaction time of the workpiece in the pool can be determined due to the stable parameters of the process pool or the selected range, the reaction effect can reach the predicted value, the automatic operation of the pretreatment process can be realized, and the consumption of raw materials can be reduced due to the fact that excessive pickling and stable plating assistant components are avoided.
Example 3:
the on-line detection system comprises a central controller, a pickling bath concentration detection module and a pickling bath pickling time detection module, wherein the pickling bath concentration detection module and the pickling bath pickling time detection module are electrically connected with the central controller, the pickling bath concentration detection module and the pickling bath pickling time detection module detect the concentration and the pickling time in the pickling bath, and the central controller automatically controls and adjusts the concentration and the pickling time in the pickling bath according to detection data; by automatically adjusting the retention time in each pickling tank according to the tank liquor parameters, the consumption of acid is reduced, the automatic operation of pretreatment of a production line is realized, and the automatic operation of auxiliary equipment of acid preparation, regeneration equipment and environmental protection equipment is realized.
The on-line detection system comprises a rinsing pool concentration detection module, the rinsing pool concentration detection module is electrically connected with a central controller, the rinsing pool concentration detection module detects the concentration of rinsing liquid in the rinsing pool, and the central controller automatically adjusts the concentration of the rinsing liquid according to detection data; can make the water in the rinsing pond always be in qualified state through rinsing pond concentration detection module, according to the liquid level decrement, use the automatic replenishment of clean water, until reaching the liquid level setting value, do not influence production.
The online detection system comprises a plating assisting tank concentration detection module, the plating assisting tank concentration detection module is electrically connected with the central controller, and the plating assisting tank concentration detection module is used for detecting the usage amount of zinc chloride and ammonium chloride raw materials; can maintain the cleanliness in auxiliary agent pond through helping plating pond concentration detection module, no silt in the pond guarantees that liquid composition is stable in the technology pond, qualified, and product quality is stable.
This embodiment is through automated inspection, does not use artifical parameter detection to pretreatment liquid to reduce artificial work load, and avoid artifical work in the environment of high pollution, improve data and provide the frequency, improve the stability of data, realize joining in marriage the automation mechanized operation of acid, regeneration facility, environmental protection equipment auxiliary assembly.
The above description is for the purpose of illustrating the preferred embodiments of the present invention and is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed, and all modifications, equivalents, and improvements that may occur to those skilled in the art and that fall within the spirit and scope of the invention are intended to be embraced therein.
Claims (8)
1. A hot galvanizing automatic treatment process based on an online detection system is characterized by comprising the following steps:
s1: pickling the qualified workpiece, removing oxide skin and floating rust on the surface of the workpiece, detecting the concentration of hydrogen ions and the concentration of ferrous ions in the pickling solution by using an online detection system, and monitoring and adjusting the parameter data of the solution in the pickling tank and the pickling time in real time;
s2: rinsing the workpiece with hydrogen chloride and ferrous chloride adhered on the surface by using water, detecting the concentration of the hydrogen chloride and the ferrous chloride in the water by using an online detection system, and regenerating the rinsing water when the cleaning capacity of the rinsing water is weakened;
s3: putting the rinsed workpiece into a plating assistant solution consisting of zinc chloride and ammonium chloride, detecting the concentrations of the zinc chloride and the ammonium chloride, the concentration of ferrous chloride and the pH value by using an online detection system, controlling the concentration of each parameter of the plating assistant solution, performing regeneration treatment on the plating assistant solution to remove the ferrous chloride and adjust the pH value, and simultaneously adding the zinc chloride and the ammonium chloride to maintain the concentrations of the zinc chloride and the ammonium chloride;
s4: controlling the galvanizing solution at 445-450 ℃, and placing the workpiece in the galvanizing solution for 40-50s to perform galvanizing operation;
s5: and (3) cooling the hot-dip galvanized workpiece by air, and then placing the hot-dip galvanized workpiece in a water cooling tank for water cooling.
2. The automatic hot galvanizing treatment process based on the on-line detection system as claimed in claim 1, wherein the temperature of the galvanizing solution in the S4 is controlled to be 450-460 ℃, and the workpiece is placed in the galvanizing solution for 50-60S to perform galvanizing operation.
3. The automatic hot galvanizing treatment process based on the online detection system as claimed in claim 2, wherein the adjustment of the pickling time in the S1 comprises the following steps:
s11: during the production process of a workpiece, dividing a batch of workpieces to be pickled into a plurality of stages according to the composition and thickness parameters of oxide skin of hot rolling and cold rolling of a production process, the thickness of the oxide skin of different specifications of the same type of workpieces and the grade parameters of the workpieces based on experience and acid pickling duration by workers, inputting the batch into an online detection system, judging the acid pickling duration according to the acidity of an acid pool to be entered, automatically feeding, and automatically discharging after acid pickling at regular time;
s12: after the liquid level in the acid tank is reduced due to evaporation and workpiece carrying-out factors, adding new acid into the tank to replenish the liquid level to a normal height, and immediately detecting acidity to avoid transition pickling;
s13: when the acidity is detected to reach the waste acid degree, the waste acid is automatically pumped into a waste acid tank, fresh acid and water are conveyed into an acid tank in proportion, the acidity of the prepared acid liquor is detected to reach the acidity, the waste acid is automatically discharged, and the fresh acid is automatically prepared.
4. The automatic hot galvanizing treatment process based on the online detection system as claimed in claim 1, wherein the rinse water regeneration treatment in the S2 comprises the following steps:
s21: when the online detection system detects that the concentration of the washing water reaches a set value, part of rinsing water is pumped out of the rinsing pool;
s22: according to the liquid level reduction amount, clean water is used for automatic replenishment until a liquid level set value is reached;
s23: pumping the rinsing water into a rinsing water treatment device, adding an alkaline agent into the water for neutralization after the treatment device receives an incoming water signal, and oxidizing ferrous iron into ferric iron by aeration;
s24: and reusing the filtered rinsing water into a water washing tank, and carrying out online detection and online treatment to ensure that the water in the water washing tank is always in a qualified state.
5. The hot galvanizing automatic treatment process based on the online detection system as claimed in claim 1, wherein the concentration adjustment of the plating assistant solution in the S3 comprises the following steps:
s31: when the online detection system detects that ferrous chloride or the PH value in the auxiliary agent liquid reaches a set value, part of the plating assistant liquid is pumped out of the plating assistant pool, and the reserved qualified plating assistant liquid is automatically replenished according to the liquid level reduction amount until the liquid level set value is reached;
s32: the pumped plating assistant solution enters plating assistant solution regeneration treatment equipment, hydrogen peroxide and liquid caustic soda are sequentially added into water for reaction after the treatment equipment receives an incoming liquid signal, ferrous iron is oxidized into ferric iron, the adding amount of the hydrogen peroxide is adjusted according to the concentration of ferrous chloride in the incoming liquid and the feed liquid amount, and the phenomenon that excessive hydrogen peroxide is added to return to an auxiliary agent tank is avoided;
s33: adding ammonia water into the auxiliary agent liquid according to the pH value, filtering, and storing to supplement the reduced liquid level of the auxiliary agent pool;
s34: when the concentration of the zinc chloride reaches a set low value, automatically calculating the adding amount, automatically starting a zinc chloride adding pump, stopping adding when the flow reaches the calculated value, and detecting the concentration of the zinc chloride on line;
s35: when the concentration of the ammonium chloride is detected to reach a set low value, the online adjustment is carried out by adopting the same adjustment method as the zinc chloride;
s36: the detection and adjustment are carried out for multiple times every day, and the fluctuation amount of the components of the auxiliary agent is reduced;
s37: the liquid temperature in the plating assisting pool is maintained at 60-65 ℃, the evaporation speed is increased, and when the zinc chloride or ammonium chloride solution is supplemented, if the liquid level is still lower than a set value, clear water can be automatically supplemented.
6. The hot galvanizing automatic processing technology based on the online detection system as claimed in claim 5, wherein the online detection system comprises a central controller, a pickling bath concentration detection module and a pickling bath pickling time detection module, the pickling bath concentration detection module and the pickling bath pickling time detection module are electrically connected with the central controller, the pickling bath concentration detection module and the pickling bath pickling time detection module detect the concentration and the pickling time in the pickling bath, and the central controller automatically controls and adjusts the concentration and the pickling time in the pickling bath according to the detection data.
7. The hot galvanizing automatic treatment process based on the online detection system as claimed in claim 6, wherein the online detection system comprises a rinsing bath concentration detection module, the rinsing bath concentration detection module is electrically connected with a central controller, the rinsing bath concentration detection module detects the concentration of rinsing liquid in the rinsing bath, and the central controller automatically adjusts the concentration of the rinsing liquid according to detection data.
8. The hot dip galvanizing automatic treatment process based on the online detection system as claimed in claim 7, wherein the online detection system comprises a plating assistant tank concentration detection module, the plating assistant tank concentration detection module is electrically connected with a central controller, and the plating assistant tank concentration detection module detects the usage amount of zinc chloride and ammonium chloride raw materials.
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