alkaline zinc barrel and rack plating line

Home > Surface Treatment Process Plant & EquipmentElectroplating & treatment lines >

Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating Line

Stock Code: BOT500Manufacturer: Process Plant and EquipmentModel: Fully Automatic Alkaline Zinc BarrelYear of Manufacture: 2000New or Used: Used (Second Hand)Work Envelope (WxDxH mm): 800//1440 x 1400 x 1000Process Stages: 32Other Info: 3/4 loads p/hr // 500kg SWL TransporterExternal Dimensions (WxDxH): 4500 x 36,900 x 4500

Process Plant and Equipment Alkaline Zinc Barrel & Rack Plating Line (Specification & Photos Set 1)

The following specification forms part of

Alkaline Zinc Barrel and Rack Plating Facility comprisingAlkaline Zinc Barrel and Rack Plating Line (Spec & Photos1) (Photo 2) (Photo 3)NEW! 2021 Significant Upgrade to Control Equipment for above lineThe whole available forjust £100,000 + VAT

To register an interest for the whole, or individual components, please contact Helen on +44 (0)1922 749 284

The Marketplace for Surface Technology.New and Used Process Equipment & Machinery.

Riley Industries LtdA subsidiary of Barry Riley & Sons Ltd. Director: M P A Riley, Secretary: D Hemming

Registered in England no. 1965748

/17

https://www.rileysurfaceworld.co.uk

https://www.rileysurfaceworld.co.uk/surface_treatments.asp

https://www.rileysurfaceworld.co.uk/surface-treatment-electroplating.asp

/machines/30031.htm

/machines/30031.htm

/machines/30048.htm

/machines/30049.htm

/machines/30222.htm


Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineTechnical SpecificationPlant Design: Straight Line Automatic Plant.Process: Alkaline Zinc ElectroplateBase Metal ofComponents: Mild SteelComponents: Work Storage and Racking System PartsOperation: Fully AutomaticEstimatedPlant Output: 3 to 4 loads per hour Tank Section: 1400 mm wide x 1000 mm deepTransporters: One 500kg SWLTransporterHoist/Traverse Motors: Variable speed with frequency invertorFlight Bars: 4 off to accommodate platingracks.Plating Racks - A quantity to be provided with plant.Motorised Barrel Rigs - 7 off Progalvano Model420.Heating: Thermal Fluid with 6 Hour heat up time.Cooling via: Chiller Unit/External Heat ExchangerElectricalSupply: 415v 50hz 3ph with neutral

Approx. Plant Dimensions: (Including Ancillary Equipment)Length: 36.9.0 MetresWidth: 4.50 Metres Height: 4.50 Metres

General Construction

The Automatic Plating Line is arranged in a straight line with the Load/Unload station at one end for efficiency ofoperation. The work is carried automatically through the line by an enclosed transporter complete with motorisedraise lower and traverse.At the load end of the line is a five position buffer section for on line storage of barrel rigs or flight bars dependant onwhat type of work is being processed.

The work after loading travels over the post treatment section to the middle of the line where it then goes through theall-important section pre-treatment of two stage cleaning and activation before the electroplating stations (two barreland one rack). On completion of electroplating the work is immediately rinsed and then carried over the pre-treatment section to thepost treatment area where alternative passivation finishes can be carried out. This section runs back toward theunload station for maximum efficiency via two inline dryers, one for rack work and one for in barrel drying.

At the unload station hopper chutes and roller track is provided to enable barrel work to be manually offloaded intotote pans for the option of centrifugal drying in two offline stainless steel Krom units.

The line is provided with a barrel or flight bar maintenance station at the opposite end to the load/unload station.

Upgrade Potential

The existing electroplating stations (two barrel and one rack) are located at the far end of the line from the loadstation where there is already a potentially 3.5 metre long overrun section of transporter track which lends itself toinstallation of additional plating stations. There is also space allocated for installing a third in-line dryer (thermal fluidvalved offtakes already in place) to service an increase in output if extra plating stations are fitted.

With the installation of the additional ampere hour controlled dosing systems required for Nickel metal, brightener,and leveller replenishment etc. the line could be converted to Zinc Nickel Alloy plating with its benefit of highercorrosion resistance as favoured by the automotive industry.




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineTransporter Equipment

1 Off Fully motorised 500kg SWL transporter system, to operate in two modes.

Mode 1 Fully AutomaticWhere all traverse and hoist movements automatically follow pre-set routes and process times. Either in fixedtimeway or random control.

Mode 2 Semi-AutomaticWhere all transporter movements are under the control of the operator via a pendant or joystick or keyboard controlThe transporter has features as follows:

The traverse drive is by means of a variable speed motor and gear box under the control of a frequency inverterdesigned to give a smooth accelerating and decelerating speed ramp with traverse adjustable according to distancesbetween stations.

The hoist mechanism is by means of a variable speed motor and gear box under the control of a frequency invertordesigned to give a smooth accelerating and decelerating speed ramp with the ability to set different lift and lowerrates.

The transporter is fitted with full safety interlocks, barrel rotation, anti-collision and pendant control forsemi-automatic mode.

The transporter is fully enclosed to contain residual fume when work is raised from the tank.

Track Support Structure

The transporter runs on a gantry system manufactured in stainless steel RHS, supported on stanchions from thefloor and lateral members to the external bodies of the tanks. The gantry system is 36.90 m long with track height of2.06 m and centres of 2.15 m.

The full length of the operator side of the line is provided with a raised walkway manufactured in stainless steel withhandrail, kick strips, grp decking and access steps at each end.

The self-supporting structure is in bolted sections lined and levelled without the need for special foundations.

Control System

The control system on the plant is fully automatic PLC based which will enable a variety of process routes to be run,with choices between rack or barrel plating and which passivation finish is required. All transporter movements aresafety interlocked to comply with the applicable regulatory requirements. The PLC and control gear is located in thecentral control panel with a remote HMI at the load/unload station for convenient use by the operator.

The PLC and control software is currently being upgraded to a brand new 2020 version and a full technicalspecification along with operating instructions and wiring schematics will be available shortly.




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineProcess Tanks

The line is constructed as modular free-standing tanks supporting all fittings and services. Each section is completewith stainless steel adjustable levelling feet. There are removable drip covers between each tank.

Process tanks are constructed according to the chemical process involved as indicated in the appropriate stationdescription and generally as follows:

9mm thick rigid PVC, strengthened as necessary externally with encapsulated reinforcing bands. All welding isinternal and external on all joints.9mm thick rigid polypropylene, strengthened as necessary externally with bodybands. Tanks welded both internally and externally on all joints.9mm thick rigid PVC or polypropylene strengthenedas necessary externally with body bands and reinforced with GRP. All welding is internal and external on all joints.All joints are complete with spark discharge test strips.304 or 316 stainless steel or titanium reinforced externally asnecessary with body bands and tank top lip.6mm thick rigid polymer liners within mild steel coated tanks,strengthened externally as necessary with body bands. Tanks welded both internally and externally on all joints.

Electrolytic stations will be fitted with all necessary DC contact systems complete with interconnecting conductorsand anode bars. Anode bars may be removable from the tanks.

All tank fittings and service components are secured with stainless steel hardware throughout wherever possible. **

Services

WaterRinse tanks will be fitted with water inlets, manual control valves and weir or standpipe overflow outlets to drains.Adjacent rinse tanks will be connected in counterflow as indicated in the tank specification for water conservation asshown in the appropriate station description.Drain valves will be fitted to those process tanks indicated in the attached specification sheets.3 off drain pipework runs are fitted to the line. It will be approximately 1.1/2" diameter.

Compressed Air1 off compressed air line with branches

ElectricalThe equipment is complete with a box section ducting running the length of the line with flexible conduit connectionto the components.

Heating and cooling

All heating, unless otherwise specifically stated, is PTFE (Teflon), 316 grade stainless steel, titanium electrical orheat exchange coil/plate immersion heaters, either vertically or base mounted within the process tanks, as indicatedin the appropriate tank description.

All electrical heating systems will be complete with digital indicating solid state thermostatic controls, AC contactor,residual current circuit protection, magnetic overload protection and safety level protection devices.




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineGenerally, where appropriate all heat exchange heating coils will be complete with sight glass, float trap strainer,check valve, temperature controller, isolating valves and bypass. (Final specification dependent upon choice ofheating medial e.g. steam, high pressure hot water, thermal fluid).

All heating calculations are based on a 6 hour heat up period.

All heater controls will be wired back to a control cabinet sited at the operator end of the line which will be mountedall associated AC contactors, M.C.B'S, thermostatic controls and safety level protection controllers.

The cabinet provides a fully wired distribution system for electrical circuits within the cabinet and will require a singleAC source run from the customer's adjacent isolator mounted within 3 metres of the cabinet.

Fume Extraction

Lip exhaust ducts are located between the appropriate process tanks.Adjustable dampers are provided to restrict the individual flow and a spigot for connection of the factory manifold.

The equipment is complete with 9 off lip fume extraction ducts manufactured from polypropylene material extractingfrom the following processes:

Stage 14 PassivationStage 17 Soak CleanerStage 18 Anodic CleanerStage 21 Acid Dip Stage 27 Zinc PlateBarrelStage 28 Zinc Plate BarrelStage 29 Zinc Plate RackStage 31 Dissolution Tank Zinc Plate VatStage 32Dissolution Tank Zinc Plate Barrel

The ducts are connected to a main manifold running the length of the plant through a horizontal fume scrubbingsystem, to a centrifugal fan, mounted on a support steel structure, with a discharge stack to atmosphere withtermination in a high velocity discharge cone.System sized for a second twin station barrel zinc plating tank.

Overview Features2 x Water input 1''3 x Drain 2"31m Track and catenary1 X Transporter Autoline Type1 xEmergency Stop Pull-cord4 x Flight Bars (Vat plating)1 x Control CabinetStations Overview

Station 1 - Load/Unload

Tank construction: Stainless Steel1 x Twin hopper unloading chute (Removable for jig work)1 x Operator activatedbarrel rotation button1 x Roller track for component box removalBarrel location cones Dimensions: 800 x 1400 x1000 mm

Stations 2 - 6 Buffer Station

Tank construction: Stainless Steel10 x Barrel location conesDimensions: 4300 x 1400 x 1000 mm

Station 7 - Caltherm Hot Air Dry (In barrel)




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineTank construction: Stainless SteelThis is a single barrel location system comprising the following:1 x Insulation 2 xStainless steel lids4 x Pneumatically operated cylinders for lid operation2 x Barrel location cones 1x Barrel rotationcontacts2 x Internal brush seals 2 x Directional air louvres1 x Centrifugal air circulation fan2 x Heat exchangebatteries (thermal fluid) 1 x Drain facilities Temperature: 50°cDimensions: 990 x 1,400 x 1000 mm

Station 8 - Caltherm Jig Vat Dryer (on rack)

Tank construction: Stainless Steel1 x Insulation 2 x Pneumatically operated cylinders for lid operation2 x Flight Barlocation cones 2 x Directional air louvres1 x Centrifugal air circulation fan2 x Heat exchange batteries (thermal fluid)2x Isolating Valves1 x Air Operated Control Valves 1 x Drain facilities Temperature: 50°cDimensions: 800 x 1,400 x1000 mm

Station 9 - Lacquer Dip (seal)

Tank construction: Polypropylene1 x Valved water inlet1 x Drain valve2 x Isolation valves1 x Air operated controlvalve1 x Thermal fluid coil2 x Level control2 x Temperature probe1 x Digital temperature controller2 x Locationcones1 x Barrel rotation contactTemperature: 35°c currently set to 20°cVolume: 896 LitresDimensions: 800 x 1,400 x1000 mm

Station 10 - Rinse (D.I Water)

Tank construction: Polypropylene1 x Valved water inlet1 x Tank insulation1 x Inlet corner weir1 x Corner weir flow todrain1 x Drain valve1 x Valved air sparger2 x Isolating valves1 x Air operated control valve1 x Thermal fluid coil1 xLevel control1 x Temperature probe1 x Digital temperature control2 x location cones1 x Barrel rotationcontactTemperature: 60°c currently set to 45°cVolume: 896 LitresDimensions: 800 x 1,400 x 1000 mm

Stations 11-13 Rinse

Tank construction: Polypropylene1 x Valved water inlet1 x Inlet corner weir1 x Corner weir overflow to drain1 x Drainvalve1 x Valve air sparger2 x Location cones1 x Barrel rotation contactVolume: 896 LitresDimensions: 800 x 1,400 x1000 mm

Station 14 - Yellow Passivate

Tank construction: Poly Vinyl Chloride1 x Valved water inlet1 x Drain valve1 x Valved air sparger2 x Isolating valves1x Air operated control valve1 x Thermal fluid coil1 x Level control1 x Temperature probe1 x Digital temperaturecontroller2 x Location cones1 x Barrel rotation contactTemperature: 25°c currently set to 35°cVolume: 896LitresDimensions: 800 x 1,400 x 1000 mm

Station 15 - Blue Passivate




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineTank construction: Poly Vinyl Chloride1 x Valved water inlet1 x Drain valve1 x Valved air sparger2 x Isolating valves1x Air operated control valve1 x Thermal fluid coil1 x Level control1 x Temperature probe1 x Digital temperaturecontroller2 x Location cones1 x Barrel rotation contactTemperature: 25°cVolume: 896 LitresDimensions: 800 x 1,400x 1000 mm

Station 16 - Nitric Dip

Tank construction: Poly Vinyl Chloride1 x Valved water inlet1 x Drain valve1 x Valved air sparger2 x Location cones1x Barrel rotation contactVolume: 896 LitresDimensions: 800 x 1,400 x 1000 mm

Station 17 - Soak Cleaner

Tank construction: Polypropylene1 x Tank Insulation1 x Valved water inlet1 x Drain valve1 x Lip fume extractionplenum chamber with control dampers1 x Thermal fluid coil2 x Isolating valves1 x Air operated control valve1 x Levelcontrol1 x Temperature probe1 x Digital temperature controller1 x Solution overflow weir1 x Coalescing type oilseparator including:-1 x Undermounted collection tank1 x Circulating pump1 x Coalescing bed (vertical type)1 x Oiloverflow1 x Aqueous overflow through a sparger located within the cleaner tank2 x Location cones1 x Barrel rotationcontactTemperature: 70°c currently set to 64°cVolume: 1008 LitresDimensions: 900 x 1,400 x 1000 mm

Station 18 - Anodic Clean

Tank construction: Polypropylene1 x Tank Insulation1 x Valved water inlet1 x Drain valve1 x Lip fume extractionplenum chamber with control dampers1 x Recirculating pump and filter system (in tank Flo-king type)1 x Thermalfluid coil2 x Isolating valves1 x Air operated control valve1 x Level control1 x Temperature probe1 x Digitaltemperature controller2 x Anode bars1 x 12 volt 1000 amp Rectifier1 x set Bus bar connections2 x location cones1 xBarrel rotation contact2 x Stainless steel cathodesTemperature: 70°cVolume: 1120 LitresDimensions: 1,000 x 1,400x 1000 mm


Tank construction: Polypropylene1 x Valved water inlet1 x Inlet corner weir1 x Corner weir overflow to drain1 x Drainvalve1 x Valve air sparger2 x Location cones1 x Barrel rotation contactVolume: 896 LitresDimensions: 800 x 1,400 x1000 mm

Station 21 - Acid Dip

Tank construction: Polypropylene1 x Valved water inlet1 x Drain valve1 x Lip fume extraction plenum chamber withcontrol dampers1 x Recirculating pump and filter system (in tank Flo-king type)2 x location cones1 x Barrel rotationcontactVolume: 896 LitresDimensions: 800 x 1,400 x 1000 mm





/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineTank construction: Polypropylene1 x Valved water inlet1 x Inlet corner weir1 x Corner weir overflow to drain1 x Drainvalve1 x Valve air sparger2 x Location cones1 x Barrel rotation contactVolume: 896 LitresDimensions: 800 x 1,400 x1000 mm

Station 26 - Pre-dip

Tank construction: Polypropylene1 x Drain valve1 x Barrel rotation contactVolume: 896 LitresDimensions: 800 x1,400 x 1000 mm

Station 27/28 - Alkaline Zinc Barrel Electroplate

Tank construction: Polypropylene1 x Valved water inlet1 x Lip fume extraction plenum chamber with controldampers1 x Recirculating pump and filter system located in an external dissolution tank with balanced solution return(Tank sized from second barrel plating tank)1 x Solenoid operation water fed cooling oil4 x Anode bars1 x Tankdivider (two cells) stray current baffle1 x Level control1 x Temperature probe1 x Digital temperature controller2 xAutomatic chemical dosing pump2 x 16 volt 1000 amp Rectifier2 x set Bus bar connections4 x location cones2 xBarrel rotation contact4 x Stainless steel cathodesTemperature: 25°cVolume: 2352 LitresDimensions: 2,100 x 1,400x 1000 mm

Station 29 - Alkaline Zinc Barrel Electroplate

Tank construction: Polypropylene1 x Valved water inlet1 x Lip fume extraction plenum chamber with control damper2x Valved air spargers1 x Recirculating pump and filter system located in an external dissolution tank with balancedsolution return 1 x Solenoid operation water fed cooling oil3 x Anode bars1 x Level control1 x Temperature probe1 xDigital temperature controller1 x Automatic chemical dosing pump1 x 8 volt 1000 amp Rectifier1 x set Bus barconnections2 x location cones2 x Barrel rotation contact3 x Stainless steel cathodesTemperature: 25°cVolume: 1612LitresDimensions: 1,440 x 1,400 x 1000 mm

Station 30 - Barrel/Anode Maintenance

Tank construction: Polypropylene1 x Valved water inlet and flexible hose1 x Drain facilityDimensions: 800 x 1,400 x1000 mmZinc Dissolving Tanks

The use of a separate zinc dissolving tank is required when operating in production applications, to enable optimumcontrol of zinc metal in the plating solution. The total volume of the dissolving tank system should be around 10 to20% of the volume of the plating tank.

The system is designed to ensure the plating solution weirs from its tank into the dissolution unit, which is loadedwith high purity zinc dome anodes contained in carbon steel mesh cages. The area of zinc under the solution isadjusted until the concentration remains stable, this quantity is typically ten times greater than daily usage.

Solution from the dissolution tank is then transferred by pump back to the plating tank via a filter.

As the rack and barrel plating solutions have different optimum zinc metal concentrations separate dissolution tanksare provided for each type of plating.




/17






Tank 31 Offline Rack Plating Zinc Dissolution Tank serving online plating station 29 has nominal internal dimensionsof 1000mm long x 800mm wide x 1000mm deep.

Tank 32 Offline Rack Plating Zinc Dissolution Tank serving online plating stations 27 & 29 has nominal internaldimensions of 2500mm long x 800mm wide x 1000mm deep.

Both tanks are constructed as freestanding steel outer tanks supporting polypropylene inner tanks which contain theprocess solution.

Both tanks are provisioned with fume extraction, heating, cooling, filtration, and pumped circulation systems tomaintain the zinc solution in the optimum condition.

Support rails are provided for the zinc anode cages to hang from: at low level when the line is in operation and athigh level in order to remove the anode cages from the solution when the line is not in use.

Rack

Station Number

Rack Zinc Electroplate

Time (min)

Temp

DC

1

Load

17

Soak Cleaner

5

64°C




/17






18

Electro Cleaner

5

66°C

Yes

19

Cold Mains Water Rinse

20

Cold DI Water Rinse

21

Acid Dip 50% HCL

1

22


23

Cold DI Water Rinse




/17






26

Pre-Dip

27 or 28

Barrel Zinc Electroplate

20

25°C

Yes

25


24

Cold DI Water Rinse

16

Pre-Dip




/17






15 or 14

Passivation

10

25°C

13 or 12

Cold DI Water Rinse

11

Cold DI Water Rinse

10

Hot DI Water Rinse

45°C

9




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineSeal

20°C

7

Hot Air Dry

10

50°C

1

Unload

Barrel

Station Number

Barrel Zinc Electroplate

Time (min)

Temp

DC

1

Load




/17






17

Soak Cleaner

5

64°C

18

Electro Cleaner

5

66°C

Yes

19


20

Cold DI Water Rinse

21

Acid Dip 50% HCL

1

22




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineCold Mains Water Rinse

23

Cold DI Water Rinse

26

Pre-Dip

29

Rack Zinc Electroplate

20

25°C

Yes

25


24

Cold DI Water Rinse




/17






16

Pre-Dip

15 or 14

Passivation

10

25°C

13 or 12

Cold DI Water Rinse

11

Cold DI Water Rinse

10




/17





Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating LineHot DI Water Rinse

45°C

9

Seal

20°C

8

Hot Air Dry

10

50°C

1

Unload

View Process Plant and Equipment Alkaline Zinc Barrel and Rack Plating Line on our web site athttps://www.rileysurfaceworld.co.uk/machines/30031.htm

PHOTOGRAPHS TAKEN PRIOR TO REFURBISHMENT.




/17




https://www.rileysurfaceworld.co.uk/machines/30031.htm

alkaline zinc barrel and rack plating line

Documents