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Machines & equipment for sale

VJL Technologies (PTY) LTD Automatic Zinc Nickel Electroplating Plant

Stock No
GUD200
Manufacturer
VJL Technologies (PTY) LTD
Model
Automatic Zinc Nickel Electroplating Plant
Year of Manufacture
2010
Serial
S826
New or Used
Used (Second Hand)
Work Envelope (WxDxH mm)
1200 x 700/800/900 x 1000
Process Stages
29 Stations
Other Info
Plating time: 30 - 40 mins
Location
Cape Town, South Africa

Description

**Please note: There is only one line available, we have created two records due to the number of images we have of the equipment **

The plant was designed by VJL Technologies (Pty) Ltd for the zinc electroplating of steel components utilising the well proven alkaline zinc/nickel process.

Primary Process (Electro Plating)

The process sequence looks as follows:

  • Loading Rinse Rinse Stripping Soak Clean Rinse Rinse
  • Acid Pickling Rinse
  • Rinse
  • Anodic Electro Clean Rinse
  • Rinse Acid Dip Rinse
  • ZincINi Plating (4x Stations) Dragout
  • Rinse Rinse
  • Acid Dip (Neutraliser) Passivate
  • Dragout
  • Black Passivate (Future) Rinse
  • Rinse Sealer Drip Off Drying Unloading

 Secondary Process (Jig Stripping)

  • Loading
  • Acid Stripping Rinse
  • Rinse
  • Unloading

Plant Duty

The plant was designed to cater for the following production requirements:

Plant Requirement:-                             

  • 800 000 components/annum (Design)
  • 400 000 + 78 000 + 78 000 + 43 000 = 600 000
  • Components/annum (actual short term)

Production throughout was calculated based on 1 x 8h shift / day x 235 days / annum

  • Component: Automotive fuel tank lids for MBSA (GUD)
  • Component size: ± 103mm diameter (as per attached drawings)
  • Type of Plating:  Alkaline Zinc/ Nickel with clear passivation and sealer 
  • Plating Thickness: 10-12µm
  • Plating Window: 1 000 x 700 mm (LxH)
  • Racking density: 60 / jig = 120/ double flightbar
  • Plating Time:  30-40 minutes
  • Production Rate: 5 loads/ h (90% efficiency) based on 235 days x 8 h shift/ annum
  • Cycle Time: 12 minutes

Process Stations

Load

  • Quantity: 1
  • Material: Mild steel epoxy coated
  • Dimensions: 1200 x 700 x 1000 mm (LxWxH)
  • Accessories: 2 x V blocks

Soak Cleaner

  • Quantity: 1
  • Material: Steel reinforced polypropylene
  • Dimensions: 1200 x 800 x 1000 mm (LxWxH)
  • Volume: 860 litres
  • Temperature: 80 °C
  • Accessories: 2 x V blocks 
    3 x 5 kW stainless steel heaters 
    1 x Automatic water filling system, i.e. solenoid valve and level probe 
    1 x Outlet valve
    1 x Temperature probe

 Rinse

  • Quantity: 13
  • Material: Steel reinforced polypropylene
  • Dimensions:  1200 x 700 x 1000 mm (LxWxH)
  • Volume: 750 litres
  • Temperature: Ambient
  • Accessories: 2 x V blocks
    1 x Overflow weir 
    1 x Outlet valve
    1 x Water filling valve with flow meter

Acid Dip I Acid Stripping

  • Quantity: 4
  • Material: Steel reinforced polypropylene
  • Dimensions: 1200 x 700 x 1000 mm (LxWxH)
  • Volume: 750 litres
  • Temperature:  Ambient
  • Accessories: 2 x V blocks

    1 x Outlet valve
    1 x Water filling valve

Electrolytic Cleaner

  • Quantity: 1
  • Material: Steel reinforced polypropylene
  • Dimensions: 1200 x 900 x 1000 mm (LxWxH)
  •  Volume: 970 litres
  • Temperature: 60 ºC
  • Accessories:  2 x V blocks
    1 x 5 kW stainless steel heaters
    1 x Automatic water filling system, i.e. solenoid valve and level probe

 Zinc I Nickel Plating

  • Quantity:  4
  • Material: Steel reinforced polypropylene 
  • Dimensions: 1200 x 900 x 1000 mm (LxWxH)
  • Volume: 970 litres
  • Temperature: 20 - 30 °C
  • Accessories: 4 x V blocks, 1 x Outlet valve, 1 x Temperature probe

 Dragout I Drip Off

  • Quantity: 3
  • Material: Steel reinforced polypropylene
  • Dimensions: 1200 x 700 x 1000 mm (LxWxH)
  • Volume: 750 litres 
  • Temperature: Ambient
  • Accessories: 2 x V blocks

    1 x Overflow weir 
    1 x Outlet valve
    1 x Water filling valve

 Clear Passivation (Chrome VI Free)

  • Quantity: 1
  • Material: Steel reinforced Polypropylene 
  • Dimensions:1200 x 800 x 1000 mm (LxWxH)
  • Volume: 860 litres
  • Temperature: 70°C
  • Accessories: 2 x V blocks
    1 x Outlet valve
    1 x Water filling valve 
    3 x 5 kW heaters
    1 x Level probe
    1 x Temperature probe

 Sealer

  • Quantity: 1
  • Material: Steel reinforced Polypropylene
  • Dimensions:  1200 x 800 x 1000 mm (LxWxH)
  • Volume: 860 litres
  • Temperature: 25°C
  • Accessories: 2 x V blocks
    1 x Outlet valve

    1 x Water filling valve 
    1 x 4 kW heater
    1 x Level probe
    1 x Temperature probe 1 x Circulation Pump 

Dryer

  • Quantity: 1
  • Material: Stainless Steel 304
  • Dimensions: 1200 x 700 x 1000 mm (LxWxH)
  • Temperature: 90 ° C
  • Accessories: 2 x V blocks

    6 x 5 kW electric heaters
    1 x Temperature probe 

Unload

  • Quantity: 1
  • Material: Mild steel epoxy coated
  • Dimensions: 1000 x 700 x 1000 mm (LxWxH)
  • Accessories: 2 x V blocks

 

Filtration and Circulation

The zinc plating tanks are serviced by a central circulation and anode dissolution tank complete with:

  • One filter system and vertical spindle polypropylene pump for filtering the zinc plating solution
  • One set of heat exchangers complete with chiller system for maintaining the temperature at 24 - 28 ° C
  • 1 x Temperature and Level probe
  • One set of electrical 3 x 5kW heaters and instrumentation for heating up the solution to optimum temperature during cold conditions
  • Two circulation pumps, flow eductors and piping
  • Polypropylene Anode baskets

Piping

We supplied the following piping:

2 x Polypropylene pipes along the plant for effluent connected to relevant tanks

1 x  Galvanised header pipe along the plant for water to all relevant tanks 1 x set interconnecting piping between circulation tank and plating tanks

Fume Extraction

Some of the tanks in the plant release harmful fumes. We provided a fume extraction system comprising of:

 Polypropylene lip extraction plenums on each of the heated process tanks including the two acid and zinc plating tanks

  • 2 x Polypropylene extraction ducts
  • 2 x polypropylene dry demister units with drop out chambers
  • 2 x Polypropylene centrifugal fans
  • 2 x 4m long polypropylene discharge stacks mounted on the fans

The fume extraction system was designed to comply with OSHA requirements.

Carrier System

Two off  SC 150 side arm carriers, each with a capacity of up to 150 kg. The carriers are each equipped with hoist and traverse geared  motors,  proximity switches, limit switches, manual operating station and electric junction box.

The carriers are controlled through a PLC system in both manual and automatic modes.

Steel Structure

Includes Steel gantry for the carriers, as well as loading / unloading stations and one walkway along the plant.

All steel was sandblasted and then epoxy coated.

The walkway is equipped with hand railing and GRP grating.

Rectifiers

4 off rectifiers with capacity of 500 A, 12 VDC with less than 5% ripple for the zinc plating stations and 1 rectifier with capacity of 1000 A, 12 VDC for the electrolytic cleaning. 
The rectifiers are forced air cooled with electronic control and a special control circuit connected to the plant PLC

 Flight bars

 12 load bearing double flight bars for jigging of the components.

Chiller

As the plating process performs best at a controlled temperature of approximately 24° C, we provided a chiller which circulates water at 5°C in the heat exchanger mounted in the circulation tank.

Electrics

one plant control and supply panel housing all the switchgear for the plant operation. The panel also houses the PLC, carrier control system, temperature and level control system and supply circuits to rectifiers, pumps and filter. This is complimented by a satellite panel and operator interface panel located at the loading station housing the HMI.

All cabling between the plant equipment and control panel was supplied and installed on galvanised heavy duty cable trays.

Automatic Dosing Equipment

For the automatic chemical maintenance of the Zinc/Nickel solution there is installed six automatic dosing pumps interlocked with the rectifier (Ah measurement) and controlled through the PLC complete with polypropylene dosing tanks and low level alarms.

DI PLANT

 One semi-automatic demineralisation plant rated for 1250 t/h complete with cation and anion resin columns.

The demin plant is designed to operate fully automatic with operator interface required only for the following operations:

(i)                   replenishment of reagent chemicals

(ii)                  initiation of regeneration cycle once conductivity reaches pre-set high level

CHROME Ill PASSIVATION ION EXCHANGE SYSTEM

 Due to the inherent fact that passivation baths become contaminated with iron, especially from parts with complex geometry, we supplied an ion exchange system which was incorporated adjacent to the passivation bath. The main purpose was to prevent the discolouration of the passivation layer and especially ensure that corrosion resistance is not compromised.

This system consists of a column of ion exchange resin which is used by pumping the passivation solution through the resin on a selective basis to remove iron from this solution. This resin can be regenerated from time to time using hydrochloric acid.

In addition the Zinc is removed by precipitation through a compact clarifier.

Using this modular system to maintain the solution at optimum operating condition it has the advantage of rendering the bath a "never-dump" system.

 

**Please note: There is only one line available, we have created two records due to the number of images we have of the equipment **

 

pdf icon Print / Download VJL Technologies (PTY) LTD Automatic Zinc Nickel Electroplating Plant Datasheet

Additional files

Plant layout drawing

Drawings

Equipment Schedule

Photographs taken prior refurbishment. Our refurbishment service is not available on all machines.