Industrial Plants

Process Sequence:

• Pickling tank HCL Acid
• Water rinsing
• Water Spray PICKLING PLANTS for wire rod & heat treated wire coils
• Wash
• Phosphating at 70 degree centrigrate
• Water rinsing
• Lime coating at 90 degree C
• Baking pickled coils at 130-150 degree C for around 20 min.

We design and supply pickling plants for S.S wire rod coils, coating & decoating tanks & baking oven

Phosphating Tank :

Tank is fabricated using S.S sheets. The S.S tank is used for holding phosphate solution, the solution is heated to 70 degree C using oil-fired heating system or electrical heaters with automatic temperature control. The tank is insulated from all sides & bottom using vermiculite/ceramic fibre insulation. The outermost side of the tank is covered with sheets coated with FRP to prevent corrosion of the outerside of the tank. Tank top is covered with insulated covers to minimize radiation losses. The tank covers can be open or closed using geared motor drive. A S.S tray is provided  at the bottom of the tank for sludge removal.

*Hot Dip multi strand continuous wire galvanizing plants

• Inline lead bath for sub-critical continuous annealing of running wires at 680 c. The lead furnace could be oil fired double lead bath system for thicker gauges of higher output per hour. Double lead bath system consists of one pre-heating lead bath at around 500 c and heating lead bath at around 680 c.The furnace could be oil fired as also gas fired.
• For fine wire galvanizing the lead bath could be made electrically heated.
• For high carbon wires inline lead bath at around 480 to 500 c could be used for stress relieving.
• Hot dip wire galvanizing plants may use inline direct furnaces. 
• CONFUR make hot dip wire galvanizing plants have spools/coils at pay off, inline annealer, pickling, water washing, fluxing, hot dip galvanizing, wire wiping, cooling and coiling.
• Zinc bath furnace for hot dip wire galvanizing uses zinc tank with or without lead jacketing. The furnace could be oil/gas fired or electrically heated for finer gauges.
• For finer gauges the zinc bath furnace could be electrically heated .The plant uses high speed method.

*CONTINOUS type multi-strand electro-galvanising plants

• Plant could be for heavy zinc coating having soft and ductile zinc deposition with dull grey surface finish.
• Plant could be for light coating with hard and bright deposition.
•  Mix plant uses both systems for heavy deposition followed by bright deposition.
• Plant consists of pre vacuum annealed wire coils/spools at payoff followed by bi polar anodic electro-cleaning,Jet water rinse,pickling,washing,plating,post treatment ,air wiping and wire coiling.
• Zinc plating plants could be for thicker and finer wire gauges as also for brass wires to make EDM wires. 
• In galvanizing plant, all solution and pickling, water rinsing & plating are using double tanks that is top & bottom.The solution from bottom tank is pumped to top tank and then overflowing solution returns to the bottom tanks.The agitating pickling solutions gives good pickling effect hence, better surface preparation. Re-circulation of water in jet rinsing system minimizes water consumption.The water could be drained out partially and fresh make-up water added to maintain to pH value at around 5. Jet water rinsing gives clean wires to recieve coating in plating tank. In plating tank solution is re-circulated to get good deposition. Use of continous filtration and air agitation gives better movement of irons and hence better deposition. The plating tank flows Faraday's law of electricity varying equivalent weight of metal is deposited if a unit ampere current is pass through the circuit.

*CONFUR make equipments/furnaces for cable industry

• Batch type furnace-PIT type for annealing of copper wires under vacuum using AISI-304 fabricated rubber sealed retort assembly for spools/coils.
• Continuous type multi wire annealing furnace for fine gauges uses steam cloud for scale free annealing of wires in AISI-304 SS Tubes .The wires are dried in oven before spooling
• Electro tinning plant for copper wire say 20-30-40 wires are continuously electro-tinned using bi-polar cathodic cleaning, rinsing, tin plating, post treatments and spooling.
• XLPE cable curing tanks
• Continuous type multi strand annealing for brass wires using inert atmosphere for surface protection of running wires.

CONFUR make Bi-Polar Electro Cleaners are used to remove lubricant residues from drawn wire surface, there are number of methods to be used for lubricant removal. One of which include the use of batch dipping either in acid or alkaline solutions or the material pass through tanks containing chemicals. To increase the reaction speed the agitation or the temperature is increased of the treatment solution. The other method used is electrolysis. Further, the two ways supplying electrical current to the running wires is with mechanical contact or Bipolar cell. The higher the current used the faster the material is cleaned or dissolved. The limiting factors in high current application the thickness of diffusion is considered most important, therefore to decrease its thickness the flow rate of electrolyte along the surface is increased. At the time of electrolysis the gas will evolve at both the electrodes which should be removed immediately. Higher the voltage used the more gas is evolved. By reducing the distance between electrodes lower voltage is used at higher currents. It consists of two electrodes of insoluble metal placed in two chambers with a slotted wall in between. The electrodes are placed at a distance from the wire and it is pumped into the cell and electrodes are connected to a D.C source. Further, the wire becomes the opposite polarity as compared with the electrode. It shows that the wire surface is cathodic in the anode section and anodic in the cathode section.