Wuxi Wondery Industry Equipment Co., Ltd

Industry Insight: Stringent Demands for Temperature Uniformity and Melt Purity in Industrial Tinning Processes In the precision manufacture of mechanical bearings, processing of high-end electrical Babbitt alloy bushings, and surface anti-corrosion treatment of electronic components, hot-dip tinning is a critical process for establishing inter-facial bond strength. Although the melting point of tin is relatively low (approx. 232°C), in actual production, the working temperature of the molten tin must be stably maintained within a higher medium-temperature process window to obtain optimal leveling performance and an excellent wetting diffusion layer. At elevated temperatures, molten tin reacts aggressively with iron elements in conventional steel, generating hard, brittle Fe-Sn inter-metallic compounds (such as $FeSn_2$ dross). This not only accelerates localized corrosion and thinning of the pot wall but also introduces hard particulates into the molten pool, undermining coating density and surface gloss. Concurrently, if the heat flux density surrounding the pot is uneven, localized overheating will induce intense thermal convection, exacerbating surface oxidation. Through a targeted low-surface-load plate heating matrix and extra-thick low-carbon pure iron pot technology, WONDERY successfully resolved the temperature control and material corrosion pain points in molten metal processing for a prominent UAE engineering company (Osborne Engineering LLC). Technical Solutions and Parameterized Evidence 1. 1.1m Customized Pure Iron Pot: Eradicating "Iron Contamination" at the Source To satisfy the strict requirements of hot-dip tinning for melt purity, WONDERY deeply customized both the metallurgy and geometry of the reactor: Structural Dimensions: The effective internal working dimensions of the tin pot are 1.1 L × 1.1 W × 1.0 H meters, providing a standard vertical steady-state structure capable of accommodating large batches of heavy-duty precision bearing pads or bushing components for entire immersion dipping. 30mm Extra-Thick Plate Technology: The pot walls are fabricated entirely from 30mm high-purity low-carbon pure iron plates (Pure Iron Pot) by specialized welding. Compared with general stainless steel or carbon steel, high-purity pure iron contains negligible levels of carbon, silicon, and other impurities. This significantly passivates the grain boundary penetration rate of high-temperature tin liquid, minimizes iron dissolution, multiplies the operational lifespan of the pot body, and ensures long-term melt purity. 2. Four-Sided Plate-Type Heating Matrix and Balanced Y-Type Wiring To eliminate "dead zones" or localized tin boiling caused by excessive local thermal density and non-uniform radiation from traditional tubular heating pins, WONDERY deployed an all-enveloping thermal field configuration: Large-Area Plate Heating Elements: The perimeter of the tin pot is closely surrounded by 4 pieces of heavy-duty plate-type heating wires, with individual plate dimensions reaching 1200 mm (Width) × 850 mm (Height) and a rated output of 12.5 kW per piece. Low Surface-Load Heat Transfer: A total output of 50 kW (configured as a 7×7 kW balanced load design) is distributed evenly over a vertical heating area of nearly 4 square meters. This large-area, low-surface-load mechanism ensures that thermal energy flows into the pure iron pot wall via gentle conduction and radiation, mitigating material thermal fatigue caused by steep temperature gradients. National Standard Y-Type Configuration: The heating arrays are connected using a Y-type (Star) configuration to a 380VAC 3-phase industrial power supply. The neutral-balanced design minimizes single-phase voltage stress and is paired with 25 $mm^2$ national standard (GB standard) pure copper cables in the primary circuit to guarantee safe conductor temperature rise under full continuous load. 3. Closed-Loop Visual Power Regulation Securing an Exact ±1°C Control Accuracy The thickness and adhesion of hot-dip coatings are exceptionally sensitive to thermal fluctuations (typically, a variance of just 5°C alters the viscosity of molten tin and the thickness of the diffusion layer significantly). WONDERY therefore engineered a smart closed-loop electronic control architecture: Dual-End Collaborative Temperature Measurement: Precision thermocouple nodes are integrated symmetrically at both ends of the 1.1m tin pot. When the system detects a drop in local melt temperature below the setpoint, dynamic signals are fed back instantly to the central processing core. Thyristor Power Modulation: The core control incorporates 1 set of modularized SCR Power Controllers rather than traditional on-off contactors. Utilizing advanced algorithms, the system performs microsecond-level linear phase-angle or cycle微调 (fine-tuning) on the primary circuit current. 10-Inch Visual HMI Console: The front panel of the centralized control cabinet (dimensions: approx. 1500 × 600 × 500 mm) integrates a 10-inch Weinview high-resolution industrial touchscreen. The fully graphical interface displays real-time thermal trajectory logs, locking the temperature accuracy of the entire molten tin pool to a strict ±1°C boundary. Standard Export Delivery and Turnkey Execution WONDERY strictly adheres to industrial-grade turnkey supply protocols, explicitly demarcating boundaries to ensure seamless project integration overseas: Comprehensive Supply Scope: The delivery includes the high-purity pure iron pot core, insulated containment furnace casing, 4 full-scale plate heating units, an independent intelligent control cabinet (housing the Weinview HMI, SCR regulator, and Chint low-voltage switchgear), a complete array of compensation wires and sensing components, alongside comprehensive technical prints including general assembly drawings, electrical schematics, and full-lifecycle maintenance handbooks. Standardized Performance Assurance: All internal piping, wiring, and electrical pressure tests are completed at the Wuxi production base. The fully integrated skid design allows the UAE buyer to bring the system online immediately after connecting the main power supply, satisfying all industrial demands for continuous, premium hot-dip tinning production.

1. Project Background A steel structure manufacturer planned to build a natural gas heated linear hot dip galvanizing line for processing steel components up to 8.6 meters in length, including transmission towers, highway guardrails, and building embedments. Customer requirements: Zinc pot size: 8.6m × 1.0m × 1.6m Zinc capacity: 75 tons Hourly output: 3 tons Must meet emission standards for acid mist and zinc fumes WUXI WONDERY INDUSTRY EQUIPMENT CO., LTD. was responsible for process design and equipment integration. 2. Technical Challenges and Solutions H2: Acid Mist Treatment – Sealed Negative Pressure + Two-Stage Spray Neutralization Operating conditions: Three pickling tanks, each 8.6m × 1.0m × 1.6m Immersion time: 6 minutes per tank (adjustable) High acid mist generation requiring complete containment Design solution: Fully enclosed acid mist chamber: 11m × 10.6m × 4.0m, flame-retardant fiberglass panels Negative pressure maintenance: 11kW variable frequency fan Two-stage scrubber tower: Tower size: φ1800mm × 6500mm, PP material (10mm thickness) Filler: PP wreath (3.5 inches diameter), two layers Defogging layer: PP spheres (2.0 inches diameter), one layer Spray layer: PP-1/2 spiral nozzles, two layers Circulating pump: 5.5kW vertical acid/alkali resistant pump Automatic pH control: Dual pH probes (inlet/outlet) with automatic dosing Technical conclusion: The combination of enclosed structure + negative pressure exhaust + two-stage spray neutralization effectively controls acid mist escape. Online pH monitoring ensures accurate chemical dosing, suitable for continuous pickling of 8.6-meter long tanks. H2: Zinc Fume Treatment – Double-Sided Suction + Bag Filter + Water Curtain Deodorization Operating conditions: Zinc pot size: 8.6m × 1.0m × 1.6m Zinc bath temperature: 438–450℃ (PLC controlled) High volume of zinc particulate fume during immersion Design solution: Double-sided suction ducts: Side ducts: 8600mm × 2500mm × 250mm, two sets End duct: 6000mm × 3000mm × 250mm, one set With deflectors, flanges, and sealing strips Bag filter system: Main unit size: 5540mm × 3000mm × 6500mm Filtration area: 640m² Filter bags: φ133mm × L3500mm, 426 sets Filter material: waxed nylon needle-punched (service life ≥2 years) Fan: 55kW double-sided suction variable frequency fan Water curtain deodorization tower: Tower size: φ2800mm × 6500mm, PP material (12mm thickness) Circulating pump: 7.5kW vertical acid/alkali resistant pump Operation strategy: Variable frequency fan runs only 2–3 minutes per zinc pot loading Bag filter collects zinc particles; water curtain removes odors Technical conclusion: For an 8.6-meter long zinc pot, double-sided suction covers the entire fume generation area. The 640m² filtration area meets the 3 tons/hour production requirement. The VFD control strategy reduces continuous power consumption. 3. Waste Heat Recovery Options (Selected by Customer) Module Technical Parameters Function Combustion air preheating Alloy tube heat exchanger, 50–150℃ air preheat Reduces natural gas consumption Sludge drying box 304 stainless steel, 5500×750×375mm Reduces filter cake moisture from 80% to 10% Pot edge heat recovery Double-layer stainless steel coil, pot edge temp ~200℃ Heats water for acid preheating or workshop heating 4. Engineering Interface Responsibilities in this case: Supplier: Equipment supply, internal piping, control cabinet & internal cables, installation guidance, commissioning guidance, training materials Buyer: Civil work, plant building, external utilities (water/electricity/gas), compressed air, hoisting equipment, scaffolding, meals/accommodation for technicians, fire protection, lightning protection 5. Case Summary For this 8.6m hot dip galvanizing line, the following fume treatment solutions were implemented: Acid mist: Sealed negative pressure chamber + two-stage spray neutralization Zinc fume: Double-sided suction + bag filter + water curtain deodorization All equipment parameters match the 8.6m × 1.0m × 1.6m tank dimensions and 3 tons/hour capacity. The waste heat recovery modules further reduce operating energy costs.

Project Background and Core Process Requirements WONDERY recently completed the delivery of a custom WDL-DM-200 Medium Frequency Induction Melting Furnace for a client in Lebanon (Rashid). The project supports a 250kg iron melting operation. Given the high melting point of iron and the need for rapid heating, the client’s core requirements were high heating efficiency, a stable tilting control system, and operational safety under high-temperature conditions (up to 1650 ℃). Technical Solutions and Parameterized Evidence 1. IGBT Induction Power System (98% Startup Success Rate) To achieve fast melting and lower energy consumption, WONDERY implemented advanced induction technology: Core Power: Features a 200kW Medium Frequency IGBT induction power supply with an input voltage of 3×380V/50Hz. Frequency Management: The output frequency ranges from 1-10kHz, automatically adjusting based on the charge state to ensure maximum melting efficiency. Reliability: The system is designed with a 98% startup success rate, minimizing production downtime caused by initialization failures. 2. Reinforced Steel Shell and High-Conductivity Induction Coil Engineered for a working temperature of 1650 ℃ (maximum 1800 ℃), the furnace body is highly specialized: Induction Coil: Fabricated from high-purity copper tubing, providing superior conductivity and water-cooling performance to prevent overheating under high current densities. Furnace Structure: Utilizes a robust steel shell design, which offers better electromagnetic shielding and structural stability compared to aluminum shells, making it ideal for the high-temperature demands of iron melting. Crucible Mold: Delivered with a dedicated 250kg crucible mold to facilitate on-site lining construction for the client. 3. Precision Hydraulic Tilting System To ensure safe and smooth pouring of molten iron, the equipment integrates a comprehensive hydraulic power unit: System Composition: Includes a hydraulic tank, pump, precision valves, and pressure gauges. Operational Control: Operators can manage tilting, stopping, and resetting the furnace via buttons or manual handles, ensuring precise movement and preventing accidental splashing of molten metal. 4. High-Efficiency Cooling and Water-Cooled Cables Water-Cooled Cables: Equipped with heavy-duty water-cooled cables to connect the power supply to the furnace. These manage the 200kW load while utilizing internal water circulation to maintain safe operating temperatures. Closed Cooling Tower: Accompanied by a 30T closed cooling tower (optional) to provide a continuous loop of pure cooling water for the power supply, induction coils, and cables, preventing internal scaling and blockages. Delivery Specifications and Key Parameters Melting Capacity: 250 kg (Iron). Maximum Operating Temperature: 1800 ℃. Rated Output Power: 200 kW. Transformer Requirement: 250 kVA. Scope of Supply: Medium frequency control cabinet, steel shell furnace body, hydraulic system, water-cooled cables, crucible mold, and closed cooling tower.