Wuxi Wondery Industry Equipment Co., Ltd

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.

Project Background and Core Process Requirements As the die-casting industry demands higher energy efficiency and melt quality, WONDERY delivered the WDL-CDJ-5000 Vertical Immersion-type Holding Furnace. The client, specializing in high-precision die-casting, sought to overcome the low efficiency and high oxidation losses of traditional radiant heating. The core objectives were to achieve a precise control accuracy of ±2 ℃ and significantly reduce operational energy consumption. Technical Solutions and Parameterized Evidence 1. Immersion Direct Heating Technology (Energy Savings >30%) This system revolutionizes thermal transfer by placing heating elements directly into the molten aluminum: Thermal Efficiency: Heat is transferred directly from the inside out, preventing the formation of oxide skins. Compared to standard radiant furnaces, energy consumption is reduced by more than 30%. Core Components: Equipped with a 70kW SOCE immersion heating element paired with a Thai Silicon T6 series power regulator for linear and stable energy output. 2. Siemens Fully Automated Control System To meet Industry 4.0 standards, WONDERY implemented a comprehensive Siemens control architecture: Hardware: Features a Siemens S7-200 SMART PLC and a SMART 71000 IE V5 touchscreen. Precision Monitoring: Integrates a Keyence LR-TB5000 laser rangefinder for non-contact liquid level monitoring and Siemens analog modules for real-time data acquisition. Control Accuracy: Achieves a verified melt temperature accuracy of ±2 ℃, ensuring consistent quality for high-end die-cast parts. 3. Patented Structure and Nano-Insulation Insulation Performance: The furnace top and upper walls are insulated with a heat-insulating nano-layer, ensuring minimal thermal loss. Surface Temperature: The furnace wall temperature rise is kept within 20 ℃ above ambient, significantly improving the safety and comfort of the workshop environment. Longevity: The patented structural design ensures a longer furnace lifespan even under continuous immersion in molten aluminum. 4. Efficient Maintenance and Consumables Management Easy Replacement: The immersion element design allows for convenient on-site replacement following basic training, minimizing production downtime. Spare Parts Strategy: WONDERY provided a recommended inventory of 4 thermocouples and 2 heating elements to safeguard continuous operation. Delivery Specifications and Key Parameters Model: WDL-CDJ-5000 (Vertical insertion type). Heating Power: 70 kW. Key Components: Siemens automation suite, Keyence laser sensors, and nano-insulation technology. Support Documents: Includes full electrical schematics, installation drawings, and comprehensive technical protocols.