Improving Performance for Hot Dip and Continuous ... - Pyrotek
Improving Performance for Hot Dip and Continuous ... - Pyrotek
Improving Performance for Hot Dip and Continuous ... - Pyrotek
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<strong>Improving</strong> <strong>Per<strong>for</strong>mance</strong> <strong>for</strong><br />
<strong>Hot</strong> <strong>Dip</strong> <strong>and</strong> <strong>Continuous</strong> Galvanizers<br />
In-House Zinc Recovery<br />
Temperature Monitoring<br />
Pot Hardware<br />
Dross Management<br />
Metal Transfer
In-House Zinc Recovery<br />
Few galvanizers are aware of the true value of the skimmings created during production.<br />
Traditional recycling practices involve direct resale to specialist recovery companies. There is<br />
another, economically viable option available from <strong>Pyrotek</strong>.<br />
The Metaullics Zinc Recovery (MZR) system is a patented low cost thermal process which<br />
allows free zinc to be recovered from zinc skimmings <strong>for</strong> re-use in the galvanizing process.<br />
Data collected over several years indicates that recoverable zinc from galvanizing skimmings<br />
may be as much as 90% with an average of about 70% by weight. The MZR payback can be<br />
as low as 6 months, depending on the operational <strong>and</strong> market conditions. The MZR system is<br />
available in two sizes:<br />
Temperature Monitoring<br />
MZR-1500<br />
The MZR-1500 has been designed <strong>and</strong> built to<br />
accommodate large-volume skimmings producers<br />
such as continuous galvanizing <strong>and</strong> large general<br />
hot dip galvanizing groups. MZR-1500 has a nominal<br />
waste processing capacity of 1500 kg (3300 lbs.) per<br />
batch <strong>and</strong> incorporates many of the basic operational<br />
characteristics of the MZR-750. Heating chamber<br />
properties have been enhanced with better insulation,<br />
accurate temperature monitoring <strong>and</strong> high-efficiency<br />
infra-red burners.<br />
MZR-750<br />
MZR-750 has a nominal waste processing capacity<br />
of 750 kg (1650 lbs.) <strong>for</strong> each recycling batch. It is<br />
simple to operate <strong>and</strong> does not need special dedicated<br />
personnel during use.<br />
For accurate melt temperature measuring, <strong>Pyrotek</strong><br />
offers a wide array of Thermocouple Assemblies<br />
featuring O’Sialon Protection Tubes. Non-wetting,<br />
highly oxidation, corrosion <strong>and</strong> abrasion resistant,<br />
<strong>and</strong> with excellent thermal response properties, an<br />
assembly with a O’Sialon TCPT is a reliable solution<br />
<strong>for</strong> temperature monitoring.
Pot Hardware<br />
<strong>Continuous</strong> galvanizers must rely on their pot hardware, particularly roll bearings inside the melt. Bearing failure<br />
occurs due to a combination of strip loading <strong>for</strong>ces, rotational wear, <strong>and</strong> inter-metallic reaction on the bearing surface.<br />
<strong>Pyrotek</strong> offers high quality bearings made from a patented alloy specifically <strong>for</strong>mulated to address these issues: the<br />
MSA Bearing.<br />
Dross Management<br />
Metaullics Self-Aligning Bearings<br />
Metaullics Super Alloy (MSA) bearings are designed to replace current bearing materials,<br />
such as cobalt-based alloys <strong>and</strong> ceramic bushings, with new super alloy materials. These<br />
alloys are specifically <strong>for</strong>mulated with high hot hardness <strong>for</strong> exceptional wear resistance<br />
<strong>and</strong> concentrated carbide compositions <strong>for</strong> world-class corrosion resistance in molten zinc<br />
alloy environments, optimizing dynamic per<strong>for</strong>mance <strong>and</strong> maximizing overall operational<br />
life. The MSA Bearing compensates <strong>for</strong> roll / arm misalignment through its patented selfaligning<br />
technology, seen below.<br />
Removing the top dross deposits out of the snout <strong>and</strong> away<br />
from the strip will increase your strip quality <strong>and</strong> lower<br />
maintenance costs on the line. <strong>Pyrotek</strong> offers a variety of<br />
systems engineered to effectively remove unwanted dross<br />
<strong>and</strong> debris from the snout.<br />
Installing a Metaullics Push-Pull System<br />
• Enhances sheet finish <strong>for</strong> higher coil coating quality.<br />
• Avoids top dross accumulation in the snout, preventing<br />
large dross masses from sticking to the sheet surface<br />
<strong>and</strong> the submerged roll causing surface blemishes <strong>and</strong><br />
defects.<br />
• Removes “zinc dust” <strong>and</strong> other fine contaminants that<br />
develop during high-speed sheet coating processes.<br />
• Removes oxide “flakes”, refractory <strong>and</strong> debris that<br />
typically fall into the snout following line stoppage,<br />
minimizing the number of scrap “clean-out” coils.<br />
MSA Self-aligning Bearing Design Typical Journal Bearing Design<br />
Depending on the contaminant you wish to<br />
remove, the engineered system will include<br />
various combinations of the following pumps:<br />
• MetJet Snout Removal Pump<br />
• D-13SD-MSA “Push/Pull” Pump<br />
•<br />
D-13XD-MSA high flow “Pull” Pump
Metal Transfer<br />
Metaullics D13XL Galvanizing Transfer Pump<br />
When it is time to pump out the pot, <strong>Pyrotek</strong> offers the reliable, efficient<br />
Metaullics D13XL Galvanizing Transfer Pump. This pump was designed<br />
to limit maintenance <strong>and</strong> increase durability with a bearing-less shaft<br />
design <strong>and</strong> a minimal number of wearing parts. Reliable <strong>and</strong> simple<br />
to install, the D13XL requires no preheating, <strong>and</strong> has a high flow /<br />
high head capacity of over 2,000 lbs/min MAX flow. Also available with<br />
ceramic-fiber lined piping <strong>for</strong> minimal heat loss during transfer.<br />
Heated Launders<br />
Keep molten zinc hot during transfer from the premelt pot to the coating<br />
pot <strong>and</strong> maintain a more stable temperature in the coating pot with<br />
custom engineered heated launders. Less temperature fluctuations<br />
while coating means a more consistent coating <strong>and</strong> less dross<br />
generation. Save costs by reducing furnace temperature, reducing<br />
gas consumption, extending refractory life <strong>and</strong> lowering overall energy<br />
consumption. These systems keep refractory surfaces hot, thus<br />
avoiding thermal shock damage.<br />
REGIONAL OFFICES<br />
NETHERLANDS<br />
(31) (0)180-590890<br />
barendrecht@pyrotek-inc.com<br />
ITALY<br />
(39) 02-96458222<br />
caronnopertusella@pyrotek-inc.com<br />
SWEDEN<br />
(46) (0)534-62000<br />
ed@pyrotek-inc.com<br />
AUSTRALIA<br />
(61) (0)2 9631-1333<br />
un<strong>and</strong>erra@pyrotek-inc.com<br />
Ingot Molds<br />
Custom made cast steel ingot molds are available locally <strong>for</strong> holding molten<br />
metal or hot dross while cooling after emptying a furnace or skimming pot.<br />
Reduce your purchasing costs through vendor consolidation <strong>and</strong> <strong>Pyrotek</strong>’s<br />
competitive pricing. Depending on customer use, these durable molds can<br />
last <strong>for</strong> several years.<br />
JAPAN<br />
(81) (0)78-265-5590<br />
kobe@pyrotek-inc.com<br />
SOUTH KOREA<br />
(82) (0)53-523-5202<br />
daegu@pyrotek-inc.com<br />
INDIA<br />
(91) 22-2809-2561<br />
mumbai@pyrotek-inc.com<br />
TAIWAN<br />
(886) 7-224-8222<br />
taiwan@pyrotek-inc.com<br />
BRAZIL<br />
(55) 11-4786-5233<br />
saopaulo@pyrotek-inc.com<br />
CANADA<br />
(1) 519-787-1421<br />
fergus@pyrotek-inc.com<br />
MEXICO<br />
(52) 81-8336-9117<br />
santacatarina@pyrotek-inc.com<br />
USA<br />
(1) 724-318-8290<br />
ambridge@pyrotek-inc.com<br />
<strong>Pyrotek</strong> inc. • corPorate office • 9503 e. MontgoMery avenue, SPokane valley, Wa 99206, uSa<br />
P: 509-926-6212 • f: 509-927-2408 www.pyrotek.info • email: info@pyrotek.info Mar-09-el-939
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