STEP Smart® Hot Dip Galvanizing Plant

Home|STEP Smart® Hot Dip Galvanizing Plant

We specialise in large-scale turn-key galvanizing plants, undertaking a full range of Engineering, Procurement and Construction activities through project completion.

We design and build plants considering various factors like type of material, fuel arrangement, production rate, available area and degree of automation.

Our STEP Smart®™ Hot Dip Galvanizing plants integrate automation of Pulse Fired High-Velocity Galvanizing Furnace, which has an automated burner management system alongwith fume extraction systems ensuring highest efficiency of galvanizing process with minimal operational cost.

  • Turnkey Project
  • Project consultancy
  • Engineering
  • Procurement
  • Manufacturing
  • Installation & Commissioning
  • Spare parts
  • Plant Up gradation
  • Zn kettle replacement
  • Process tanks
  • Repairs and modification
  • AMC

STEP SMART® PULSE FIRED HIGH VELOCITY FURNACE

Design Features :

  • Heating system - Oil, Gas or Dual fuel with fully automated system
  • Light weight low thermal mass insulation
  • Quick load change response
  • Uniform zinc temperature
  • Burners always fire at their highest velocity
  • Automatic temperature control system
  • Safety alarm for low level of zinc
  • Remote access of PLC port
  • Simple site installation

Key Benefits :

  • Low fuel consumption, maximum thermal efficiency
  • Uniform heating
  • Free of maintenance
  • High life of zinc kettle
  • Pollution emissions (NOx, S, CO, PM) within acceptable or legal limits

ZINC KETTLE

Design Features :

  • Kettle thickness 50 mm to 60 mm
  • Dross protection layer at bottom
  • Heat shield to prevent the kettle corners from erosion
  • Ultrasonic tested plates
  • 100% Radiography tested on all the welded joints to eliminate porosity

Key Benefits :

  • Long Life
  • Round corners creates more room for zinc flow
  • Easy Dross Removal

RE-CIRCULATING HOT AIR DRYER

Design Features :

  • Insulated sliding covers with drive units
  • Covers Coated with acid resistance epoxy paint
  • High capacity air circulation fan
  • Push button operating station on both ends of the dryer
  • Motorized air damper
  • Control cabinet with temperature control

Key Benefits :

  • Effective drying with uniform heating
  • Reduce deformation risk of low thickness material
  • Fuel saving
  • No need of auxiliary burners

STEP STRONG® PRE-TREATMENT TANKS

Design Features :

  • Fusion Welded Polyproylene tanks
  • Designed as per DVS 2205 and manufactured as per DVS 2207 standard
  • Reinforcement coating for corrosion prevention

Key Benefits :

  • Long Life (10-15 Years)
  • Modifiable / Repairable at site
  • Leak Proof Tanks due to fusion welding

STEP STRONG® POST-TREATMENT TANKS

Design Features :

  • Welding standard = All weld and weld
  • preparation will per AS 1554 and all welds will be continuous fillet.
  • Material - Mild steel, plates & RHS
  • Painted with heat resistant paint 400 degree
  • Drain Pipe nipple with flange
  • Drain connection = Dia. 3 inch with flanged end and PP ball valve
  • Lifting hook = 4 no’s
  • Jig resting = Jig resting arrangement mild steel with paining

STEP STRONG® ACID STORAGE TANKS

Design Features :

  • Fusion Welded Single material / Dual material tanks based on suitability
  • Single Material Layers : PP-H, PP-C, HDPE, PVC, PVDF, ECTFE
  • Dual Material Layers : PP-GL, PP-FRP, PVDF-FRP, ECTFE-FRP, PVC-FRP
  • Designed as per DVS 2205 and manufactured as per DVS 2207 standard
  • Reinforcement coating for corrosion prevention

Key Benefits :

  • Long Life (10-15 Years)
  • Modifiable / Repairable at site
  • Leak Proof Tanks due to fusion welding

STEP SAFE® ACID FUME ENCLOSURE

Design Features :

  • Leak-proof multiwall panel
  • Heavy-duty rolled steel sections
  • LED flood lights
  • The steel structure with stairway, handrails & service platform
  • Anti-Corrosive standard
  • Toughened glass viewing windows, automatic sliding door & Control
  • Specialized rubber insulation

Key Benefits :

  • Lowers breakdown in over head cranes, hoists, drives and electrical from acidic fumes
  • Avoid damage to the shed steel structure
  • More comfortable working conditions
  • Quick cost paybacks
  • Monorail hoist, overhead smart mobility

STEP SAFE® ZINC FUME ENCLOSURE

Design Features :

  • Push Button Control, Automatic Operation
  • Limit switches for safe travel for skimming doors
  • Two stage automatic controlled opening to fervent fume leakage
  • Chain and sprocket driven geared motors
  • Arresting arrangement for safety in the event of the skimming door failure Sensor operated controls of skimming door to avoid accident
  • Internal lighting & viewing windows from the end doors

Key Benefits :

  • Efficient uniform, lateral extraction
  • Easy accessibility for skimming zinc ash

STEP SAVER® ZINC RECOVERY SYSTEM

Design Features :

  • Drum Capacity 750 Kgs
  • Heating system - Oil, Gas or Dual fuel
  • Drum Life -  200 cycle
  • Average cycle time 3 hours for 750 kgs drum

Key Benefits :

  • Reduced volume of residual skimming being
  • Disposed Low operational cost
  • Reduction in the volume of virgin zinc
  • Easier to use, greater ease in loading the drum

STEP SAVER® FLUX REGENERATION SYSTEM

Design Features :

  • Control system, reaction system and filtering system
  • Automatic Dosing system

Key Benefits :

  • Reduce zinc consumption
  • Minimize the transfer of iron to the molten zinc
  • Reduce ash and dross generation
  • Lower flux consumption
  • Flux operates with at a low iron concentration

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