Galvanic line of suspension type copper-nickel-silver plating

Project description

Mechanized electroplating line is a multifunctional production complex designed for applying protective, protective, decorative and functional coatings to products made of ferrous and non-ferrous metals individually on suspensions. The processed products are subsequently used in high-load power and power plants with increased requirements for coating.

The uniqueness of this production complex is the possibility of simultaneous processing of products from ferrous and non-ferrous metals with the production of single- and multi-layer coatings with the organization of environmentally friendly production and the use of effective cyanide-free technologies.

The equipment complex is arranged in such a way that the following technological processes can be carried out simultaneously (sequentially or in parallel):

1. Matte and shiny nickel plating of products made of steel, aluminum, copper, etc.;
2. Copper plating of products made of steel, aluminum, copper, etc.;
3. Cyanide-free silver matte and shiny products made of steel, aluminum, copper, etc.
4. Carrying out individual processes of surface preparation and etching of products made of steel, aluminum, copper, etc.;
5. Zinc treatment of aluminum and titanium products.

The design capacity of the galvanic line is not less than1000 m²/yearIn single-shift operation, the hourly productivity is not less than0.5 m²/h(according to the coverage of the SR).

The customer put forward the following requirements:

1. Maximum energy efficiency and flexibility of the production process;
2. Adaptability of technological processes;
3. Environmental friendliness of production, reduction of associated risks;
4. Development and implementation of modern electroplating technology;
5. Tight deadlines for project implementation (time limit for order execution).

Work done

During the implementation of the project for the commissioning of the production line, the specialists of the IVESS company performed:

• Assistance was provided to the Customer in determining the requirements for the production line and technology, taking into account productivity, nomenclature, overall dimensions and weight of products, types of coatings, processing methods and productivity;
• Optimal design, technological and engineering solutions aimed at minimizing the consumption of raw materials, materials, heat and energy resources have been developed and applied;
• A set of specialized technological equipment was designed and handed over to the Customer for manufacture;
• A set of documentation for anodes, cathodes, special equipment was designed and handed over to the Customer for manufacture or purchase;
• The technology and technological process of electroplating were developed: the compositions of working solutions and electrolytes of process baths were selected with an indication of the manufacturers of reagents, modes of the process, the required consumption of basic and auxiliary materials, cathodes, anodes and energy carriers, recommendations were provided on the number of line personnel with an indication of qualifications;
• A full range of design work was carried out using modern CAD systems, as well as specialized TANK DESIGNER programs, in order to ensure the optimal design of equipment and meet safety requirements;
• The design documentation for the general construction part of the project has been developed;
• Manufacturing and comprehensive equipment of technological equipment using structural materials and components of the world's leading manufacturers was carried out;
• Installation and commissioning, running and production tests of the line equipment were carried out, training of production personnel was carried out;
• A list of required equipment, devices and reagents for equipping the laboratory of chemical analysis of electroplating production has been prepared and recommended.

The commissioning of the galvanic line made it possible to:

1. Organize modern high-efficiency electroplating production;
2. Reduce the environmental burden (through the use of cyanide-free technologies), optimize the cost of waste disposal and wastewater treatment;
3. To exclude the use of highly toxic substances in the production process, thereby reducing the cost of transportation and storage, increasing the level of safety of workers;
4. To ensure the optimal quality/cost ratio of the final product;
5. To significantly expand the range of products and diversify the revenue side;
6. To ensure the efficiency and flexibility of the enterprise;
7. To increase the competence of production and technical personnel.