Environmental-Friendly Electroplating Oxidation Production Line for 80% Wastewater Circulation Rate

Equipment Description:

‌I. Process flow‌
‌1. Pretreatment‌: Ultrasonic degreasing → Alkaline etching → Multi-stage water washing (3 times of municipal water washing + 3 times of pure water washing) → Neutralization → Pure water washing.
‌2. Electrolytic oxidation‌: Anodic oxidation: Electrolyte (sulfuric acid/oxalic acid system), current density 1-2A/dm², time 30-60 minutes, film thickness 8-12μm.
3. Multi-stage oxidation tank series: Some production lines adopt a 6-tank series design to improve oxidation efficiency.
‌Post-treatment‌: Dyeing → Sealing → Drying → Quality inspection → Finished product unloading.

2. Technical parameters and features‌
‌1. Key parameters‌
Oxide film thickness: 8-12μm (customizable to 20μm).
Processing efficiency: Single-line daily production capacity ≥5 tons (aluminum profile length ≤7m).
Energy consumption: Power consumption ≤150kWh/ton, heat recovery rate ≥20%.
‌2. Intelligent control‌
PLC+touch screen: real-time monitoring of 2000+ parameters (temperature, current, liquid level, etc.), process fluctuation rate <1%.
AI predictive maintenance: through vibration/temperature data analysis, fault warning accuracy ≥90%, annual reduction of downtime 500 hours.
‌3. Environmental protection and energy saving‌
Wastewater circulation rate ≥80%, red mud comprehensive utilization rate ≥50% (matching cement production line).
Waste heat power generation module: annual power generation of 80 million kWh, covering 20% of the power demand of the production line.

3. Equipment selection recommendations‌
‌Small production line‌: manual/semi-automatic mode, suitable for customized small batch production (such as aluminum water tanks, precision parts).
‌Large production line‌: fully automatic gantry design, suitable for continuous production of industrial aluminum profiles (such as building profiles, automotive parts)

Main structures and components:

I. Pretreatment system ‌
‌1. Cleaning tank group ‌
‌Ultrasonic cleaning tank‌: Multi-stage cleaning (city water washing + pure water washing) is used to remove oil and particulate impurities on the surface of aluminum to ensure the cleanliness of the substrate.
‌Alkali etching tank‌: Equipped with NaOH solution, the aluminum oxide layer is accurately removed through temperature and concentration control to avoid over-corrosion.
‌Neutralization tank‌: Use nitric acid or sulfuric acid to neutralize residual alkali solution to stabilize the surface state.
‌2. Auxiliary equipment ‌
‌Filter circulation device‌: Real-time filtering of impurities in the cleaning solution to extend the service life of the solution.

‌II. Core oxidation system ‌
‌1. Electrolytic tank group ‌
‌Material and design‌: Acid and alkali resistant PVC/PP material, multi-tank series design (single tank volume ≥5000L), supports continuous production.
‌Temperature control‌: Equipped with titanium tube heater and cooling system, temperature control accuracy ±2℃. ‌2. Power supply system‌
‌DC regulated power supply‌: output current density 1-3A/dm², voltage 0-24V adjustable, adapt to different oxide film thickness requirements.
‌High frequency pulse power supply‌ (high-end model): improve the uniformity and density of the oxide film and reduce energy consumption.

‌III. Post-processing system‌
‌1. Dyeing and sealing unit‌
‌Multi-stage dyeing tank‌: constant temperature control (40-60℃), equipped with a circulation filtration system, and supports multi-color sequence switching.
‌Sealing tank‌: high temperature steam (95-100℃) or nickel salt sealing process is used to improve the sealing and corrosion resistance of the oxide film.
‌2. Drying equipment‌
‌Hot air circulation drying furnace‌: temperature 80-120℃, segmented temperature control to avoid coating cracking.

IV. conveying and automation system‌
‌1. Conveying equipment‌
‌Gantry crane system‌: track-type automatic lifting, horizontal speed 4-40m/min, lifting speed 7-12m/min, supporting multi-station collaboration.
‌Hanging design‌: titanium alloy or aluminum alloy, corrosion-resistant and stable conductivity.
‌2. Intelligent control system‌
‌PLC integrated module‌: real-time monitoring of 200+ parameters such as current, temperature, liquid level, etc., supporting process recipe storage and fault warning.
‌Human-machine interaction interface‌: touch screen operation, realizing production data visualization and remote control.

V. auxiliary system‌
‌1. Environmental protection treatment device‌
‌Wastewater treatment‌: membrane filtration + reverse osmosis technology, reuse rate ≥80%.
‌Waste gas treatment‌: alkali spray tower + activated carbon adsorption, meeting GB16297 emission standards.
‌2. Energy recovery system‌
‌Waste heat recovery device‌: use the waste heat of the curing furnace to preheat the cleaning water and reduce steam consumption by ≥30%.

Features:

1.High cost performance: Based on the customer's product positioning and development strategy, and with economic affordability as the foundation, we achieve the best cost performance.
2.The advanced and meticulous design concept of the equipment, along with the highly automated industrial equipment, showcases the image of a modern and advanced enterprise.
3. It has high adaptability, meeting the current production requirements and reserving room for development, taking into account the needs of increased production and improved quality in the future.
4.Quality compliance strictly adheres to the ISO900 quality management system, with every minute detail of the entire equipment installation being strictly controlled.