Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2005
COMPLETE SPECIFICATION
(See section 10, rule 13)
1. TITLE OF THE INVENTION:
SYSTEM AND METHOD FOR HOT DIP GALVANIZATION
2. APPLICANT
(a) Name: Larsen & Toubro Limited
(b) Nationality: An Indian Company
(c) Address:
Mount Poonamalle Road, Manapakkam, Post Box No:979, Chennai, Tamil Nadu, India. 600 089
3. PREAMBLE TO THE DESCRIPTION
PROVISIONAL
The following specification describes the invention. COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
The present invention relates to an industrial coating of materials, specifically, galvanization, and more particularly, the present invention relates to a system and method for hot dip galvanization, that deploys sustainable fuel such as compressed biogas and leverages Internet of Things (IoT) sensors and electronic monitoring and control of the system parameters.
BACKGROUND ART
Hot dip galvanizing involves coating iron or steel with a layer of zinc by immersing the metal in a bath of molten zinc. The process results in enhancing the corrosion resistance properties of stainless steel for a longer duration. The process of hot dip galvanization involves steps such as cleaning the steel object to be coated by applying chemicals to remove grease and dirt, fluxing to wet the surface of the object, immersing the object into a bath of molten zinc, and post-treatment of the coated object.
Typically, the bath containing molten zinc may have length and depth in the range of 13m and 2.5m respectively, and may contain 130 metric tons of zinc. The temperature of the bath is maintained at 450 ± 10°C. To achieve these temperatures fossil fuels such as Light Diesel Oil (LDO) and Liquid Petroleum Gas (LPG), are being used currently. However, the combustion of fossil fuels generates considerable carbon emissions, contributing to the environmental footprint of the galvanizing industry. Furthermore, the costs and supply of fossil fuels are highly volatile, complicating budgeting and operational planning for galvanizing facilities.
Attempts have been made to incorporate renewable energy sources, such as solar power, to reduce the carbon footprint. However, the bath capacity and the enormous amount of deployed zinc are the factors that make it difficult to achieve and maintain the necessary temperature solely with solar power, when it comes to mass production settings in the galvanizing industry. Moreover, integrating renewable energy sources would require comprehensive changes to the existing infrastructure, including the replacement of existing zinc baths to suit the alternate fuel types. This may result in significant capital investment. Hence, providing a more sustainable alternative to currently used fossil fuels in the hot dip galvanization process calls for the utilization of other types of gaseous fuels.
Reference may be made to a related art DE102023206581A1, which discloses a galvanizing furnace and method of operating such a furnace. The document talks about a galvanizing furnace that is designed with a furnace shell with a galvanizing kettle arranged in the furnace shell with heating zones and a burner designed for renewable energy sources and/or fossil fuels. The heat source is designed to burn renewable energy sources such as hydrogen and/or methane produced using biogas as well as to burn fossil energy sources such as crude oil, natural gas, and/or liquid gas. However, the document does not disclose the modifications needed in the burner design to make it compatible with renewable energy sources. Moreover, the document does not teach about a system to carry the biogas to the galvanizing kettle, as replacing conventional fossil fuels by alternate fuels such as compressed biogas requires certain amendments in the traditional hot dip galvanization system.
Galvanization demands close monitoring and control of certain process parameters. Industrial automation has paved the way for eliminating the limitations of manual monitoring and control of the process parameters. Reference may be made to a related art CN215481192U that discloses a hot dip galvanizing device capable of automatically controlling temperature. The device along with other components comprises an electromagnetic valve, a temperature sensor, and a control device. It further includes a gas pipeline arranged between the furnace body and the pot wall of the zinc pot, and the burners arranged around the pot wall of the zinc pot at intervals. The control device is in the form of a programmable logic controller (PLC).
Thus, currently available hot dip galvanization systems as well as the prior art do not teach the use of sustainable fuel for hot dip galvanization wherein the process parameters are monitored and controlled in real-time by using an electronic monitoring controlling system by deploying IoT sensors.
Accordingly, there exists a need for a system and a method for hot dip galvanization that minimizes carbon footprint by utilization of sustainable fuel. Additionally, a system and a method are required that ensure close monitoring of the process parameters in real-time by deploying IoT sensors and an electronic controller.
. SUMMARY OF THE INVENTION
This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.
The present disclosure generally relates to galvanization. More particularly, the present disclosure relates to a system and method for hot dip galvanization, that deploys sustainable fuel such as compressed biogas and leverages Internet of Things (IoT) sensors and electronic monitoring and control of the system parameters.
In an aspect, the present disclosure relates to a system for hot dip galvanization, wherein, the hot dip galvanization is carried out in a kettle containing molten zinc. The system includes a gas delivery module configured to receive compressed biogas (CBG) at a pressure in the range of 40-250 bar at one end thereof from a CBG carrying vehicle and successively reduce the pressure of the CBG by deploying a plurality of stages such as a first stage, a second stage, and a third stage or further reduction stages if required according to the application and usage, that are mechanically connected in succession. The system includes an ignition module, at the first end thereof, mechanically coupled to the third stage of the gas delivery module, and at the second end thereof, operably coupled to the zinc kettle and is configured to ignite and maintain flame to provide heating to the zinc kettle. The system includes an electronic monitoring and control module communicatively coupled to the gas delivery module and the ignition module and is configured to receive the data from a plurality of sensors deployed therewithin.
In an aspect, the present disclosure relates to a method for hot dip galvanization performed by the system. The method includes connecting the first stage of the gas delivery module to the CBG carrying vehicle to receive the CBG at a pressure in the range of 40-250 bar. The method includes reducing the pressure of the CBG by the first stage in the range of 15-30 bar. The method includes reducing the pressure of the CBG by the second stage in the range of 1.5-2 bar. The method includes reducing the pressure of the CBG by the third stage in the range of 100-150 millibar while maintaining the temperature thereof in the range of 30-400 C. The method includes sensing and communicating the values of the pressure and temperature of the CBG to the PLC by a plurality of pressure sensors, a plurality of temperature sensors, and flow sensors. The method includes communicating, by the PLC, the received values of the pressure, temperature, and flow of the CBG to the application software via a GSM-based gateway. The method includes tracking and displaying the received values by the application software on a display and generating an alarm when the pressure of the CBG supplied by the vehicle drops below 30 bar. The method includes supplying the CBG by the third stage to the ignition module. The method includes arresting the moisture content in the CBG by deploying a mechanical moisture trap before the entry thereof in the ignition module. The method includes checking, by the pressure switch, the CBG pressure in the ignition module and shutting down the system if the pressure exceeds or falls below predefined values. The method includes activating by the PLC the pilot line of the ignition module to start the ignition upon receiving a signal from a flame detector. The method includes activating the main line of the ignition module to maintain continuous burner operation. The method includes controlling the operation of the variable frequency drive by the PLC to adjust the air supplied by the combustion blower and the CBG flow through the control valve in the main line to achieve and maintain a temperature of the zinc kettle at 450 ± 10°C.
OBJECT OF THE INVENTION
An object of the present invention is to provide a system for hot dip galvanization.
Another object of the present invention is to provide a system for hot dip galvanization that deploys a sustainable fuel such as compressed biogas (CBG).
Yet another object of the present invention is to provide a system for hot dip galvanization which incorporates a module for reducing the pressure of the CBG to make it suitable for combustion.
Yet another object of the present invention is to provide a system for hot dip galvanization that incorporates a module for ignition management of the CBG to achieve the desired temperature of the molten zinc kettle.
Yet another object of the present invention is to provide a system for hot dip galvanization that incorporates a module for real-time monitoring and control of the system parameters and alarm generation.
Yet another object of the present invention is to provide a method for hot dip galvanization.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 illustrates a block diagram of the system for hot dip galvanization (100) comprising a gas delivery module (200), an electronic monitoring and control module (300), and an ignition module (400) in accordance with an embodiment of the present invention;
Figure 2 represents a schematic of the gas delivery module (200) in accordance with an embodiment of the present invention;
Figure 3 represents a schematic of the electronic monitoring and control module (300) in accordance with an embodiment of the present invention; and
Figure 4 represents a flow diagram of the method for hot dip galvanization (500) in accordance with an embodiment of the present invention.
It should be appreciated by those skilled in the art that any schematic diagrams herein represent conceptual views of illustrative systems embodying the principles of the present invention. Similarly, it will be appreciated that any flowcharts, flow diagrams, and the like represent various processes that may be substantially represented in computer-readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments herein provide a system for hot dip galvanization (100) (hereinafter referred to as “system (100)”) comprising a gas delivery module (200), an electronic monitoring and control module (300), and an ignition module (400) configured to achieve and maintain a desired temperature of zinc kettle by using compressed biogas as fuel. The system (100) further comprises a plurality of sensors, a plurality of communication links, a plurality of displays, a controller, and an application software for real-time monitoring of the system parameters.
Throughout this application, with respect to all reasonable derivatives of such terms, and unless otherwise specified (and/or unless the particular context clearly dictates otherwise), each usage of:
“a” or “an” is meant to read as “at least one”,
“the” is meant to be read as “the at least one.”
References in the specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
Hereinafter, embodiments will be described in detail. For clarity of the description, known constructions and functions will be omitted.
Parts of the description may be presented in terms of operations performed by at least one processor, electrical/electronic circuit, a computer system, using terms such as data, state, link, fault, packet, and the like, consistent with the manner commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. As is well understood by those skilled in the art, these quantities take the form of data stored/transferred in the form of non-transitory, computer-readable electrical, magnetic, or optical signals capable of being stored, transferred, combined, and otherwise manipulated through mechanical and electrical components of the computer system; and the term computer system includes general purpose as well as special purpose data processing machines, switches, and the like, that are standalone, adjunct or embedded. For instance, some embodiments may be implemented by a processing system that executes program instructions so as to cause the processing system to perform operations involved in one or more of the methods described herein. The program instructions may be computer-readable code, such as compiled or non-compiled program logic and/or machine code, stored in a data storage that takes the form of a non-transitory computer-readable medium, such as a magnetic, optical, and/or flash data storage medium. Moreover, such processing systems and/or data storage may be implemented using a single computer system or may be distributed across multiple computer systems (e.g., servers) that are communicatively linked through a network to allow the computer systems to operate in a coordinated manner.
The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in brackets in the following description and a table below.
Reference
No. Component Reference
No. Component
100 System for hot dip galvanization 300 Electronic monitoring and control module
200 Gas delivery module 301 PLC
201 CBG carrying vehicle 302 GSM based gateway
202 First stage 303 Application software
203 Second stage 304 Display
204 Second stage 305 Variable frequency drive
205 Third stage 400 Ignition module
P1 Inlet pressure sensor T1 Inlet temperature sensor
P2 Intermediate pressure sensor T2 Intermediate temperature sensor
P3, P4 Outlet pressure sensors T3, T4 Outlet temperature sensors
F1 Flow totalizer F2 Flow sensor in the third stage
In one of the exemplary embodiments of the present invention, the gas delivery module (200) comprises an arrangement for transporting the compressed biogas (CBG) from a gas-carrying vehicle to the site of deployment, a plurality of sensors for monitoring the parameters of the CBG while it is being transported, a plurality of safety interlocks, and a plurality of equipment for varying the pressure and temperature of the CBG.
In one of the exemplary embodiments of the present invention, the gas delivery module (200) is configured for receiving the CBG at a pressure in the range of 40-250 bar at one end thereof and successively reducing the pressure to suit the design of the ignition module (400).
In one of the exemplary embodiments of the present invention, the system (100) is configured to generate an alarm when the pressure of the CBG supplied by the vehicle drops below a predefined value.
In one of the exemplary embodiments of the present invention, the plurality of sensors for monitoring the parameters of the CBG may comprise a plurality of pressure sensors, a plurality of temperature sensors, and a plurality of flowmeters.
In one of the exemplary embodiments of the present invention, the plurality of safety interlocks is configured to check the pressure of the CBG in the ignition module (400) and shut the system (100) when the pressure is below and/or above a predefined value.
In one of the exemplary embodiments of the present invention, the gas delivery module (200) is communicatively coupled with the electronic monitoring and control module (300) in a wired and/or wireless manner. Moreover, the gas delivery module (200) is mechanically coupled to the ignition module (400).
In one of the exemplary embodiments of the present invention, the electronic monitoring and control module (300) is configured for receiving inputs from the plurality of sensors deployed in the system (100) to achieve the predefined temperature of the zinc kettle. The electronic monitoring and control module (300) comprises a programmable logic controller (PLC) and a supervisory control and data acquisition (SCADA) based application software. The application software is configured for continuously tracking and displaying the data provided by the plurality of sensors deployed in the system (100).
In one of the exemplary embodiments of the present invention, the ignition module (400) comprises a dual-line arrangement for CBG flow, a plurality of valves, a plurality of regulators, and a plurality of burners. The dual-line arrangement includes a pilot line and a main line configured for igniting and maintaining the burner flame. The ignition module (400) further includes a solenoid valve, a spark plug, a flame detector, and valves to ensure continuous burner operation. Advantageously, each of the plurality of burners is fitted with a nozzle that is designed for the CBG.
In one of the exemplary embodiments of the present invention, the system (100) is configured to maintain the temperature of the zinc kettle at 450 ± 10°C.
In an implementation of a preferred embodiment of the present invention, the constructional and functional features of the system (100) are explained by referring to Figures 1-3. The system (100) comprises a gas delivery module (200), an electronic monitoring and control module (300), and an ignition module (400).
As shown in Figure 2, the gas delivery module (200) is configured for successively reducing the pressure of the CBG to suit the burner design. The CBG is delivered by CBG carrying vehicle (201) at a pressure in the range of 40-250 bar. The gas delivery module (200) implements a stage-wise pressure reduction of the CBG. The first stage (202) comprises a vaporizer having a first end and a second end. The first end of the first stage (202) is connected to the outlet of the CBG-carrying vehicle (201) and configured to receive the CBG at a pressure in the range of 40-250 bar. A pressure sensor P1 and a temperature sensor T1 are configured to measure the pressure and the temperature of the CBG at the outlet of the CBG-carrying vehicle (201). The first stage (202) is configured to reduce the pressure of the CBG in the range of 15-30 bar. As the pressure of the CBG reduces significantly, the temperature of the CBG may fall below the freezing point. The first stage (202) includes a heating arrangement to maintain the CBG temperature to ensure fluidity and prevent the solidification of the CBG. A pressure sensor P2 and a temperature sensor T2 are configured to measure the pressure and the temperature of the CBG at the second end of the first stage (202). The second end of the first stage is connected to a second stage (203, 204). The second stage comprises a plurality pressure relief device (PRD) (203, 204) that is configured to function as a stand-by unit for each other. Each of the plurality of the pressure relief devices (203, 204) is configured to reduce the CBG pressure further to 1.5-2 bar. Pressure sensors (P3, P4) and temperature sensors (T3, T4) are configured to measure the pressure and the temperature of the CBG at the outlet of the plurality of pressure relief devices (203, 204) respectively. A third stage (205), at the first end thereof, is mechanically connected to the outlet of the plurality of pressure relief devices (203, 204). The third stage (205) is configured to receive the CBG at a pressure in the range of 1.5-2 bar and further reduce the pressure and the temperature of the CBG in the range of 100-150 millibar and 30-400C respectively. The third stage (205), at the second end thereof, is mechanically connected to the ignition module (400). The third stage comprises a gas train module that includes a pressure regulator, a flow meter (F2), and a solenoid valve. The CBG provided by the third stage (205) is utilized by the ignition module (400) as a fuel for heating the zinc kettle. The system (100) deploys a mechanical moisture trap (not shown) for arresting the moisture content in the CBG before the entry thereof in the ignition module.
A flow totalizer (F1) is configured for measuring the amount of CBG supplied by the gas delivery module (200). The system (100) incorporates a pressure switch (not shown) configured to mitigate the effects of pressure fluctuations ensuring safe operating conditions. The ignition module (400) is designed to operate within the pressure range of 100-200 millibars. An arrangement in the form of a pressure switch is configured to shut down the system (100) when the pressure does not fall within this range.
Figure 3 represents the components of the electronic monitoring and control module (300). A programmable logic controller (PLC) (301) is configured to receive the values of parameters from the pressure sensors (P1, P2, P3, P4), the temperature sensors (T1, T2, T3, T4), and the flow totalizer (F1). The PLC (301) is communicatively coupled to a SCADA-based application software (303) via a GSM-based gateway (302). The application software (303) is configured to continuously track and display the system parameters and total CBG consumption received from the PLC (301) graphically on a display (304). The display (304) can be a screen of a device selected among a personal computer, a tablet, a laptop, or a mobile phone. Moreover, the application software (303) is configured to generate an alarm when the pressure of the CBG supplied by the vehicle (201) drops below 30 bar. The PLC (301) is programmed with a set of instructions that when executed provide a signal to a variable frequency drive (305) that is configured to vary the burner flame size in the range of 5% to 100% by adjusting the pressure of air supplied by the combustion blower. To achieve this, the PLC (301) utilizes the values of the parameters such as RPM of the combustion blower (not shown), the flow rate of the CBG through the gas train module measured by a flow sensor (F2), and control valve opening in the main line of the ignition module (400). The combustion blower is configured to supply air for igniting and maintaining the flame in the plurality of burners along with the CBG flow. A human-machine interface (HMI) (306) is communicatively coupled to the PLC (301). The HMI (306) is configured to facilitate the authorized person to alter/set values of the parameters such as the CBG flow rate through the gas train module, RPM of the combustion blower, and opening of the control valve in the main line of the ignition module (400) required for the operation of the plurality of burners to achieve the predefined temperature of the zinc kettle.
The ignition module (400), at the first end thereof, is mechanically coupled to the third stage (205) of the gas delivery module (200). The ignition module (400), at the second end thereof, is operably coupled to the zinc kettle (not shown). The ignition module (400) includes a plurality of burners placed beneath the zinc kettle and configured to provide heating to the kettle by using the CBG as fuel supplied at pressure in the range of 100-150 millibar. Moreover, the ignition module (400) includes a dual-line arrangement to carry the CBG to the plurality of burners. Each of the plurality of burners is fitted with a nozzle to ensure an adequate supply of the CBG for flame ignition and maintenance. Advantageously, the orifice of each nozzle has a diameter in the range of 5-15 mm for combustion of the CBG to achieve and maintain the optimum temperature of the zinc kettle. The dual-line arrangement includes a pilot line and a main line configured for igniting and maintaining the burner flame. The ignition module (400) further includes a solenoid valve, a spark plug, a flame detector, a plurality of safety shutoff valves, and a plurality of pressure regulators placed in the pilot line. The pilot line when activated, generates a spark via the spark plug. The flame detector, upon detection of the flame, communicates with the PLC (301) and in turn, the PLC (301) signals the solenoid valve to operate and thus initiate ignition. The main line is fitted with a plurality of safety shutoff valves, a gas pressure switch, and a control valve. The PLC (301) is configured for maintaining a continuous burner operation by manipulating airflow from the combustion blower and the CBG flow through the main line of the ignition module (400) by controlling the operation of the variable frequency drive (305). The variable frequency drive (305) is operably coupled to the combustion blower to control the pressure of air therefrom. The PLC (301) is configured to control the opening of the control valve placed in the main line. The main line may contain a plurality of venting and relief valves for the safe operation of the ignition module (400).
In an implementation of a preferred embodiment of the present invention, the method for hot dip galvanization (500) (hereinafter referred to as “method (500)”) is explained by referring to Figure 4. The method (500) is performed by the system (100). The method (500) starts at step 501, wherein, the first stage (202) of the gas delivery module (200) is connected to the CBG carrying vehicle (201) to receive the CBG at a pressure in the range of 40-250 bar. At step 502, reducing the pressure of the CBG by the first stage (202) in the range of 15-30 bar happens. The step 503 corresponds to further reducing the pressure of the CBG by the second stage (203 or 204) in the range of 1.5-2 bar. At step 504, further reduction of the pressure of the CBG by the third stage (205) in the range of 100-150 millibar while maintaining temperature thereof in the range of 30-400 C is carried out. The step 505 corresponds to sensing and communicating the values of the pressure, temperature, and flow of the CBG to the PLC (301) by a plurality of pressure sensors (P1, P2, P3, P4), a plurality of temperature sensors (T1, T2, T3, T4) and a flow sensor (F1). At step 506, the PLC (301) communicates the received values of the pressure, temperature, and flow of the CBG to the application software (303) via a GSM-based gateway (302). At step 507, tracking and displaying the received values by the application software (303) on a display (304) and generating an alarm if the pressure of the CBG at the outlet of the CBG carrying vehicle drops below 30 bar, happens. The step 508 corresponds to arresting the moisture content in the CBG by deploying a mechanical moisture trap before the entry thereof in the ignition module. The step 509 corresponds to supplying the CBG by the third stage (205) to the ignition module (400). At step 510, the pressure switch checks the CBG pressure in the ignition module (400) and shuts down the system if the pressure exceeds or falls below predefined values. At step 511, the pilot line of the ignition module (400) is activated by the PLC (301). The step 512 corresponds to the activation of the main line of the ignition module (400) to maintain continuous burner operation. At step 513, controlling the operation of the variable frequency drive (305) by the PLC (301) to adjust the air supplied by the combustion blower and the CBG flow through the control valve in the main line to achieve and maintain a predefined temperature of the zinc kettle, happens.
ADVANTAGES OF THE INVENTION
1. The system results in significant cost savings in the galvanization process as the CBG is economic when compared to other fossil fuels, thus reducing carbon footprint.
2. The system facilitates organic waste utilization and derivation of biogas therefrom, minimizing the waste going to landfills.
3. The system significantly improves real-time visibility of critical parameters, facilitating better decision-making.
4. The system results in longer flame length, and thus, faster temperature pickup of the zinc kettle.
5. The system enhances operational efficiency, reduces manual intervention, and improves process reliability.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

, Claims:We claim:
1. A system for hot dip galvanization (100), the hot dip galvanization carried out in a kettle containing molten zinc (hereinafter “zinc kettle” or “kettle”), the system (100) comprising:
a gas delivery module (200), the gas delivery module (200) configured to receive compressed biogas (CBG) at a pressure of 200 bar at one end thereof from a CBG carrying vehicle (201) and successively reduce the pressure of the CBG by deploying a plurality of stages such as a first stage (202), a second stage (203, 204) and a third stage (205) mechanically connected in succession;
an ignition module (400), the ignition module (400) at the first end thereof, mechanically coupled to the third stage (205) of the gas delivery module (200), and at the second end thereof, operably coupled to the zinc kettle and configured to ignite and maintain flame to provide heating to the zinc kettle; and
an electronic monitoring and control module (300), the electronic monitoring and control module (300) communicatively coupled to the gas delivery module (200) and the ignition module (400) and configured to receive the data from a plurality of sensors (P1, P2, P3, P4, T1, T2, T3, T4, F1, F2), deployed therewithin.
2. The system (100) as claimed in claim 1, wherein, the first stage (202) is configured to receive the CBG at a pressure in the range of 40-250 bar and, alter the pressure thereof in the range of 15-30 bar.
3. The system (100) as claimed in claim 1, wherein, the second stage (203, 204) is configured to alter the pressure of CBG in the range of 1.5-2 bar by deploying a plurality of pressure relief devices, each serving as a stand-by unit for the other.
4. The system (100) as claimed in claim 1, wherein, the third stage (205) is configured to alter the pressure and the temperature of the CBG in the range of 100-150 millibar and 30-400C respectively by deploying a gas train module.
5. The system (100) as claimed in claim 1, wherein, the electronic monitoring and control module (300) includes:
a PLC (301) configured to control the temperature of the zinc kettle within a predefined range and communicatively coupled with the plurality of sensors (P1, P2, P3, P4, T1, T2, T3, T4, F1, F2) placed within the gas delivery module (200) and the ignition module (400) transmitting the values of a plurality of parameters thereto;
a SCADA-based application software (303) configured to continuously track and display the system parameters on a display (304) and communicatively coupled to the PLC (301) via a GSM-based gateway (302);
a variable frequency drive (305) configured to vary the burner flame size in the range of 5% -100% and communicatively coupled to the PLC (301); and
an HMI (306) configured to facilitate the authorized person to alter/set values of the parameters required for the operation of the plurality of burners and communicatively coupled to the PLC (301).
6. The system (100) as claimed in claim 1, wherein, the ignition module (400) includes:
a plurality of burners placed beneath the zinc kettle and configured to provide heating to the kettle by using the CBG as fuel supplied at a pressure in the range of 100-150 millibar;
a dual-line arrangement with a pilot line and a main line configured to carry the CBG to the plurality of burners and ignite and maintain the burner flame, the pilot line fitted with a solenoid valve, a spark plug, a flame detector, a plurality of safety shutoff valves, and a plurality of pressure regulators and the main line fitted with a plurality of safety shutoff valves, a gas pressure switch, and a control valve; and
a nozzle fitted in each of the plurality of burners with a diameter in the range of 5-15 mm.
7. The electronic monitoring and control module (300) as claimed in claim 1 and claim 5, wherein the PLC (301) is programmed with a set of instructions that when executed provides a signal to a variable frequency drive (305) to adjust the pressure of air supplied by the combustion blower to maintain the temperature of the zinc kettle at 450 ± 10°C.
8. The system (100) as claimed in claim 1 comprises a pressure switch (not shown) configured to check the CBG pressure in the ignition module (400) and shut down the system (100) if the pressure exceeds or falls below predefined values of 200 mbar and 100 mbar respectively.
9. The electronic monitoring and control module (300) as claimed in claim 1 and claim 5, wherein the application software (303) is configured to generate an alarm when the pressure of the CBG supplied by the vehicle drops below 30 bar.
10. A method for hot dip galvanization (500) performed by the system (100), the method (500) comprising:
connecting the first stage (202) of the gas delivery module (200) to the CBG carrying vehicle (201) to receive the CBG at a pressure in the range of 40-250 bar;
reducing the pressure of the CBG by the first stage (202) in the range of 15-30 bar;
reducing the pressure of the CBG by the second stage (203 or 204) in the range of 1.5-2 bar;
reducing the pressure of the CBG by the third stage (205) in the range of 100-150 millibar while maintaining the temperature thereof in the range of 30-400C;
sensing and communicating the values of the pressure and temperature of the CBG to the PLC (301) by a plurality of pressure sensors (P1, P2, P3, P4), a plurality of temperature sensors (T1, T2, T3, T4) and flow sensors (F1, F2);
communicating, by the PLC (301), the received values of the pressure, temperature, and flow of the CBG to the application software (303) via a GSM-based gateway (302);
tracking and displaying the received values by the application software (303) on a display (304) and generating an alarm when the pressure of the CBG supplied by the vehicle drops below 30 bar;
arresting the moisture content in the CBG by deploying a mechanical moisture trap;

supplying the CBG by the third stage (205) to the ignition module (400);
checking, by the pressure switch, the CBG pressure in the ignition module (400) and shutting down the system (100) if the pressure exceeds or falls below predefined values;
activating by the PLC (301) the pilot line of the ignition module (400) to start the ignition upon receiving a signal from a flame detector;
activating the main line of the ignition module (400) to maintain continuous burner operation; and
controlling the operation of the variable frequency drive (305) by the PLC (301) to adjust the air supplied by the combustion blower and the CBG flow through the control valve in the main line to achieve and maintain a temperature of the zinc kettle at 450 ± 10°C.

Dated this on December 19, 2024

Prafulla Wange
(Agent for Applicant)
(IN/PA: 2058)