Pickling & phosphating line
Among the surface treatment methods for wire rods and steel pipes, the use of pickling treatment is a common process used by most manufacturers in the metal product industry. This is also the treatment process with the highest treatment quality at present, and there is no alternative process that can achieve the same effect of pickling.
At present, most manufacturers adopt open pickling, using manual and ordinary trucks for lifting pickling, and the pickling tank is completely exposed to the air. A large amount of acid mist will be generated during the pickling process, which will seriously affect the health of the operators. The escaped acid mist diffuses into the air, which not only poses a serious threat to the health of the operators, but also continues to corrode equipment and workshops, causing serious pollution to the environment. The current pickling mode can no longer meet the government and society’s requirements for the metallurgical industry to achieve high efficiency, high quality, low consumption, and environmental protection. Enterprises with open pickling must rectify and replace the pickling process.
Based on this background, the company began to develop a new wire rod and steel pipe surface treatment line. With the diligence and hard work of the company’s R&D personnel, the company has developed the highest level of wire rod and steel pipe surface treatment methods among similar products in my country. The automatic tunnel closed pretreatment line meets the huge existing pickling process replacement needs of steel pipe companies, steel strands, steel ropes, fasteners and other related companies. It also solves the problem of substandard environmental protection that the current pickling line generally faces.
2.5T castings processed to imitate the size and weight of the wire rod
Eco-Friendly Steel Pickling Line Manufacturer
Wuxi T-control steel pickling line company provides services for consumers with the most innovative techniques. Based in China, it has a well-experienced R & D team that provides solutions for numerous industries with integration approaches. It is well-equipped with modern centers to plan the tasks in a comfy environment. Additionally, the company follows high standards in the pickling line process that can help remove impurities efficiently. The costs are an affordable one that allows steel producing companies to ensure that their products come with the most effective qualities while selling them on the markets.
The pickling line equipment needs plenty of energy consumption during procedure. Some customers have abundant sources in terms of energy sources, so they can save numerous electricity bills. There are many types of energy such as heat transfer oil and natural gas. If these energy sources are used to transfer heat energy, heat pump services can be used.
Principle description of heat pump:
- The high temperature quenching oil exchanges heat with the phosphating tank and the pre-cleaning tank, and the energy is supplemented by the water source heat pump.
- The quenching oil exchanges heat with the water source heat pump to improve the thermal efficiency of the unit, thereby heating the temperature in the square water tank.
- The auxiliary tank and the saponification tank are continuously circulated through the circulation pump and the connecting pipe to ensure that the temperature of the saponification tank is maintained at the process temperature
- The tanks do not affect each other. When the temperature of the detection tank reaches the set temperature, the solenoid valve will be closed. When the temperature is not reached, the solenoid valve will be opened, and the circulating pump will be turned on for heat exchange to ensure the tank temperature.
- The high temperature water tank and the heat pump are heated by the water pump in circulation.
- PPR pipes are used between the water tank and the host.
Features of the new wire rod pickling and phosphating production line:
Pollution-free —— The global requirements for environmental protection are becoming stricter. The original acid treatment line basically does not meet the national environmental protection requirements. Our closed pretreatment line adopts a special process, a proprietary tank structure design, and low levels of acid. The amount of mist generated is matched with the negative pressure system, through the combination of acid discharge control and secondary utilization, the acid mist will not diffuse to the outside of the equipment at all, making the equipment fully meet the national environmental protection requirements.
Low Emissions——The atmospheric emission index is as low as 10mg/M³, which fully meets the national and EU standards. The proprietary acid tank design, acid circulation filtration system, and acid tank reverse overflow system basically realize zero discharge of acid.
The countercurrent cleaning system combined with the wastewater treatment system saves 40% of water compared to similar products, while achieving the standard discharge and recycling of cleaning water
Low investment——Under the premise of fully guaranteeing the completion of equipment related indicators, our company provides linear and circular products with an annual output of 30,000 to 400,000 tons of various specifications. Users can be flexible according to their needs. At the same time, we also reserve room for the user’s possible output expansion, which can help users achieve the optimal combination of equipment investment.
High efficiency —— fully automatic operation, continuous production; high production efficiency, large output, especially suitable for large-volume, centralized production; different processes can be flexibly realized according to the specifications of the wire rod without manual intervention; the maximum production capacity can be Reach 400,000 tons/year; use replaceable walking track, the steel structure of the equipment is wear-free; and use high-quality components, the equipment maintenance cycle is long; the process parameters are automatically controlled by the computer, and the production process is stable;
1. Use a new generation of manipulators
★ Special customized electric hoist and structure specially designed for pickling process, high protection level;
★ 4 walking motors run synchronously, with high reliability of equipment operation and strong fault tolerance;
★ Multi-group steering mechanism with 2×4 structure, flexible steering and low operating noise;
★ The track turning radius can be as small as 3 meters, and the layout is compact. Compared with similar products, it saves 1/3 of the workshop space;
★ 2×2 structure guide mechanism, to ensure that the manipulator rises and falls smoothly without shaking;
★ The manipulator does not directly contact the track during walking, and the track has no wear.
2 .Compact layout, factory production, high-strength bolt connection
★ The maintenance station is placed inside the production line and does not occupy external space;
★ Easy to maintain and save plant investment;
★ High-strength bolt connection, without welding, completely eliminates the influence of stress, and is more secure and safe;
★ The equipment is beautiful, easy to install, and short in construction period.
3.Patented acid tank
★ The auxiliary tank is used for heating, and there are no heating elements and heating coils in the main process tank;
★ Long maintenance period of acid tank;
★ Dynamic pickling with high turbulence, high pickling efficiency;
★ The pickling sediment is automatically filtered outside the tank, and the residue is removed online to increase the acid life cycle;
★ Automatic reverse acid overflow, increase the acid life cycle and save acid consumption;
★ The acid tank cover with automatic switch can be equipped to reduce the acid mist produced by acid washing by 50%, reduce the operating load of the acid mist absorption tower, and reduce the use of neutralizing lye;
★ Lower emissions;
★ Reduce production costs and improve economic efficiency.
4.Efficient water recycling technology
★ Synchronous countercurrent water circulation technology;
★ Rinse the inner and outer surfaces of the wire rod at the same time, the cleaning effect is good;
★ Water consumption is as low as 40Kg/ton;
★ Lower emissions;
★ Reduce production costs and improve economic efficiency.
5.Low acid mist emission
★ Design of double towers in series; step countercurrent water circulation technology;
★Using new type of packing, the acid mist emission can reach 10mg/m³;
★ With acid regeneration equipment, zero discharge of acid mist can be realized.
6 .Advanced control system and reliable program design
★ Multiple positioning, with software algorithm to prevent collision accidents;
★ High positioning accuracy, positioning error <5mm;
★ Flexible process control, one-key re-washing function;
★ Advanced multi-point roaming WIFI control, stable online control signal;
★ Internet of things interface, cloud platform control, mobile phones and tablets can be remote online.
★ Simply increase the number of manipulators to increase productivity;
★ Adding two more manipulators can easily expand the production capacity to 250,000 tons/year, saving investment.
Note: The output size is determined by the number of process tanks and the number of robots.
8.Strict quality management and manufacturing
★ All steel structures and manipulators are tested for flaw detection.;
★ All tanks are tested for water injection for 24 to 48 hours;
★ All electric control cabinets and power distribution cabinets are in compliance with 3C certification;