The 1850mm Width Pickling Line represents a state-of-the-art continuous hydrochloric acid (HCl) pickling system engineered for precision surface treatment of hot-rolled steel. This fully automated line integrates High-Speed Pickling technology to achieve operational efficiencies of 180 m/min, making it ideal for high-volume production environments. Designed for carbon steel, silicon steel, and stainless-steel substrates, it combines robust construction with advanced regeneration systems to minimize environmental impact. Key specifications include:
A. Entry Section
The line begins with dual-mandrel uncoiling for seamless coil handling:
Hydraulic Expandable Drum: Accommodates Ø508/610mm inner diameters (switch time ≤90 seconds).
Tension Leveler: 90 kW unit eliminates 95% of yield point elongation, ensuring strip flatness during high-speed feeding.
Automatic Threading: Laser-guided system with >99.8% success rate, minimizing downtime.
B. Pre-treatment Zone
Prepares surfaces for efficient acid penetration:
Multi-Stage Cleaning: Nylon brushes (0.5–1.5 bar adjustable pressure) remove scale and debris.
High-Pressure Rinsing: 20-bar demineralized water flow at 3,000 L/min.
Electrolytic Degreaser (Optional): Operates at 50 A/dm² for critical contaminant removal.
C. Pickling Section
The heart of the 1850mm Width Pickling Line, optimized for High-Speed Pickling:
HCl Turbulent Flow: Venturi nozzles generate 25 m/s flow, reducing contact time by 40% for rapid oxide removal.
Temperature Control: Maintains 70°C ±2°C via plate heat exchangers.
Real-Time Monitoring: Conductivity/pH sensors (±0.1% accuracy) ensure consistent acid concentration.
D. Regeneration System
Features a closed-loop design to enhance sustainability:
Spray Acid Recovery: 98% efficiency reclaims HCl.
Vacuum Evaporator: Concentrates acid to 18% for reuse.
By-Product Treatment: Converts FeCl₂ into 99.9% recyclable material.
E. Post-Treatment Zone
Ensures superior surface quality:
Cascade Rinsing: 4-stage demineralized water system (conductivity <50 µS/cm).
Hot Air Drying: Centrifugal fans at 120°C achieve residual moisture ≤0.5 g/m².
Passivation Unit: Chromate-free nano-ceramic coating for corrosion resistance.
A. Intelligent Control System
Powered by Siemens S7-1500 PLC:
Predictive Maintenance Algorithms: Increase mean time between failures (MTBF) by 30%.
HMI Interface: 3D virtual line visualization for real-time fault diagnosis and automated strip tracking (±0.5 mm edge control via laser CCD).
Energy Optimization: Recovers 85% waste heat, saving 1,200 MWh/year.
B. Precision Monitoring
Guarantees product integrity during high-speed operations:
Thickness/Width Sensors: X-ray gauge (±0.003 mm accuracy at 180 m/min) and laser systems.
Quality Assurance: Integrated modules for defect detection and adaptive process adjustments.
A. Verified Material Performance
B. Typical Applications
Hot-rolled carbon steel pretreatment for cold rolling.
Silicon steel substrate processing for electrical components.
Surface preparation in galvanizing or color coating lines.
A. Eco-Compliance
Emissions Control: Acid mist scrubber (>99% efficiency, outlet HCl ≤2 mg/m³).
Wastewater Management: Automated neutralization (pH 7.0±0.5).
Safety & Noise: SIL-3 emergency stops (response <0.2 sec) and acoustic enclosures (<78 dB(A) at 1 m).
B. Operational Economics
Cost Savings: Acid regeneration reduces chemical costs by 65% versus conventional systems; energy recovery yields ≤14-month ROI.
Productivity: Processes 500,000 MT/year at 90% overall equipment effectiveness (OEE), with material grade changeovers in ≤15 minutes.
Flexibility: Customizable for varied thicknesses (0.8–8.0 mm), supporting diverse industrial needs.
