Pickling Line Automation

Pickling Line Automation is a state-of-the-art automation solution that assists operators, plant managers and maintenance engineers in a steel plant, who want to achieve enhanced process control, increased safety, and reduced downtime by increasing operational flexibility and reducing risks through real-time monitoring, advanced pickling models, and seamless integration.

In the realm of steel processing, achieving optimal pickling line performance is crucial. The advanced pickling model developed by Primetals Technologies calculates scale thickness and the state of iron oxide, optimizing strip speed based on a chemical-physical model. This model considers coil primary data, actual bath temperatures, and concentration values in each pickling circuit, ensuring precise control across different segments such as head-end, body, and tail-end. Additionally, the system features real-time monitoring and control of acid concentration, temperature, and fluid flow, utilizing advanced sensors and automation controls. The integration of a scale breaker enhances efficiency by preparing the strip surface through controlled tension and bending, which improves the overall pickling process.

Benefits of Pickling Line Automation

• Enhanced process control: the automation system ensures precise control over strip tension, speed, and elongation, leading to consistent product quality.

• Increased safety: advanced safety systems, including emergency stop protocols and safety interlocks, protect operators and equipment, reducing the risk of accidents.

• Operational flexibility: the system is adaptable to various production requirements, accommodating different material types and thicknesses without compromising performance.

• Reduced downtime: efficient coordination and control minimize unplanned stoppages, enhancing overall productivity.

Features of Pickling Line Automation

• Advanced pickling model: calculates scale thickness and iron oxide state for precise process control, optimizing the pickling process by dynamically adjusting parameters like acid concentration and bath temperature in real-time, using detailed coil data and a production schedule to ensure efficient resource use and consistent product quality.

• Scale breaker control: enhances pickling efficiency to ensure optimal strip flatness and surface quality, by precisely control elongation and preparing the strip surface through controlled tension and bending.

• Real-time monitoring and adjustment: continuous oversight of process parameters allows for immediate adjustments, ensuring optimal performance and quality.

• Optimum strip speed calculation: based on coil data, bath temperatures, and concentration values.

• Forecast calculation: predicts coils in advance for proactive process management.

• Temperature gradient control: ensures consistent quality throughout the pickling bath.

• Automated coordination: synchronizes operations across different sections of the pickling line, from entry to exit, ensuring a seamless workflow.

• User-friendly interface: intuitive controls and displays simplify operation and monitoring, reducing the learning curve for operators.

• Scalable architecture: designed to accommodate future upgrades and expansions, ensuring long-term viability and adaptability to changing production needs.