Pickling Optimizer

The Pickling Optimizer is a digital optimization tool designed to support operators, engineers, and managers in steel plants and cold rolling mills. By focusing on enhancing product quality, improving process efficiency, and reducing operational costs, the tool streamlines the pickling process through precise optimization of pickling rates.

This solution tackles key challenges such as managing complex chemical reactions, controlling speed and temperature, and preventing over-pickling, which can compromise product quality. Using advanced model-based calculations, the Pickling Optimizer ensures that these variables are balanced effectively to maintain optimal performance.

The Pickling Optimizer is a cutting-edge digital tool designed to enhance the efficiency and precision of steel strip pickling by employing sophisticated real-time process simulations. It factors in the conditions of prior strip treatments, such as the finishing or coiling temperature from the Hot Strip Mill (HSM), as well as the strip's chemical composition, geometry, and current temperature. These parameters are critical for accurately estimating the thickness and composition of the pickling scale, enabling precise control over the pickling process.

In addition to these inputs, the optimizer evaluates the actual pickling bath conditions, including acid concentration, bath temperature, and the strip warming gradient. This in-depth analysis also considers the operation of the mechanical scale breaker, which plays a vital role in opening the strip surface for better acid penetration. Based on these parameters, the optimizer calculates the required pickling time and determines the optimal pickling speed to achieve efficient and consistent processing.

The Pickling Optimizer also monitors pickling quality by assessing the risks of over-pickling or under-pickling. By comparing actual operational speeds to the calculated optimum speed, the system ensures the process remains within defined quality parameters. It can estimate the ideal bath temperature, often set at its maximum to boost mill throughput. This model-based approach not only optimizes the pickling rate but also minimizes the risk of defects, ensuring higher product quality and process efficiency.

A standout feature of the optimizer is its ability to prepare optimal temperature and speed profiles for up to 100 scheduled strips. This functionality allows plant operators to anticipate potential issues and make proactive, data-driven decisions, improving the reliability and efficiency of the pickling process. With its comprehensive capabilities, the Pickling Optimizer is a powerful tool for reducing defects, enhancing throughput, and delivering superior-quality finished products.

Benefits of the Pickling Optimizer

• Increased throughput: the Pickling Optimizer enhances production efficiency by calculating the optimal speed and temperature profiles for the pickling process. This ensures that the maximum number of strips can be processed in the shortest possible time, significantly increasing the throughput of the pickling line.
• Improved quality control: by simulating the pickling process in real time, the optimizer ensures consistent quality across all processed strips. It accurately predicts and adjusts parameters to prevent over-pickling or under-pickling, thereby reducing defects and ensuring high-quality surface treatment.
• Cost efficiency: the optimizer reduces operational costs by minimizing material loss and optimizing resource usage. By preventing over-pickling, it conserves acid and energy, leading to significant cost savings in the long run.
• Enhanced process reliability: the optimizer's ability to simulate different scenarios and anticipate potential issues allows operators to make informed decisions, enhancing the overall reliability of the pickling process. This proactive approach minimizes downtime and ensures smooth operations.