Pickling Lines

PICKLING LINES – CLEAN AND SCALE-FREE SURFACES FOR OPTIMIZED DOWNSTREAM PROCESSES

Modularly designed continuous pickling lines from Primetals Technologies are known for their efficiency, economic operation and use of advanced technologies such as i-Box pickling.

Continuous and push-pull pickling lines are equipped with compact scale breakers, the latest welders and turbulent pickling systems that are designed and optimized on the basis of extensive operational experience. Customers have the choice of different pickling concepts (i-Box, turbulent tank, shallow bath tank) to meet their specific productivity requirements or preferences. Accurate strip and pickling control, fast and stable processes, and precise strip tracking are decisive factors for optimized pickling operations. The assurance of highest strip surface quality and cleanliness is paramount in importance to ensure reliable and cost-efficient downstream processing.

Primetals Technologies supplies the full range of solutions for descaling hot rolled strip. Pickling lines supplied by us are characterized by high pickling rates, low-cost operation, flexible production, and for a wide range of product sizes, qualities and coil weights. The lines are reliable in operation, have low maintenance and meet the highest standards of environmental protection.

We have a record of over 207 pickling line deliveries since 1954. Applying the knowledge of extensive experience, and offer various types of pickling tanks for continuous pickling lines. This makes it possible for our customers to select the tank type, which best meets their needs.

Overall line features:

  • Comprehensive package and complete in-house design (mechanical, electrical, process)
  • Laser welder
  • Compact scale breaker
  • Turret-type side trimmer with flying width adjustment and edge monitoring
  • Trimmed scrap chopper, baller or bailer
  • Coil clamp opener
  • Fish tail detector for end crop

Process section features:

  • High pickling efficiency (i-Box or turbulent (jet) flat tank design)
  • Side-jet pickling action on the edge areas where the scale layer is thickest
  • Acid concentration control system
  • Perfectly sealed pickling tanks
  • Pickling at moderate temperature
  • New anti-stain rinse system
  • Polypropylene pickling tank option

  

Fig.1- i-Box pickling tank | Fig.2- Circulation type tank

Modernization

Primetals Technologies has vast experience in upgrading and modernization of processing lines. With a systematic approach, we work closely with our customers to develop a tailored modernization concept based on their individual needs taking all boundary conditions fully into account. The solution may be purely electrical, automated, mechanical or a combination. Based on the selected concept, the modernization can be carried out in several steps or during a plant shutdown. Primetals Technologies’ experience minimizes downtimes and ensures a fast start-up and top quality.

Primetals Technologies also supply continuous pickling lines for stainless steel which include an annealing furnace prior to pickling.

​For the pickling of up to approximately 1,000,000 tons of strip per year, push-pull pickling lines offer significant advantages when it comes to investment costs and operational flexibility. This is the case particularly when you frequently change strip dimensions and steel grades. Primetals Technologies offers a uniquely designed V-shape flat pickling tank, which improves the strip stability during its passage through the tank. This eliminates strip buckling and flattening, and assures reliable threading. To prevent strip staining in the rinsing section, Primetals Technologies has developed a special antistain system that does not require chemical additives. The energy efficient design of the fume extraction and sealing system significantly reduces energy costs and acid losses. 

Overall line features:

  • Comprehensive package and complete in-house design (mechanical, electrical, process)
  • Laser welder
  • Compact scale breaker
  • Turret-type side trimmer with flying width adjustment and edge monitoring
  • Trimmed scrap chopper, baller or bailer
  • Coil clamp opener
  • Fish tail detector for end crop 

Process section features:

  • High pickling efficiency (i Box or turbulent (jet) flat tank design)
  • Side-jet pickling action on the edge areas where the scale layer is thickest
  • Acid concentration control system
  • Perfectly sealed pickling tanks
  • Pickling at moderate temperature
  • New anti-stain rinse system
  • Polypropylene pickling tank option

    

Fig.1- Process circulation system |  Fig.2- Scale-Breaker / TL plunger-type bridles  |  Fig.3-  Coil preparation station  

Modernization

Primetals Technologies has vast experience in upgrading and modernization of processing lines. With a systematic approach, we work closely with our customers to develop a tailored modernization concept based on their individual needs taking all boundary conditions fully into account. The solution may be purely electrical, automated, mechanical or a combination. Based on the selected concept, the modernization can be carried out in several steps or during a plant shutdown. Primetals Technologies’ experience minimizes downtimes and ensures a fast start-up and top quality.

Laser welder

Primetals Technologies is proud to introduce into the market the state of the art heavy-gauge laser welder performing welding and cutting using asolid laser source. This heavy laser welder, called LW21H, is mainly targetting continuous pickling lines and tandem cold mills. Easy and low maintenance thanks to beam transmission via fiber optic cable making the troublesoom mirror reflected transmission are past history. Repeatable and constant cutting performance and high level of availability are achieved thanks to the choice of laser cutting. The other advantage of the latter is the compactness of the machine which enables an easy installation in existing lines with minimum field work.

High-capacity/tension scale breakers

The Primetals Technologies range of scale breaker machines starts from 35 tons tension capacity up to 100 tons. The related bridle roll drive systems configuration available are from the full electrical version (individual drive per roll), or the hybrid (the two most powerful rolls connected to a differential gear box, the other rolls having their own individual electrodrive), or the full mechanical configuration which connects all bridle rolls through several mechanical gear boxes. The stand configuration, wet or dry, includes two sets of two leveling units and an anti-crossbow unit, a dust collection system.

Hot skin pass mill

Our solution range encompasses skin-pass mills that cover all applications. With rolling force capacities ranging from 500 to 1,800 tons, skin-pass mill stands can be of two-high or four-high or six-high design, thus providing a best-in-class solution, whatever your application.

PropertyMon® –  Inline Mechanical Properties Measurement System

With Primetals Technologies inline and real time measuring system for pickling lines, steel producers can not only determine mechanical properties (tensile and yield strength) but also steel magnetic behaviour in a non destructive way. The specific sensor head design and associated innovative signal processing ensure highest results guarantees. PropertyMon offers a continuous and full coil length measurement and informs of any process deviations. Customer claims are thus significantly reduced.

Turret-type side trimmer with flying width adjustment and edge monitoring

Primetals Technologies innovative side trimmers dedicated to hot rolled application are called ST21H. Coming in turret or single head type, these machines can also feature options such as the Dynamic Width Adjustment (DWA) and/or the EdgeMon system. Our single-stand or turret or dual shifting scrap choppers SC21 are designed and manufactured to ensure the highest quality cutting and strongest availability. The pertinent choice of drum diameter and number of knives ensures the longest running time available in the market. Close association of side trimmer and SC21 scrap chopper is a guarantee for a best scrap disposal and lowest cobble ratio.

SIAS®

SIAS detects and identifies critical defects, for deep-drawing applications such as fine slivers, holes or scratches, as well as coating defects. The tiniest defects such as arc spots, may be detected even at maximum speed. SIAS® picks up all major surface defects early in pickling lines before the value adding processes. It provides warnings on pickling issues. A result of SIAS® is that the pickling speed can be optimized. On coupled pickling line-tandem mills, additional benefits can be expected from an early detection of defects right before cold rolling: the potentially harmful defects are reported to the mill operator who can take action (slow down or open stands), eliminating defects-induced strip breaks. Inspection speeds are ranged easily up to 1,200 mpm for hot mill applications.

TCO® – Total Cost Optimizer

The TCOptimizer offers the means to secure the production by keeping an eye on all the signals of the whole metallurgical route (from casting to downstream process) and triggering just-in-time alarms against performance degradation regarding equipment conditions, process and product quality. It enables an automatic process follow up, a direct product quality estimation thanks to embedded metallurgical models and just in time alarms for immediate actions to reach final quality requirements. TCOptimizer helps you also to better control your consummables in order to reduce costs.

Condition monitoring system

With the inline measuring system for pickling lines, steel producers can determine mechanical properties (tensile and yield strength) in a non-destructive way. The process can be optimized effectively and quality can be guaranteed. In comparison to time-consuming destructive testing, PropertyMon continuously inspects the product, informs of any process deviations and avoids customer claims. Defects in the strip are identified through continuous monitoring, not only at the beginning or end of strip. Comprehensive quality documentation makes it possible for plant operators to influence the processes and thus improve the production setup.

    

Fig.1- Heavy-gauge laser welder LW21H  |  Fig.2- Light scale breaker SB21L on a push pull pickling line  |  Fig.3 Heavy side trimmer ST21H

Complete process control at every level

The efficient and uninterrupted production of high-quality value-added products in strip-processing lines can only be assured by the application of advanced automation and process-control systems. This is particularly true for seamlessly linked processing lines where the varying speeds of the individual plant facilities have to be optimized to ensure best product quality and maximum output. 

Our portfolio of solutions includes the following systems and models 

  • The Advanced Pickling Set-Point Model (APM) for uniform pickling
  • The Automatic Strip-Quality Detection System to gather and classify all quality data
  • The Steel Quality Manager to document quality of discrete strip segments
  • Adaptive Elongation Control to achieve closest elongation tolerances
  • DynaWipe for fully automatic zinc thickness control
  • Closed-Loop Galvannealing Process Control to control the iron content in galvannealed coatings
  • And Fully Automatic Pickling Liquor Analysis and Control (FAPLAC) to ensure optimal pickling results

Your benefits are:

  • Reproducible and consistently high product quality
  • Higher product yields and output
  • Full transparency of all process and quality-relevant data
  • Reduced maintenance with automatic diagnostic systems
  • Process simulation and thorough pretesting of entire automation system
  • Fast line start-up  

Lifecycle services maximize the productivity of your plants and assure their value over the long term

Integrated Plants & Solutions for pickling lines - Experience that Matters

Please follow the corresponding links to learn more about our competences:

    

Reference Story

Reconstruction & modernization of the pickling line after fire damage

Customer
Tata Steel IjmuIden BV, IjmuIden, The Netherlands
Type of Line
Pickling Line
Our solutions
Tata Steel’s PL22 pickling line was damaged by a fire requiring a huge revamp to recover the line production as quickly as possible. 
The challenging project was based on a full, brand-new process section with Primetals Technologies pickling technology, and also by integrating Primetals Technologies key equipment to yield better production new steel grades) and line availability. The production of 1.2 million tons per year before the line was damaged was targeted to increase to 1.6 million tons per year.