High pressure water jet treatment of a wire coil

HiJetRod Pilot – Resource-efficient hydromechanical descaling system for wire coils

Initial situation

  • Descaling of stainless steel wire requires several pickling steps with high consumption of chemicals and long treatment time.
  • Stainless steel grades that are difficult to descale have to be treated with up to 100 % of double passages of the wire coils through the pickling line.
  • In the forerunner project HiJetRod a process for hydromechanical descaling of wire coils has been developed.

Project objectives

  • Scale-free surface of wires after a single passage through the pickling line, including high-alloyed steel grades
  • Avoiding double passages through the pickling line and increasing production capacity
  • Reduction of water and energy consumption of hydromechanical descaling
  • Demonstration of hydromechnical descaling in pilot tests
  • Quantification of process benefits (reduction of treatment time and acid consumption)

Innovative process approaches

  • Use of new pulsating nozzles for efficient descaling
  • New concept for coil rotation to minimize contact marks due to wire-wire contact
  • Pilot tests for determination of efficiency including life cycle assessment

Current results (as of 03/2018)

  • First pilot tests have shown the efficiency of hydromechanical descaling for 13 stainless steel grades.
  • In laboratory tests, pulsating nozzles have shown better descaling results than flat fan nozzles. However, for utilization in pilot installations their start-up behavior has to be improved.
  • Contact marks due to wire-wire contact can be minimized with a modified turning mandrel.
  • A representation of the descaling process has been set up with the program SIMBA# for development of a water recycling concept.

Outlook

  • Pilot tests for a wide range of stainless steel wire coils, determination of descaling efficiency, resource consumption and maintenance effort
  • Life cycle assessment for process evaluation

Applications and transferability of the hydromechanical descaling process

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