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

Presentations from the international workshop November 11, 2019

BFI-Workshop-Pickling-Solutions-Technology-2019-Information-Flyer

1-BFI Workshop-Presentation- Surface_treatment_by_pickling_(M_ Kozariszczuk)
2-BFI-Workshop-Presentation-Mechanical_Descaling_(M_Pohanka)
3-BFI-Workshop-Presentation_Pickling_bath_online_concentration_analysis_(M_Werner)
4-BFI-Workshop-Presentation-Operational_expierence_online_pickling_bath_analysis_(F_Kolinke)
5-BFI-Workshop-Presentation-Optimisation_of_pickling_process_by_model-based_simulation_(I_Gonzales)
6-BFI-Workshop-Presentation-Polymeric_Sensor_Coatings_(J_Engblom)
7-BFI-Workshop-Presentation-Operational_experience_for_the_recycling _of_process water_and_acids_(Steuler)
8-BFI-Workshop-Presentation-Pickling bath particle separation and atline analysis_(Scanacon)
9-BFI-Workshop-Presentation-Recovery_of_Acids_and_Metals_from_Pickling_Solution_(J_Koschikowski)
10-BFI-Workshop-Presentation-Recycling_valuable_components_(R_Wolters)

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