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The wire rod online pickling line is a continuous automated production line designed to efficiently remove surface scale and corrosion from wire rods (coils). It primarily adopts tunnel or circular track configurations, with C-shaped hooks/RGV trolleys serving as core transfer units. Through processes including degreasing, pickling, washing, neutralization, passivation, and drying, combined with PLC-controlled automation and an acid solution recycling system, it achieves efficient, environmentally friendly, and stable surface treatment. This equipment is suitable for wire rods made of carbon steel, stainless steel, and other steel grades (diameter 5-40mm, inner diameter 850-1250mm, weight ≤2.0t). A single line can produce 100,000-125,000 tons annually, with a processing speed of 3-5 coils per hour and a pickling cycle of 24-30 minutes per coil. It meets the surface quality requirements for subsequent precision machining processes such as drawing and cold heading.
- Material handling trolley/RGV track car: Capable of transporting coil coils (1.8-2.0t per unit), automatically positioning and conveying them to the processing line entrance with ±2mm track accuracy and 0.5-1m/s speed. Equipped with automatic weighing and diameter measurement functions, compatible with coil coils with outer diameters of 850-1250mm.
- Type C Hook/Mechanical Arm: Core hoisting device, designed to transport coils within tunnels. Constructed from acid-resistant stainless steel, the hook body has a load capacity of ≥2.5t and is equipped with anti-disengagement devices. It works in conjunction with lifting/translation mechanisms to achieve precise slot entry/exit, with repeat positioning accuracy of ±5mm.
- Stripping and Scale Removal Device (Optional): Mechanical stripping machine + steel wire ball scrubbing, used for pre-scaling of high oxide scale layer wire rods to reduce pickling load; for stainless steel wire rods, optional salt bath furnace (450-500°C) can be employed to crack the oxide scale through thermal expansion, thereby improving pickling efficiency.
- De-oiling tank: Material: PP/FRP (thickness ≥20mm), capacity: 10-15m³, temperature: 40-50℃, NaOH concentration: 3-5%, ultrasonic/spray agitation, treatment time: 3-5min, removes oil stains from wire rod surface to prevent contamination of pickling process.
- Pickling Tank Group (Three in Use, One Standby): Four tanks arranged in series with countercurrent flow, constructed with PP plates (≥20mm) and single-tank capacity of 15-20m³. Operating at 40-50℃ with controlled hydrochloric acid concentration gradient (12%-20%), equipped with vibration mechanism and high-turbulence nozzles. The acid circulation rate ranges from 50-80m³/h, while PLC automatically regulates temperature, replenishes liquid, and discharges slag. The pickling cycle lasts 24-30 minutes. -Pre-washing Tank (Tanks 1-2): Recycle acid (HCl 12%-15%) to remove most scale. When Fe²⁺ reaches saturation, FeCl₂·4H₂O crystals precipitate, requiring periodic cleaning. -Main Washing Tank (Tanks 3-4): Use fresh acid (HCl 18%-20%) to completely remove residual scale. The system automatically replenishes acid, with overflow directed to the preceding tank for cascaded acid utilization.
- Auxiliary tank material and configuration: The tank is constructed with PP/FRP + steel skeleton, lined with acid-resistant rubber, equipped with an external heating system (steam/electric heating), level gauge, pH/concentration online monitor, automatic acid replenishment/drainage, with a normal service life of ≥5 years.
- Multi-stage washing tank: 3-4 stages in series, counter-current rinsing, operating temperature from ambient to-60°C (hot water tank). Stages 1-2 are for recycled water washing, stage 3 is high-pressure water washing (pressure 10-15 MPa, flow rate 50-100 L/min), and stage 4 is pure water rinsing to remove surface acid solution, with conductivity ≤50 μS/cm.
- Neutralization tank: Na₂CO₃ concentration 2%-5%, temperature 40-50°C, treatment time 2-3 minutes, neutralize residual acid, pH controlled at 7-8 to prevent subsequent rusting.
- Passivation tank (stainless steel-specific): Nitric acid + hydrofluoric acid mixed solution (HNO₃ 8%-12%, HF 0.5%-1%), temperature 40-50°C, treatment time 3-5 minutes, forming a dense passivation film to enhance corrosion resistance; carbon steel may optionally undergo phosphating/soaping tank treatment to provide a lubricating layer for drawing.
- Hot air drying tunnel: operating temperature 80-120℃, air velocity 2-3m/s, drying duration 5-8min, with coil surface moisture content ≤0.1% to prevent post-drying corrosion.
- Material handling cart and baling machine: Receives dried coils, performs automatic weighing and diameter measurement, then bales them with a tension of 50-80kN, suitable for subsequent storage and transportation.
- Acid circulation pump set: Acid-resistant fluoroplastic pump with a flow rate of 50-100 m³/h and a head of 15-20 m, providing high turbulence circulation for the pickling tank to enhance pickling uniformity; equipped with a filtration device to remove suspended impurities from the acid solution.
- Acid mist absorption tower: Combines spray scrubbing and activated carbon adsorption, with a treatment capacity of 10,000-20,000 m³/h. The acid mist emission concentration is ≤10 mg/m³, meeting the emission standards of GB 26452-2011.
- Acid regeneration unit (core environmental protection equipment): Hydrochloric acid regeneration employs roasting method to recover FeCl₂ crystals, with regeneration acid concentration ≥18% and recovery rate ≥90%; acidic wastewater undergoes neutralization + membrane filtration treatment to meet discharge standards (pH 6-9, SS≤50mg/L).
- PLC control system: Siemens S7-1500 series, coordinating all line equipment with automatic adjustments for pickling time, temperature, and acid concentration, achieving ≤1s response time and ≥99% fault alarm accuracy.
- Online monitoring system: real-time monitoring of acid concentration (HCl/mixed acid), temperature, liquid level, pH, and conductivity, with automatic data recording, supporting remote monitoring and historical data traceability.
- Safety interlock system: Overfill/overtemperature alarms for tank compartments, acid mist leakage triggers ventilation, and emergency shutdown upon personnel intrusion, ensuring production safety.
|Parameter Category|Specific Parameter|Control Requirements| |Material Compatibility|Carbon steel/stainless steel wire rod|Pre-washing with hydrochloric acid (12%-20% for carbon steel, mixed acid HNO₃+HF for stainless steel)| |Acidizing Temperature|40-50°C in hydrochloric acid tank, 45-55°C in mixed acid tank|Temperature fluctuation ≤±2°C, automatic temperature control via external heating system| |Treatment Time|Total cycle 24-30min|Acidizing 15-20min, water washing/neutralization/passivation 10-15min| |Acid Solution Concentration|12%-20% HCl in hydrochloric acid tank, 8%-12% HNO₃ in mixed acid tank|PLC-controlled acid replenishment with counter-flow circulation, reducing acid consumption by 30%| |Water Quality Requirements|Rinse water conductivity ≤50μS/cm|Multi-stage filtration + ion exchange to prevent surface salt residue|
- Production capacity: The single-hook system for 100,000-ton annual capacity pick-and-roll tunneling, and the dual-hook parallel system for 125,000-ton capacity, with a processing speed of 3-5 coils per hour, compatible with coils of 850-1250mm outer diameter.
- Material selection: The tank body shall preferably be made of PP board (≥20mm) or FRP, with C-type hooks constructed from 316L stainless steel and pipelines using PVDF, ensuring an acid resistance lifespan of ≥5 years.
- Environmental compliance: Must include an acid mist absorption tower and acid regeneration system, with hydrochloric acid regeneration achieving a recovery rate ≥90%. Wastewater must meet discharge standards after treatment, complying with new environmental regulations.
- Automation level: Recommended configuration: PLC + touch screen control with online concentration/temperature monitoring, reducing manual intervention and improving stability, achieving a failure shutdown rate ≤1%/month.
- Daily maintenance: Check acid concentration, liquid level, and nozzle patency daily; clean acid tank sediment and filtration devices weekly; inspect C-type hook/track car wear and replace seals monthly; conduct annual corrosion testing on tanks/pipelines and repair damaged areas.
- Safety protection: Operators shall wear acid-resistant gloves, face shields, and protective clothing; acid mist leakage alarms and emergency sprinkler systems shall be installed; regular emergency drills shall be conducted to prevent acid burns and acid mist poisoning.
- Core Advantages: Continuous automated operation with acid pickling uniformity ±5%, reducing acid consumption by 30%-40% and doubling processing efficiency; countercurrent acid pickling + acid solution regeneration for green production; compatible with multiple steel grades, enabling rapid process parameter switching to meet diverse wire rod surface treatment requirements.
- Application scenarios: Surface treatment of carbon steel/stainless steel wire rods before drawing, deoxidation of spring steel/bearing steel wire rods, and pickling/passivation of steel cord/welding wire wire rods. Widely used in wire rod processing plants, metal product factories, and automotive parts industries.
The wire rod online pickling line is a continuous automated production line designed to efficiently remove surface scale and corrosion from wire rods (coils). It primarily adopts tunnel or circular track configurations, with C-shaped hooks/RGV trolleys serving as core transfer units. Through processes including degreasing, pickling, washing, neutralization, passivation, and drying, combined with PLC-controlled automation and an acid solution recycling system, it achieves efficient, environmentally friendly, and stable surface treatment. This equipment is suitable for wire rods made of carbon steel, stainless steel, and other steel grades (diameter 5-40mm, inner diameter 850-1250mm, weight ≤2.0t). A single line can produce 100,000-125,000 tons annually, with a processing speed of 3-5 coils per hour and a pickling cycle of 24-30 minutes per coil. It meets the surface quality requirements for subsequent precision machining processes such as drawing and cold heading.
- Material handling trolley/RGV track car: Capable of transporting coil coils (1.8-2.0t per unit), automatically positioning and conveying them to the processing line entrance with ±2mm track accuracy and 0.5-1m/s speed. Equipped with automatic weighing and diameter measurement functions, compatible with coil coils with outer diameters of 850-1250mm.
- Type C Hook/Mechanical Arm: Core hoisting device, designed to transport coils within tunnels. Constructed from acid-resistant stainless steel, the hook body has a load capacity of ≥2.5t and is equipped with anti-disengagement devices. It works in conjunction with lifting/translation mechanisms to achieve precise slot entry/exit, with repeat positioning accuracy of ±5mm.
- Stripping and Scale Removal Device (Optional): Mechanical stripping machine + steel wire ball scrubbing, used for pre-scaling of high oxide scale layer wire rods to reduce pickling load; for stainless steel wire rods, optional salt bath furnace (450-500°C) can be employed to crack the oxide scale through thermal expansion, thereby improving pickling efficiency.
- De-oiling tank: Material: PP/FRP (thickness ≥20mm), capacity: 10-15m³, temperature: 40-50℃, NaOH concentration: 3-5%, ultrasonic/spray agitation, treatment time: 3-5min, removes oil stains from wire rod surface to prevent contamination of pickling process.
- Pickling Tank Group (Three in Use, One Standby): Four tanks arranged in series with countercurrent flow, constructed with PP plates (≥20mm) and single-tank capacity of 15-20m³. Operating at 40-50℃ with controlled hydrochloric acid concentration gradient (12%-20%), equipped with vibration mechanism and high-turbulence nozzles. The acid circulation rate ranges from 50-80m³/h, while PLC automatically regulates temperature, replenishes liquid, and discharges slag. The pickling cycle lasts 24-30 minutes. -Pre-washing Tank (Tanks 1-2): Recycle acid (HCl 12%-15%) to remove most scale. When Fe²⁺ reaches saturation, FeCl₂·4H₂O crystals precipitate, requiring periodic cleaning. -Main Washing Tank (Tanks 3-4): Use fresh acid (HCl 18%-20%) to completely remove residual scale. The system automatically replenishes acid, with overflow directed to the preceding tank for cascaded acid utilization.
- Auxiliary tank material and configuration: The tank is constructed with PP/FRP + steel skeleton, lined with acid-resistant rubber, equipped with an external heating system (steam/electric heating), level gauge, pH/concentration online monitor, automatic acid replenishment/drainage, with a normal service life of ≥5 years.
- Multi-stage washing tank: 3-4 stages in series, counter-current rinsing, operating temperature from ambient to-60°C (hot water tank). Stages 1-2 are for recycled water washing, stage 3 is high-pressure water washing (pressure 10-15 MPa, flow rate 50-100 L/min), and stage 4 is pure water rinsing to remove surface acid solution, with conductivity ≤50 μS/cm.
- Neutralization tank: Na₂CO₃ concentration 2%-5%, temperature 40-50°C, treatment time 2-3 minutes, neutralize residual acid, pH controlled at 7-8 to prevent subsequent rusting.
- Passivation tank (stainless steel-specific): Nitric acid + hydrofluoric acid mixed solution (HNO₃ 8%-12%, HF 0.5%-1%), temperature 40-50°C, treatment time 3-5 minutes, forming a dense passivation film to enhance corrosion resistance; carbon steel may optionally undergo phosphating/soaping tank treatment to provide a lubricating layer for drawing.
- Hot air drying tunnel: operating temperature 80-120℃, air velocity 2-3m/s, drying duration 5-8min, with coil surface moisture content ≤0.1% to prevent post-drying corrosion.
- Material handling cart and baling machine: Receives dried coils, performs automatic weighing and diameter measurement, then bales them with a tension of 50-80kN, suitable for subsequent storage and transportation.
- Acid circulation pump set: Acid-resistant fluoroplastic pump with a flow rate of 50-100 m³/h and a head of 15-20 m, providing high turbulence circulation for the pickling tank to enhance pickling uniformity; equipped with a filtration device to remove suspended impurities from the acid solution.
- Acid mist absorption tower: Combines spray scrubbing and activated carbon adsorption, with a treatment capacity of 10,000-20,000 m³/h. The acid mist emission concentration is ≤10 mg/m³, meeting the emission standards of GB 26452-2011.
- Acid regeneration unit (core environmental protection equipment): Hydrochloric acid regeneration employs roasting method to recover FeCl₂ crystals, with regeneration acid concentration ≥18% and recovery rate ≥90%; acidic wastewater undergoes neutralization + membrane filtration treatment to meet discharge standards (pH 6-9, SS≤50mg/L).
- PLC control system: Siemens S7-1500 series, coordinating all line equipment with automatic adjustments for pickling time, temperature, and acid concentration, achieving ≤1s response time and ≥99% fault alarm accuracy.
- Online monitoring system: real-time monitoring of acid concentration (HCl/mixed acid), temperature, liquid level, pH, and conductivity, with automatic data recording, supporting remote monitoring and historical data traceability.
- Safety interlock system: Overfill/overtemperature alarms for tank compartments, acid mist leakage triggers ventilation, and emergency shutdown upon personnel intrusion, ensuring production safety.
|Parameter Category|Specific Parameter|Control Requirements| |Material Compatibility|Carbon steel/stainless steel wire rod|Pre-washing with hydrochloric acid (12%-20% for carbon steel, mixed acid HNO₃+HF for stainless steel)| |Acidizing Temperature|40-50°C in hydrochloric acid tank, 45-55°C in mixed acid tank|Temperature fluctuation ≤±2°C, automatic temperature control via external heating system| |Treatment Time|Total cycle 24-30min|Acidizing 15-20min, water washing/neutralization/passivation 10-15min| |Acid Solution Concentration|12%-20% HCl in hydrochloric acid tank, 8%-12% HNO₃ in mixed acid tank|PLC-controlled acid replenishment with counter-flow circulation, reducing acid consumption by 30%| |Water Quality Requirements|Rinse water conductivity ≤50μS/cm|Multi-stage filtration + ion exchange to prevent surface salt residue|
- Production capacity: The single-hook system for 100,000-ton annual capacity pick-and-roll tunneling, and the dual-hook parallel system for 125,000-ton capacity, with a processing speed of 3-5 coils per hour, compatible with coils of 850-1250mm outer diameter.
- Material selection: The tank body shall preferably be made of PP board (≥20mm) or FRP, with C-type hooks constructed from 316L stainless steel and pipelines using PVDF, ensuring an acid resistance lifespan of ≥5 years.
- Environmental compliance: Must include an acid mist absorption tower and acid regeneration system, with hydrochloric acid regeneration achieving a recovery rate ≥90%. Wastewater must meet discharge standards after treatment, complying with new environmental regulations.
- Automation level: Recommended configuration: PLC + touch screen control with online concentration/temperature monitoring, reducing manual intervention and improving stability, achieving a failure shutdown rate ≤1%/month.
- Daily maintenance: Check acid concentration, liquid level, and nozzle patency daily; clean acid tank sediment and filtration devices weekly; inspect C-type hook/track car wear and replace seals monthly; conduct annual corrosion testing on tanks/pipelines and repair damaged areas.
- Safety protection: Operators shall wear acid-resistant gloves, face shields, and protective clothing; acid mist leakage alarms and emergency sprinkler systems shall be installed; regular emergency drills shall be conducted to prevent acid burns and acid mist poisoning.
- Core Advantages: Continuous automated operation with acid pickling uniformity ±5%, reducing acid consumption by 30%-40% and doubling processing efficiency; countercurrent acid pickling + acid solution regeneration for green production; compatible with multiple steel grades, enabling rapid process parameter switching to meet diverse wire rod surface treatment requirements.
- Application scenarios: Surface treatment of carbon steel/stainless steel wire rods before drawing, deoxidation of spring steel/bearing steel wire rods, and pickling/passivation of steel cord/welding wire wire rods. Widely used in wire rod processing plants, metal product factories, and automotive parts industries.
