Inline Silicon Deposition in Pickling Circuits for Clog Prevention
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Solution Overview
Problem
Pickling plants with high silicon content steel strips face frequent clogging and maintenance issues due to the formation of insoluble silicon compounds, which existing methods struggle to address efficiently, leading to reduced availability and increased energy consumption.
Innovation Solution
A device with a flocculation and deposition system integrated into the pickling circuit, utilizing a circulation pump and heating device to maintain process temperature, and a lamella separating device for efficient deposition of undissolved silicon compounds directly from the main volume flow, eliminating the need for separate cooling and reheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pickling methods are used for high silicon content steel strips, then pickling process can be performed, but insoluble silicon compounds accumulate and cause frequent clogging and maintenance issues
Solution Approach 1:
The patent implements continuous inline deposition of silicon compounds directly in the pickling circuit, eliminating interruptions for maintenance. The circulation pump continuously circulates pickling fluid through the deposition device, ensuring uninterrupted pickling operation while continuously removing silicon compounds.
Solution Approach 2:
The patent extracts undissolved silicon compounds from the pickling fluid using a deposition device with a lamella separating element. This extraction happens continuously within the pickling circuit, removing the harmful accumulations before they can cause clogging and maintain plant availability.
2Reliability
If existing deposition methods are used, then silicon compounds can be removed, but separate cooling and reheating are required increasing energy consumption
Solution Approach 1:
The patent merges the deposition process with the existing pickling circuit circulation system. The circulation pump that already exists for pickling operations is used to drive the deposition process, eliminating the need for separate cooling and reheating systems. The heating device integrated into the pressure line maintains process temperature without additional energy-intensive cooling and reheating cycles.
Solution Approach 2:
The circulation pump serves dual functions: it circulates pickling fluid for the pickling process and simultaneously drives the deposition of silicon compounds. The heating device also serves dual purposes by maintaining pickling fluid temperature and preventing cooling during the deposition process, thereby reducing overall energy consumption.
3Reliability
If microfiltration is used to remove silicon compounds, then separation can be achieved, but membranes have short service lives due to process conditions
Solution Approach 1:
The patent replaces the mechanical membrane filtration system with a gravitational deposition system using a lamella separating element. This substitution eliminates the membrane component that suffers from short service life in harsh pickling conditions, while maintaining effective separation of silicon compounds through gravity-driven settling in the lamella channels.
4Ease of operation
If washing back with lye is used to remove residues, then cleaning can be achieved, but additional substances and expensive apparatuses are required
Solution Approach 1:
The patent enables the pickling fluid to clean itself by continuously circulating through the deposition device where silicon compounds are automatically deposited and removed. This self-cleaning mechanism eliminates the need for external washing back operations with lye, reducing both chemical consumption and apparatus requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables continuous inline operation with improved pickling fluid quality, reduced maintenance intervals, and lower energy consumption by effectively depositing undissolved silicon compounds from the entire main volume flow, enhancing the pickling plant's availability and operational efficiency.
Implementation Method 1
a circulation pump having a maximum pump capacity of from 500 to 600 cubic meters per hour for circulating a main volume flow of pickling fluid from the pickling tank through the return line into the circuit tank and via the pressure line back into the pickling tank
Implementation Method 2
a heating device arranged in the pressure line for heating the main volume flow passed through the pressure line to a process temperature Tp prevailing in the pickling tank
Implementation Method 3
at least one flocculation aid is introduced into the main volume flow by means of a flocculation device having one or more mixing zone containers
Implementation Method 4
undissolved silicon compounds are deposited directly from the main volume flow by means of a deposition device arranged in the circuit tank
Data Source
AI summary
A device and a method for depositing undissolved materials, in particular undissolved silicon compounds, from a pickling fluid in a pickling plant. A pickling circuit of the pickling plant has a pickling tank for pickling metal strips, a return line between the pickling tank and a circuit tank, a circulation pump for circulating a main volume flow of pickling fluid from the pickling tank, and a heating device arranged in a pressure line between the circuit tank and the pickling tank. The device includes a flocculation device for introducing at least one flocculant into the main volume flow, and a deposition device in the circuit tank and preferably designed as an inclined clarifying device, for the sedimentation of undissolved materials directly from the main volume flow. When pickling silicon-containing steel strips (electrical steel strips), an at least two-stage flocculation can be carried out using two or more mixing zone containers.