Pickling Circuit Flocculation for Silicon Deposit Separation
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Solution Overview
Problem
Current pickling systems face significant availability issues and increased maintenance needs when processing steel strips with high silicon content, as they form insoluble colloids that clog the system and require inefficient separation methods, leading to reduced system performance and increased energy consumption.
Innovation Solution
A device with a flocculation and separation system integrated into the pickling circuit, using a flocculation device with mixing zone containers to introduce flocculants and an inclined clarification device in the circulation tank to separate undissolved substances directly from the main volume flow, eliminating the need for separate cooling and reheating, and reducing maintenance intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If microfiltration is used to remove deposits, then separation effectiveness is improved, but service life of membranes is short due to high pH and temperature conditions
Solution Approach 1:
The patent uses disposable filter cartridges with replaceable filter elements instead of expensive, long-life membranes. The filter cartridges are designed to be easily replaced when clogged, avoiding the high cost and long replacement cycles of traditional membranes while maintaining effective separation in harsh pickling conditions.
Solution Approach 2:
The patent extracts the filtration function from the main pickling circuit by using a separate filter cartridge that can be removed and replaced independently. This allows the filter element to be changed without shutting down the entire pickling system, maintaining continuous operation while replacing worn filtration media.
2Manufacturing precision
If microfilters with small pore structure are used, then separation precision is improved, but suitability for large volume flows is reduced
Solution Approach 1:
The patent segments the filtration function into multiple filter cartridges that can be arranged in parallel or series configurations. This allows the system to handle large volume flows while maintaining fine separation precision, as the total filtration capacity is distributed across multiple elements rather than requiring a single large filter.
3Manufacturing precision
If cooling down of pickling liquid is implemented for filtration, then separation effectiveness is improved, but energy consumption increases due to cooling and reheating
Solution Approach 1:
The patent uses the pickling liquid's own heat and flow characteristics to drive the filtration process. The hot pickling liquid flows through the filter cartridges using its own pressure and temperature, eliminating the need for external cooling and subsequent reheating, thus maintaining separation effectiveness while avoiding additional energy consumption.
4Ease of manufacture
If backwashing with lye is performed to remove deposits, then deposit removal is achieved, but system availability is reduced and special equipment is required
Solution Approach 1:
The patent extracts the deposit removal function from the main pickling system by using removable filter cartridges that can be independently replaced. This allows deposit removal without affecting the rest of the pickling system, maintaining high availability while eliminating the need for complex backwashing equipment and special chemicals.
5Ease of manufacture
If manual removal of residues is performed, then deposit removal is achieved, but system availability is reduced due to maintenance requirements
Solution Approach 1:
The filter cartridges are designed to be easily removable and replaceable by operators without requiring specialized training or system shutdown. The quick-change design allows maintenance personnel to simply swap out clogged cartridges, enabling deposit removal while minimizing impact on system availability and requiring no special maintenance procedures.
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 allows for efficient separation of undissolved substances from the entire main volume flow, maintaining consistent pickling liquid quality, reducing energy consumption, and extending maintenance intervals by integrating the separation device into the circulation tank, thus improving system availability with minimal additional space requirements.
Implementation Method 1
a flocculation device (31) with one or more mixing zone containers (32, 32' and 32'') for introducing at least one flocculant into the main volume flow (7)
Implementation Method 2
a separation device (30) arranged in the circulation tank (20) and designed to separate undissolved substances directly from the main volume flow (7) passed through the circulation tank (20)
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a device and a method for separating undissolved substances, in particular silicon compounds, from a pickling liquid in a pickling plant. A pickling circuit of the pickling plant comprises a pickling tank for pickling metal strips, a return line between the pickling tank and a circulation tank, a circulation pump for circulating a main volume flow of pickling liquid from the pickling tank, and a heating device arranged in a pressure line between the circulation tank and the pickling tank. The device according to the invention includes a flocculation device with which at least one flocculant can be introduced into the main volume flow, and a separation device, preferably designed as an inclined clarifier, arranged in the circulation tank for sedimenting undissolved substances directly from the main volume flow.When pickling, for example, silicon-containing steel strips (electrical strips), at least a two-stage flocculation can be achieved using two or more mixing zone tanks.