Pickling Facility Speed Control via Heat Transfer Measurement
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Solution Overview
Problem
The challenge in improving production efficiency of steel plates in continuous pickling processes is the inability to directly measure the progress of the pickling process, leading to lower set line speeds to ensure sufficient time for pickling, which limits production efficiency.
Innovation Solution
A pickling facility equipped with a measurement system to assess parameters correlated with the heat transfer coefficient between the acid solution and a reference surface, allowing for the adjustment of steel plate conveyance speed to optimize the pickling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the line speed is increased to improve production efficiency, then productivity improves, but the pickling process may become insufficient leading to poor scale removal
Solution Approach 1:
The patent implements a feedback mechanism by measuring the heat transfer coefficient between the acid solution and the steel plate, and using this measurement to adjust the line speed. The heat transfer coefficient serves as a real-time indicator of pickling progress, allowing the system to dynamically adjust conveyance speed based on actual process conditions rather than fixed predetermined speeds.
Solution Approach 2:
The patent changes the operational parameter from a fixed line speed to a variable line speed that is adjusted based on the measured heat transfer coefficient. By monitoring changes in the heat transfer coefficient during the pickling process, the system can determine when sufficient scale removal has occurred and adjust the line speed accordingly to optimize both productivity and pickling quality.
2Reliability
If a fixed low line speed is used to ensure sufficient pickling time, then pickling quality is maintained, but production efficiency decreases
Solution Approach 1:
The patent transitions from a static fixed line speed to a dynamic adjustable line speed that responds to real-time process conditions. The line speed is no longer a constant value but varies based on the measured heat transfer coefficient, allowing the system to optimize pickling quality while maximizing productivity by adjusting speed to match actual pickling progress.
Solution Approach 2:
The patent replaces the mechanical/time-based control system with a thermal/measurement-based control system. Instead of relying on predetermined time intervals or fixed mechanical conveyance speeds, the system uses thermal measurements of the heat transfer coefficient to control the pickling process, enabling more precise and adaptive process control.
3Reliability
If the line speed is set with allowance to ensure sufficient pickling time, then pickling process reliability is maintained, but loss of time occurs due to overly conservative speed setting
Solution Approach 1:
The feedback mechanism using heat transfer coefficient measurements eliminates the need for conservative time allowances. By providing real-time information about actual pickling progress, the system can determine the exact time needed for sufficient scale removal, removing the buffer time that was previously necessary to account for measurement uncertainty and process variability.
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 approach enables the determination of the pickling speed and progress state, allowing for appropriate setting of conveyance speed, thereby enhancing production efficiency of steel plates.
Implementation Method 1
measuring at least one parameter which has a correlation with a heat transfer coefficient between the acid solution and a reference surface disposed in the acid solution so as to face the steel plate
Data Source
AI summary
A pickling facility includes: a pickling tank for storing an acid solution; a conveyance part for continuously conveying a steel plate immersed in the acid solution; a measurement part for measuring at least one parameter which has a correlation with a heat transfer coefficient between the acid solution and a reference surface disposed in the acid solution so as to face the steel plate; and a conveyance speed decision part configured to decide a conveyance speed of the steel plate conveyed by the conveyance part, on the basis of a measurement result of the at least one parameter.