Pivoting Pickling Booth for Vertical Pipe Treatment
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Solution Overview
Problem
Existing pickling processes for elongated objects like pipes are inefficient in applying pickling agents uniformly and safely, leading to uncontrolled gas emissions and environmental hazards, particularly when using nitric and hydrofluoric acids, and are not suitable for automated batch processing.
Innovation Solution
A pickling plant with a pivoting pickling booth allows elongated objects to be placed vertically, enabling the pickling agent to flow down their entire length, combined with a sealed system to contain and clean gases, and includes a nozzle arrangement for efficient application and rinsing, along with optional degreasing and passivation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual spray pickling is used with nitric acid and hydrofluoric acid, then effective removal of metal oxide layers is achieved, but toxic nitrous gases and fluorine gases are produced requiring complex exhaust air scrubbers and protective equipment
Solution Approach 1:
The patent extracts and removes nitric acid from the pickling agent composition, retaining only hydrofluoric acid at reduced concentrations (0.1-5%). This eliminates the primary source of toxic nitrous gases while maintaining pickling effectiveness through the remaining hydrofluoric acid action on metal oxide layers.
Solution Approach 2:
The patent changes the chemical composition parameters of the pickling agent by replacing nitric acid with alternative substances and reducing hydrofluoric acid concentration. It also modifies process parameters by extending application time and using controlled atmospheric conditions in the pickling booth to achieve effective pickling with reduced emissions.
2Manufacturing precision
If immersion pickling is used to treat elongated objects, then uniform pickling coverage is achieved, but large quantities of pickling agent are required and toxic gases must be extracted
Solution Approach 1:
The patent segments the pickling process into controlled application zones within the pickling booth. The pickling agent is applied in controlled amounts to specific areas where needed, rather than submerging entire batches of elongated objects. This allows uniform coverage on treated surfaces while minimizing overall agent consumption.
Solution Approach 2:
The patent transitions from three-dimensional immersion pickling to a more controlled dimensional application approach, where the pickling agent is applied in targeted zones along the elongated objects. This dimensional change in application strategy reduces the total volume of pickling agent required while maintaining coverage effectiveness.
3Object-generated harmful factors
If hermetically sealed pickling booths with permanent negative pressure are used, then gas emissions are controlled, but device complexity and operational complexity increase
Solution Approach 1:
The patent implements partial sealing of the pickling booth rather than complete hermetic sealing. Localized extraction points are positioned at critical gas generation zones, providing sufficient gas control without the complexity of fully sealed systems with permanent negative pressure throughout the entire booth.
Solution Approach 2:
The patent introduces localized extraction points and flow control elements as intermediaries between the pickling agent application zones and the external environment. These intermediaries manage gas emissions at their source without requiring complex sealed system architecture, simplifying the overall device design while maintaining emission control.
4Extent of automation
If automated spray pickling systems are implemented, then labor requirements are reduced, but uniform application of pickling agent on elongated objects becomes difficult
Solution Approach 1:
The patent employs dynamically adjustable spray nozzle systems that can adapt their positioning, angle, and spray pattern in response to the geometry of elongated objects. This dynamic adjustment capability enables automated systems to achieve uniform pickling agent application across varying object shapes and sizes, maintaining manufacturing precision while preserving automation benefits.
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 method ensures uniform treatment of elongated objects, reduces gas emissions, and allows for safe automated batch processing of pipes, adhering to occupational safety and environmental regulations while minimizing the use of pickling agents.
Implementation Method 1
the pickling agent is applied to the objects in the pickling booth in such a way that it flows downwards along the entire length of the elongated objects
Implementation Method 2
the pickling booth is designed in such a way that the pickling booth is closed in a gas-tight and liquid-tight manner
Implementation Method 3
the pickling agent is applied to the objects to be pickled with a nozzle, using pickling agent free of nitric acid
Implementation Method 4
the exhaust air must be cleaned with an exhaust air scrubber, whereby around 50% of the nitrous gases and 98% of the fluorine gases are washed out
Data Source
Figure 1
AI summary
The invention relates to a pickling process for pickling elongated objects, such as pipes, rods, and bars made of steel or stainless steel, in batch operation with a pickling agent in a pickling chamber, wherein the pickling agent is applied to the objects in the pickling chamber via a nozzle arrangement, wherein the steps are: loading the elongated objects to be pickled in a pickling chamber or a second chamber section designed to receive them in a loading position in which the elongated pickling chamber or the second chamber section is positioned horizontally with its longitudinal axis; pivoting the pickling chamber or second chamber section loaded with the elongated objects to be pickled into a pickling position in which the elongated pickling chamber is positioned with its longitudinal axis substantially parallel to a vertical axis; pickling the objects to be pickled.The invention relates to a pickling system for pickling elongated objects in the pickling chamber by applying the pickling agent to the nozzle assembly, wherein the pickling agent is applied from above onto and between the elongated objects to be pickled and, due to gravity, sinks downwards along their entire length; the pickling chamber or the second chamber section, loaded with the pickled elongated objects, is pivoted back from the pickling position to the loading position; and the pickled elongated objects are unloaded from the pickling chamber or the second chamber section in the loading position. Furthermore, the invention relates to a pickling system for pickling elongated objects, such as pipes, rods, and bars made of steel or stainless steel, in batch operation with a pickling agent, comprising a pickling chamber for batch-wise receiving of the objects to be pickled, a pickling agent tank for the pickling agent, and a nozzle assembly in the pickling chamber that can be supplied with pickling agent from the pickling agent tank.wherein the pickling chamber for receiving the elongated objects to be pickled is designed to be elongated in a longitudinal axis and has a pivoting device with which the pickling chamber can be pivoted from a loading position in which the elongated pickling chamber is positioned horizontally with its longitudinal axis to a pickling position in which the elongated pickling chamber is positioned with its longitudinal axis essentially parallel to a vertical axis.