Wire Cleaning via Reused Acid Pickling Solution
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Solution Overview
Problem
Current wire rod cleaning methods using high-pressure water washing to remove smut after acid pickling result in excessive wastewater production, straining wastewater treatment systems and leading to uneven coating and rust formation.
Innovation Solution
A method involving acid pickling with hydrochloric or sulfuric acid, followed by cleaning with pressurized acidic water adjusted with reused acid pickling solution and subsequent water washing, using multiple pickling and washing tanks to optimize acid solution reuse and reduce wastewater.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure water washing is used to remove smut after acid pickling, then smut removal effectiveness is improved, but wastewater production increases excessively
Solution Approach 1:
The invention recovers and reuses the acid pickling solution after it has been used for descaling. The spent acid solution is collected from the pickling tank and reused in subsequent pickling operations, thereby reducing wastewater generation while maintaining effective smut removal through controlled acid concentration and high-pressure water washing
Solution Approach 2:
The invention optimizes the concentration parameters of the acid pickling solution to achieve effective smut removal with minimal water consumption. By controlling the acid concentration within specific ranges and adjusting the high-pressure water washing parameters, the process achieves effective cleaning while reducing overall wastewater production
2Reliability
If large amount of water is used for high-pressure cleaning, then smut removal is improved, but load on wastewater treatment system increases
Solution Approach 1:
The acid pickling solution is recovered from the pickling tank and reused in subsequent operations. This recovery process reduces the volume of wastewater requiring treatment while maintaining effective smut removal capabilities through controlled acid concentration and optimized high-pressure washing parameters
3Reliability
If acid pickling is performed to remove scale, then descaling effectiveness is improved, but non-uniform material erosion occurs
Solution Approach 1:
The invention optimizes acid concentration parameters and pickling time to achieve uniform descaling while minimizing non-uniform erosion. By controlling the acid strength and exposure time, the process removes scale effectively while maintaining surface uniformity and preventing excessive material removal
4Manufacturing precision
If acid pickling inhibitors are added to reduce material erosion, then surface uniformity is improved, but descaling rate changes
Solution Approach 1:
The invention optimizes acid concentration and pickling time parameters to achieve both uniform surface quality and high descaling rate without requiring inhibitors. By carefully controlling the acid strength and exposure duration, the process maintains surface uniformity while preserving fast descaling performance
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
Effectively removes scale and smut, prevents rust, and significantly reduces wastewater production, enhancing coating uniformity and compliance with environmental standards.
Implementation Method 1
the sulfuric acid solution reaches the surface of the wire rod material through cracks in scale to dissolve the metal and produce hydrogen, so that the scale is removed from the surface of the wire rod
Implementation Method 2
the main chemical reactions occurring on the surface of wire rod are represented by the formula below: Fe→Fe2++2e, 2H++2e→H2, Fe2O3+6H++2e→2Fe2++3H2O, Fe3O4+8H++2e→3Fe2++4H2O
Implementation Method 3
smut produced by the acid pickling is removed by high-pressure cleaning method
Implementation Method 4
the acid solution is washed away with water
Data Source
AI summary
This method for cleaning wires enables effective descaling and removal of smuts from wires, prevents yellowing after cleaning, and significantly reduces the amount of water discharged as a result of cleaning, said method including, in the stated order: (A) pickling a wire; (B) cleaning the wire with acidic pressurized water, the concentration of which is adjusted with water and collected pickle solution which has adhered to and been recovered by the wire after use in Step (A); and (C) cleaning the wire with water.