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WIRE ROD PREPARATION LINES

We will never stress enough how important it is to have a proper wire rod preparation line in front of a drawing machine. The wire rod preparation is essential to obtain a first class quality product and also necessary to obtain high production speeds. 

The main purpose of the wire rod preparation line is to remove the highly abrasive oxide layer on the surface of the wire. Drawing wire that still has an oxide layer  on its surface means that the scale will be embedded into the wire and cause breakages or premature failure of the final product.

The wire rod preparation lines can be divided in three categories: 

BATCH PICKLING LINES:

These lines are suitable for large productions and maximum flexibility in the coating.

  • The batch pickling lines are designed to use either using HCl or H2SO4 acids , depending on customer preference and the wish to effectively regenerate the acid ( in this case possible only with H2SO4)
  • The movements of the wire rod coils are performed with computer controlled overhead cranes in order to follow the pickling and coating sequences as per pre-established procedures.
  • Our batch pickling lines can be designed with push -pull fume control technology or with tunnel fume control technology. In this case the acid section of the line is fully enclosed into a tunnel that is connected to a vacuum system and a scrubber.
  • The batch pickling lines usually are composed by a series of tanks that perform the following duties:
  • Acid pickling tanks
  • Dip rinse tanks ( hot and cold)
  • Dynamic rinse tank
  • Phosphate activation tank
  • Phosphate coating tank
  • Borax coating tank
  • Lime coating tank
  • Hot air dryer tank

Waste water treatment system and acid recovery:

Our batch pickling plants can be completed with a waste water treatment plant that will neutralize and treat all effluents so that they can be effectively discharged without any harm for the environment.

If the pickling uses H2SO4, it is possible to install a very effective acid recovery system that will regenerate all the acid used by separating the iron sulfate from the acid.

IN LINE PICKLING :

Suitable for high carbon wire rod preparation in line with a drawing machine: a simple and cost effective solution for small scale production of high carbon wires.

These lines can be equipped with an acid pickling section or can be configured without.

  • The composition of the line is as follows:

  • Wire rod payoff
  • Mechanical reverse bending descaler
  • Wire rod brushing unit
  • Steam pickling tube or pressurized cold water rinse tube
  • H2SO4 electro pickling tube and hot/cold pressurized rinse
  • Borax coating unit
  • Dryer
  • For particular applications, the line can be fitted with a electrolytic  calcium phosphating unit so that the wire rod is coated with a lube carrier before entering the borax tank.

  • These lines can be configured with single storage tanks that are connected to various processing trays that can serve several lines.

IN LINE DESCALING:

Suitable for low carbon wire rod preparation in line with a drawing machine: a simple and cost effective solution for production of low carbon wires.

The wire rod preparation line for low carbon is fairly simple and foresees only a mechanical descaler and a brushing unit. For particular applications the line can be completed with a steam pickling tube followed by a borax coating unit and induction dryer.

 

ACCESSORIES:

Payoffs: ( see dedicated web site section)

  • vertical axis wire rod payoff for low carbon wire rods
  • horizontal axis wire rod payoff flipper type
  • horizontal axis wire rod payoff flyer type with pusher

Dryers:

  • We propose two types of borax dryers:

  • Induction type unit: very compact and efficient
  • Hot air type unit: very reliable and simple to use, particularly suitable for larger wire rod sizes.

 Accessories:

  • Acid filtering systems
  • PH meters
  • Single or double wire rod orbital brushing units
  • Optical pyrometers

E-PHOS LINES

Electrolytic Calcium Phosphating Unit

Phosphate serves to facilitate the subsequent drawing operations. The operation takes place in an insulated tank containing a phosphate solution.

It is similar in construction to an electrolytic pickling unit. The wire runs through upper trays that are containing the contact-less electrodes to supply the deposition current to the solution (positive polarity). The wire rod entering the unit are supplied with the current (negative polarity) by the preceding contactless electrode installed before the phosphating unit. The anodes are made by a titanium net coated by an exotic material.

The tray is supplied by re-circulating pump with the electrolytic solution which falls back by gravity into the solution reservoir located underneath. The re-circulating of the solution is made by vertical pumps installed on the side of the re-circulating tank.

Compressed air wipes are located at the tray outlets, to remove excess solution from the wire surface before final rinsing.

The re-circulating tank, polypropylene made, is covered to avoid dispersal of fumes, and includes a flange that can be connected to a fume suction hood and, consequently, to your fume exhaust system.

The bath has a high deposition speed and a simple composition that is highly resistant to pollution, therefore, the required phosphate deposit is obtained in less time, using shorter dipping length.

Hastelloy heat exchangers maintain the solution at the correct working temperature of approximately 40° C.

A level control and valves maintain the correct level. The working tank is entirely covered and a fume suction hood is provided. Evaporation is compensated by adding water to the re-circulating tank from the next rinsing unit.

The re-circulating tank includes drains for periodic cleaning.

Low pressure air blowers are located at the wire outlet, to avoid dragging of the solution.