No. 2 Continuous Pickling Line Capacity Upgrade Project

Project Case Study: No. 2 Continuous Pickling Line Capacity Upgrade Project

Client: Leading Steel Processor in Shandong

Location: Shandong Province, China

Equipment Supplier: Xiangyang Jiade Machinery Co., Ltd.

Equipment Supplied: Two-Bend One-Straighten Scale breaker (2B1S)

1. Project Background

To meet growing market demand for high-strength automotive and construction steel, the client initiated a capacity upgrade for their No. 2 Continuous Pickling Line. The primary goal was to increase production speed while maintaining stringent surface quality standards for a diverse range of advanced steel grades.

2. Project Specifications

· Material Grades: CQ, DQ, DDQ, 440DQ, 440DDQ, CQ590, HSS, HSLA, 590DP

· Strip Width: 700 – 1,440 mm

· Strip Thickness: 2.0 – 5.0 mm

· Line Speed: Up to 180 m/min

3. Our Solution: Two-Bend One-Straighten (2B1S) Scale Breaker

Xiangyang Jiade Machinery supplied a heavy-duty Two-Bend One-Straighten (2B1S) Scale Breaker, specifically engineered for high-speed continuous pickling lines. This system combines mechanical scale fracture with precision leveling to prepare the strip for optimal pickling performance.

How It Works

· The steel strip passes through heavy-duty rollers in the scale breaker.

· The rollers apply controlled pressure to:

1. Break up the oxide scale: The precise bending and straightening action induces tensile stress on the strip surface, fracturing the brittle oxide layer without damaging the base metal.

2. Correct strip shape: Eliminates waves, flatness defects, and camber by inducing uniform plastic deformation across the strip width.

· In this configuration, the scale breaker works in synergy with the line’s tension-Leveler mechanism to improve elongation and ensure maximum surface exposure to the pickling solution.

· (Note: Optional skin-pass mills may be included downstream to further enhance flatness and surface finish.)

4. Challenges Solved for the Client

Prior to this upgrade, the client faced several bottlenecks when processing advanced high-strength steels (AHSS) at higher speeds:

· Incomplete Descaling: High-strength grades like 590DP and HSLA exhibited stubborn scale adhesion, leading to surface defects.

· Shape Control Issues: At 180 m/min, thinner gauges (2.0mm) and soft grades (DDQ) were prone to center buckles and edge waves, causing threading issues and uneven acid consumption.

· Equipment Wear: Loose scale was causing premature wear on bridle rolls and subsequent process equipment.

5. Results & Key Benefits

The installation of the Xiangyang Jiade 2B1S scale breaker successfully addressed these challenges, delivering measurable improvements:

· Enhanced Surface Quality: The aggressive two-bend-one-straighten action ensures the oxide scale is thoroughly fractured and partially removed. This significantly improves pickling efficiency, ensuring a clean, uniform surface ready for subsequent coating or painting processes—critical for exposed automotive grades like DDQ and 440DDQ.

· Improved Flatness: By eliminating waves, buckles, and camber, the machine ensures the strip enters the pickling section with optimal geometry. This is particularly vital for high-strength thin-gauge materials (e.g., CQ590), where flatness is difficult to maintain at high speeds.

· Higher Production Efficiency: With superior scale fracture, the required pickling time in the acid tanks was reduced. This allowed the line to consistently run at the target speed of 180 m/min, directly contributing to the project's "capacity upgrade" objective. Faster, more consistent processing reduces energy costs per ton.

· Reduced Maintenance and Wear: By mechanically removing the bulk of the loose scale upfront, the system protects downstream equipment. The client reported a noticeable decrease in abrasive wear on tension rolls, bearings, and guides, lowering long-term maintenance costs and downtime.

6. Conclusion

The successful deployment of the Xiangyang Jiade Two-Bend One-Straighten Scale Breaker in the Shandong NO.2 Continuous Pickling Line Upgrade demonstrates our capability to deliver robust, high-precision solutions for demanding steel processing environments. Our equipment not only solved immediate production bottlenecks but also enhanced the overall quality and cost-efficiency of the client’s operation.

Xiangyang Jiade Machinery Co., Ltd.

Precision Engineered for Steel Processing Excellence.

www.xfjdmc.com

www.jiademachinery.com

robinc2007@126.com