推拉式酸洗机组技术方案

1、Technology Proposal of 8 Thousand MT Push-pull Type Pickling Line8万吨推拉式酸洗机组技术方案Content目 录Appendix 1 Process flow, parameter and product附件 1 工艺流程、参数及产品 Appendix 2 Technology specification of equipment附件 2 设备技术规格书 Appendix 1附件一Process flow, parameter and product工艺流程、参数及产品Chapter 1: Product mix产品大纲 Mat

2、erial: Hot rolled common carbon steel钢种：热轧普碳钢 Strip thickness: 24mm带钢厚度 Strip width: 610mm带钢宽度 Specification of final product: 24610 mm成品规格 Coil inside diameter: 510mm钢卷内径 Coil outside diameter: Max. 1800mm钢卷外径 Max. coil weight: 10MT最大卷重 Production capacity: 80 thousand MT/year hot rolled pickled st

3、eel coil产量：8万吨/年酸洗热轧钢卷 Working time per year: 6500H年工作时间Chapter 2: Production capacity生产能力Process parameter of pickling section酸洗段工艺参数： 3-section acid tank: 11.753=35.25m节酸槽 Pickling medium: HCL 酸洗介质: 盐酸 Pickling concentration: 518%酸洗浓度 Pickling temperature: 6085酸洗温度 Line speed 80m/min. (Max.), pick

4、ling time: 30s机组速度80米/分(Max) 酸洗时间：30秒 Threading speed: 30m/min.穿带速度 Average specification: 2.5530平均规格 Average coil weight: 8MT平均卷重 Production capacity calculation机组产量计算 Running direction: from right to left 机组右进左出Chapter 3: Main technology parameter主要技术参数Parameter name参数名称Entry入口Exit出口Strip thicknes

5、s带钢厚度(mm)2.04.02.04.0Strip width带钢宽度(mm)610610Getting across without edge cutting is allowed.允许不切边通过Coil inner diameter钢卷内径(mm)508508Max. outer diameter of coil钢卷最大外径(mm)18001800Max. coil weight最大卷重(t)1010Line speed机组速度(m/min.)80Annual production capacity (10 thousand MT)年生产能力（万吨）6Total length of ac

6、id tank酸槽总长度(m)11.753=35.25Total length of rinsing tank冲洗槽总長度(m)248Picling medium酸洗介质Industry HCL, concentration 18%工业盐酸，浓度为18%Min. pickling time最少酸洗时间(s)30Chapter 4: Process flow, medium and public facilities工艺流程、介质和公用设施l Process flow工艺流程：Coil loadinguncoilingstraighteninghead cutting, angle cuttin

7、gpicklingrinsingdryingedge cuttingoilingcoilingcoil unloadingbundlingweighingstoring上料开卷矫直切头、切角酸洗冲洗烘干剪边涂油卷取卸料打捆称重入库l Medium consuming/discharging quantity介质消耗/排放量:After the acid liquid is used to a certain extent, the acid liquid will not have the activity. Normally, when the Fe ion concentration ge

8、ts to about 180g/L, it will become into the waste liquid and must be discharged. The discharging quantity of the waste liquid in the line is about 0.5t/h. The acid content of the waste liquid is about 50kg/t (3-5%).酸液使用到一定程度，酸液没有了活性。通常铁离子浓度达到约180g/L左右，成为废液，必须排放。本机组的酸洗废液排放量大约0.5t/h，废液的含酸量约50kg/t (3-5

9、%)。New acid consumption: New acid supplying (or consumption) is about 25-31kg per ton of steel and the concentration is 28-31%.新酸用量：新酸补充（或耗量）约为每酸洗一吨钢耗酸 25-31kg，浓度：28-31%Steam consumption: 3t/h蒸汽用量Power required: 550KVA机组设备装机容量Waste water discharging quantity for rinsing: 4m3/h, discharged to the dir

10、t water treating station冲洗废水排放量：4m3/h 排放到污水处理站Water supplying quantity for rinsing: 4m3/h (soft water)冲洗用补充水量：4m3/h （软水）l Public facilities:公用设施： Workshop: 18 x 90-95m; Rail height of traveling crane: 8m 厂房： 18 x 90-95m; 行车轨道高：8m Travelling crane: 15MT, 2pcs 行车： 15吨 2台Appendix 2附件二Technology specifi

11、cation of equipment设备技术规格书1. General introduction总概述:This pickling line is pull-push type and adopts the advanced shallow tank turbulent flow pickling technology. The process equipments and technology provided is reliable, advanced, mature and proved by producing practice and can satisfy users with

12、stable production and long-term running. This process has the features of reasonable structure, high efficiency working, low consuming production, convenient operation, less fault.本报价的酸洗机组为推拉式酸洗机组，机组采用目前较为先进的浅槽酸洗技术。所提供的工艺设备与技术，是经生产实践证明了的、可靠的、先进的、成熟的，可满足买方稳定生产和长期运行的成套设备和技术。该技术具有设备结构合理，作业效率高，生产消耗低，操作方

13、便，设备运行故障少等特点。For this pickling line, the completed course of pickling steel strips from pay-off reel to tension reel is finished all online. The arrangement can simplify the equipment structure and also can make the pedestrian passageway smooth. Meanwhile, considering the local geology conditions, a

14、ll process equipments excepting the payoff reel and the tension reel adopt the overhead type for installing (running plane height of the steel strip is 2.2m). So, this can reduce the pit depth of the acid liquid circulation system (pit depth is about -2.3m).所设计的酸洗机组，钢带酸洗处理从开卷到卷取全部过程均在线完成。这种布置一方面可简化设

15、备结构，另一方面可使人行通道畅通。同时考虑到当地的地质条件，除开卷机和卷取机外，全部工艺设备采取高架形式安装（钢带运行平面高度为2.2m）。这样可减少酸液循环系统地坑的深度（地坑深度约-2.3m）。There is a fixed coil saddle at the inlet of pickling line and it can store 2 steel coils. The steel coil stored on the saddle can be transferred by one loading car driven by the hydraulic system onto

16、the coil drum of the payoff reel. The line adopts the cantilever type of payoff reel. Pickling line adopts cantilever pay-off reel, the expansion of pay-off reel drum is driven by hydraulic cylinder at one end of drum spindle and pay-off reel stand can move on the stand base by hydraulic cylinder to

17、 adjust the central position of steel coils when uncoiling. In order to ensure the steel strips straightness when threading, there is a 5-roll straightening leveler is set at the inlet of the pickling line. The crop shear is driven by the hydraulic cylinder for ensuring the max. shearing force and o

18、ne angle shear is set for cutting the strip head into the V type.机组在入口设有一固定钢卷鞍座，可同时存放2个钢卷，存放在钢卷鞍座上的钢卷可通过一台液压传动的上料小车将钢卷运送到开卷机卷筒上。机组采用悬臂式开卷机，卷筒涨缩有设置在卷筒芯轴一端的液压缸驱动，开卷机机架由液压缸驱动可在机座上移动，以调整钢卷在开卷时的中心位置。为保证钢带穿带时的平直度，在机组的入口设有一台五辊矫直机。切头剪采用液压缸驱动，以保证最大剪切力，并设置一台切角剪，将钢带的带头切成V形。The pickling tank is divided into thr

19、ee sections. The tank body is a carbon steel structure and the lining is neoprene, acid-proof porcelain bricks and granite stone strips. The guiding stone adopts the double-layer structure. There are squeezing roller and acid liquor separating rooms in each section of pickling tank. The granite at t

20、he bottom of the tank and the down roll surface of squeezing roller is on the same level. The photoelectricity sensor and displacement sensor is set at the entry and exit of the pickling tank for calculating the position of the steel strip and controlling automatically the open and close of the up r

21、oll of squeezing roll. These measures can effectively insure the normal threading of the steel strip. The thinner steel strip also can avoid to be accumulated in the acid tank.酸洗槽共分3段，槽体为碳钢结构，内衬氯丁橡胶及花岗岩石条，导卫石采用双层结构。这种结构可避免维护更换花岗岩内衬时而不破坏内衬橡胶层。各段槽之间设有酸液挤干胶辊和酸液隔离室，槽底衬花岗岩与挤干胶辊下辊面在同一平面，在酸洗槽入口和出口设有光电传感器和位

22、移传感器计算钢带位置，自动控制挤干辊上辊开闭。这些措施能够有效的保证钢带正常穿带，就是较薄的钢带也可避免钢带在酸槽内重叠堆积。Each acid tank has one set acid liquid circulation heating system. The acid liquid is heated the vertical graphite heater. The heated acid liquid is ejected directly onto the up and down surface of the steel strip by the spraying manifol

23、d. Meanwhile, acid liquor flows quickly in the turbulent flow type under the help of tank body structure to make the pickling speed be increased greatly. The new acid can be supplied continuously and quantificationally by the acid circulation pot. Meanwhile, the new acid is supplied gradually to the

24、 4#, 3#, 2# and 1# by the liquid level control system of the acid circulation pot and at last it is drained to the waste acid collecting pot. Because all sections of pickling tank are separated relatively and can circulate independently, the acid concentration grads of each section can be controlled

25、 efficiently. 每段酸槽各设置一套酸液循环加热系统，酸液加热采用立式石墨换热器加热，经加热后的酸液由喷淋集管将酸液直接喷射到钢带的上下表面，同时酸液在槽体结构的作用下，以紊流形式快速流动，从而极大的提高了酸洗速。新酸连续定量地由酸循环罐补入，同时通过酸循环罐液位控制系统，逐及向4#、3#、2#、1#补充，最后排至废酸收集罐。由于各段酸洗槽相对隔离，各自独立循环，因此，可以有效地控制各段酸槽酸液的浓度梯度。The cleaning tank adopts the 4-class circulation spraying rinsing. The clean water is supp

26、lied from the 4th rinsing tank. The rinsing water flows to the 1st section gradually in the bottom water collection tank of rinsing tank. At last, the rinsed water is drained to the rinsed water collection tank through the overflow port of the 1st section. The completed pickling tank and rinsing tan

27、k adopts micro negative pressure control, that is to say, the acid mist is took out to the acid mist washing tower of waste acid regenerating station through the draft tube at the inlet and outlet of each section and it will be drained to the atmosphere after sprayed and washed.清洗槽采用4级循环喷淋冲洗，清水由第4级冲

28、洗槽补入，冲洗水在清洗槽的下部集水箱逐级流向第1级，最后由第1级溢流口排至冲洗水收集槽。整个酸洗槽和清洗槽采取微负压控制，通过设置在各段进出口处的抽风管将酸雾抽至酸雾洗涤塔，经喷淋洗涤后排出厂外放空。Steel strips are dry up by hot air dryer and hot air is heated by air heat exchanger.钢带干燥采用热风干燥器，热风加热采用空气换热器加热。The loop is set at the exit of the line and two pinch rolls are set separately at the ent

29、ry and exit of the loop.机组出口设有活套，在活套的进出口各设一夹送辊。Steel strip edge is cut by cantilever disc shear. There is a side guiding vertical roll at the entry of the disc shear and it controls the centering of the edge cutting. The removed waste edge is coiled into pelletizing by waste edge coiler.钢带切边采用悬臂式圆盘剪

30、，在园盘剪入口设置一台侧导立辊，控制剪边对中，切除的废边通过废边卷取机将废边卷成废边球团。The tension reel adopts cantilever pull reel tension reel. The coiling tension comes from the 3-roll bridle roll. The tension reel has EPC control to make the edge is coiled orderly.卷取机采用悬臂式张力卷取机，卷取张力通过三辊张力机建立，卷取设有EPC控制卷取部卷齐。The coil unloading at the exit

31、 adopts hydraulic unloading car to unload the steel coils onto the exit coil saddle and the coil saddle can store 2 steel coils at the same time. 出口卸卷采用液压驱动卸卷小车将钢卷卸至出口钢卷鞍座，钢卷鞍座可同时存放2个钢卷。The electrical control system of the line is composed of the AC inerter conversion motor device, AC motor control

32、unit, PLC operating control system, general operating desk, sub-operating desk. The operating control of the system is finished by the PLC. The operating control system also includes the interlocking control function of the auxiliary process system in the pickling line.机组电气控制系统由配电系统、交流变频电机传动装置、交流电机控

33、制单元、PLC操作控制系统、总操作台、分操作台组成。系统的操作控制由PLC可编程控制器完成，操作系统还包括酸洗机组的辅助工艺系统连锁控制功能。 2. Basic data基本数据2.1. Main technology parameter 主要技术参数l Annual production capacity: 8MT年生产能力：8吨/年l Material: Hot rolled common carbon steel钢种：热轧普碳钢l Steel strip thickness带钢厚度: 1.84.0mml Steel strip width带钢宽度: 610mml Inner diamet

34、er of steel coil: 510, outer diameter of steel coil: 1800（max）钢卷内径：510 钢卷外径：1800（max）l Coil weight卷重: 10T (max.)l Flatness and warpage should accord with the regulation of China standard GB912平直度、挠曲度符合国家标准GB912规定2.2. Specification size规格尺寸Item项目Entry入口Exit出口Steel strip thickness带钢厚度1.84.0mm1.84.0mmS

35、teel strip width带钢宽度610mm610mmI.D. of steel coil钢卷内径508mm 508mmO.D. of steel coil (Max.)钢卷外径max.1500mm 1480mmMax. steel coil weight最大钢卷重量10t 10t 2.3. Steel strip quality带钢质量l Steel coil quality should accord with the provision of the China Standard GB2519-81.钢卷质量应符合国家标准GB2519-81的规定:l Distortion: 16m

36、m/4m波浪度l Camber: 5mm/2m镰刀弯l Width warp: 30mm宽度偏差l Telescoping height: 50mm塔形高度3. Process Explaining工艺说明3.1. Process flow diagram工艺流程图Material receiving table (2 saddles) coil loading carpayoff reelpressing roll device and opening device1# vertical roll centering device5-roll straightening leveler wi

37、th pinch rollhydraulic shearangle shear3-class HCL pickling tank4-class water rinsing tankhot air dryer2# vertical roll centering device1# pinch rollPit and swing table of loop3# vertical roll centering device2# pinch rolldisc shear and slitter edge coiler3-roll bridle rollRoll type oilerTension ree

38、lcoil unloading carreceiving table (2 saddles)受料台(2个鞍座)上卷小车开卷机压辊装置及开卷器1#立辊对中装置带夹送料辊5辊矫直机液压剪切角剪3级盐酸酸洗槽4级水洗槽热风干燥器2#立辊对中装置1#夹送辊活套坑及活套摆动台3#立辊对中装置2#夹送辊圆盘剪及废边卷取机三辊张力机辊式涂油机卷取机卸卷小车受料台(2个鞍座)3.2. Operation explaining and equipment composing操作说明及设备组成：The loading car delivers steel coils to the uncoiling positi

39、on exactly. The car goes up, conical head of pay-off reel spreads out and expands steel coils tightly. The conical cone of the pay-off reel runs after the uncoiling scraper spreads out. Steel strips are loosed out from steel coils and guided to the 5-roll straightening leveler with pinch roll throug

40、h the uncoiling scraper. The leveler with pinch roll straightens strips and their heads and then steel strips are delivered to the hydraulic crop shear for cutting out the head of steel strips to the angle shear for cutting out 2 angles in order to thread in the acid tank and complete threading oper

41、ation easily. The process section includes the acid cleaning, rinsing and drying. The steel strip enters into the acid tank (The squeezing roll is set between both sections for separating and supplying the forward power) and rinsing tank. The steel strip enters into the hot air drying device through

42、 2 pairs of squeezing rolls after water cleaning. The hot air drying device is for drying the steel strip surface.由上卷小车运送，将钢卷准确开到开卷位，小车上升，开卷机锥头开出并涨紧钢卷，开卷刀伸出后转动开卷机锥头，带钢从钢卷松出经开卷刀引至带夹送辊5辊矫直机，对带钢进行矫直和直头，夹送辊将带钢送到头部剪剪切掉带钢的头，再经切角剪切掉带钢头部2个角，以利穿带并完成穿带作业。工艺段包括酸洗、冲洗、烘干。带钢进入酸槽（每段之间有挤干辊分隔并提供前进动力）、冲洗槽，经水洗后经过2对挤干辊

43、进入热风干燥机，将带钢表面烘干。Steel strip out from the pickling section is delivered by the 1# pinch roll to the tail loop pit. The steel strip is transferred to the disc shear by 2# pinch roll for cutting the edge. The steel strip is delivered to the turning roll of the electrostatic oiler by the 3-roll bridel r

44、oll and then the steel strip is transferred into the tension reel by the turning roll of the electrostatic oiler. The 3-roll bridle roll and the tension reel form the coiling tension. After coiling, steel coils are unloaded onto the receiving table by unloading car and then wrapped by hand. At last

45、steel coils are delivered onto the final products table by crane.从酸洗工艺段出来的带钢经1#夹送辊送入活套坑，由2#夹送辊拉料至圆盘剪进行切边。三辊张力机将带钢送入涂油转向辊，然后由转向辊送入卷取机。三辊张力机和卷取机形成卷取张力。卷好的钢卷由卸卷小车卸到2个鞍座的受料台上，人工手动打捆，最后由吊车吊运到成品座上。4. Main parameter and characteristic of the line本机组主要参数和特点4.1Line speed: Max. 80m/min.机组速度Threading speed: 30

46、m/min穿带速度4.2Pickling: 3-class pickling, each acid tank length 11.750m酸洗：3级酸洗，每个酸槽长11.750m4.3Rinsing: 4-class rinsing冲洗: 4冲级洗4.4Uncoiling tension: 12KN, coiling tension40KN开卷张力：12KN，卷取张力40KN。4.5. Total length of the line: 85m机组总长Building span: 18m, rail surface level of the crane: 8m厂房跨度：18m，吊车轨面标高：8

47、m4.6Power required: 550 Kw装机容量4.7Main control function: 主要控制功能：Equipment sequence control设备顺序控制Line speed control机组速度控制Line tension control机组张力控制Automatic selecting of setting value设定值自动选定Automatic control of acid pot temperature酸罐温度自动控制Fe ion concentration detector is set in 1# tank for controlling

48、 the discharging of the waste acid.#槽设Fe离子浓度检测仪,控制废酸排放The conductivity meter is assembled at the end of the cascade rinsing section for controlling the discharging of the rinsing water.串级漂洗段未装有电导率仪,控制漂洗水排放Accident alarming事故报警Production report forms生产报表4.8. Qty. of centering对中数量：A. Floating payoff r

49、eel浮动开卷机B. Centering vertical roll after opening device开卷器后有对中立辊；C. Centering vertical roll at entry of the loop pit活套坑进口有对中立辊D. Centering vertical roll at exit of the loop pit活套坑出口有对中立辊E. EPC of tension reel卷取EPC。4.9Type of payoff reel and tension reel: Up uncoiling and up coiling开卷卷取方式：上开卷；上卷取。5.

50、Specification of equipment设备规格书5.1. Mechanical equipment机械设备部分5.1.1. Coil loading car and saddle上卷小车及鞍座 Purpose and main structure用途及主要结构 The coil loading car is a device for transferring the steel coil on the fixed coil saddle onto the payoff reel. It is composed of the lift saddle, walking car, li

51、ft hydraulic cylinder and walking motor. When operating, the coil loading car holds the steel coil stored on the saddle to the height of the payoff reel drum. The oil motor of the car moves the coil loading car onto the coil drum of the payoff reel. The saddle is used for laying the steel coil waiti

52、ng for pickling. The equipment is the welded steel structure.上卷小车是将存放在固定钢卷鞍座上的钢卷运送到开卷机上的装置，它由升降鞍座、行走小车、升降液压油缸和行走马达组成。操作时，上料小车上升托起存放在钢卷鞍座上的钢卷至开卷机卷筒高度，小车油马达移动上料小车将钢卷送至开卷机卷筒上。鞍座用于放置来料待酸洗卷。设备为焊接钢结构。 Technology performance技术性能l Max. Loading weight: 10T载重量l Outer diameter of steel coil: 9001800mm钢卷外径l Wid

53、th of steel coil: 450610mm钢卷宽度l Qty. of coil stored on the saddle: 2鞍座存放卷数l Lifting and falling height: 1100mm升降高度l Lifting cylinder: 200/160stroke 1100mm升降缸：200/160行程1100mml Walking distance: 4500mm行走距离l Lubricating: dry oil lubricating润滑：干油润滑5.1.2Pressing roll device and opening device压辊装置及开卷器 Fun

54、ction and main structure用途及主要结构It is used for opening the strip head for convenient threading of the steel strip. The opening device is composed of the movable frame driven by the movable cylinder and the upper guiding plate tongue. The bracket, swing frame and the tongue, etc. is the welded steel s

55、tructure.用于打开带头，以便带钢的穿带。开卷器由一个摆动缸驱动的摆动框架及上面的导板舌头组成。支架、摆动框架、舌头等为焊接钢结构。 Technology performance技术性能u Hydraulic cylinder of pressing roll (S2): Cylinder diameter100, stroke 560, 2pcs, Work pressure: 4-6Mpa压紧辊液压缸（S2）：缸径100 行程560 2台工作压力: 46Mpau Hydraulic cylinder of flattening roll (S1): Cylinder diameter

56、: 50, stroke 125Work pressure: 46Mpa压平辊液压缸（S1）：缸径50 行程125 工作压力: 46Mpau Hydraulic cylinder of flex moving mechanism of opening device (S2): Cylinder diameter: 100, stroke: 630, work pressure: 46Mpa开卷器伸运动机构液压缸（S2）：缸径100 行程630工作压力: 46Mpa5.1.3Payoff reel开卷机Function and main structure用途及主要结构：It is used for uncoiling the steel coil and supplying the back tension when steel strip runs. It is the cantilever type. It is mainly composed of the fixed base, transverse m