Wire rod preparation lines

It is crucial to have a proper wire rod preparation line in front of a drawing machine. Wire rod preparation is essential to obtain a first class quality product and also necessary to achieve 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 into 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 are usually composed by a series of tanks that perform the following tasks:

- 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 an effective acid recovery system to 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, in line pickling represents a cost effective solution for small scale production of high carbon wires. These lines can be equipped with an acid pickling section. 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 special 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: 

In line descaling is suitable for low carbon wire rod preparation in line with a drawing machine. The wire rod preparation line for low carbon is composed of a mechanical descaler and a brushing unit. The line can be completed with a steam pickling tube followed by a borax coating unit and induction dryer for special applications.

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:

Two types of borax dryers are available: 

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