The next Generation of Surface Treatment Solutions
Transcription
The next Generation of Surface Treatment Solutions
The next Generation of Surface Treatment Solutions Content Lifecycle partnership: a trusted partner .............................................................................................................................. 4 Innovation: a driving force ..................................................................................................................................................................... 6 Revamping and modernisation: a valid alternative ............................................................................................. 7 Strip Pickling Lines ........................................................................................................................................................................................... 8 Pickling Lines for Long Products . .............................................................................................................................................. 12 Degreasing Lines . ........................................................................................................................................................................................... 16 Acid Regeneration Technology .................................................................................................................................................... 20 Our commitment to sustainability and the environment ........................................................................ 24 2 3 The most trusted name in metal surface treatment PICKLING LINE WASTE PICKLE LIQUOR RINSE WATER REGENERATED ACID TANK FARM WASTE PICKLE LIQUOR FRESH WATER FUEL CMI Chemline engineering your success worldwide Lifecycle partnership Our worldwide team provides support throughout the entire project life cycle, from design, construction and commissioning to our after-sales and consultancy services. Our goal is to deliver comprehensive solutions based on the individual needs of our customers. Customer focus Our products are designed and manufactured to offer maximum value, from the delivery of complete new installations, to productivity and quality improvements to existing lines. A trusted partner As a wholly owned subsidiary of the CMI Group, CMI Chemline has access to the resources and financial strength of a large, international company, while remaining largely independent and thus able to react quickly to changes and new challenges. 4 “CMI Chemline has assembled a worldwide team of over 100 scientists, engineers and technicians. We have planned, designed, automated, financed, erected and commissioned chemical processing lines in every international steel market. Our proven reliability has earned us the confidence and respect of leading steel companies around the world. Our global presence guarantees local contacts wherever you are.” Why trust us with your investment… ? Our project design focuses on your requirements. Costeffectiveness and versatility make CMI Chemline one of the best qualified suppliers in the business. Our tailor-made solutions and long years of experience guarantee: • Optimised design • Continuous innovation • Environmentally friendly operation • Low operating cost • Controlled utility consumption • Cost effective maintenance • Easy to service RINSE WATER REGENERATED ACID ACID REGENERATION PLANT EXHAUST AIR OXIDE Environment: Our goal, clean solutions Stringent environmental standards and permit policies mean that capital expenditure in the steel industry is increasingly directed towards environmental improvements. CMI Chemline’s products and services enable its customers to face the challenges of reducing, or even eliminating, emissions and minimising consumption. Closed loop CMI Chemline offers experience-based pickling knowhow, process automation and operating technology, including fully integrated pickling systems that close the loop on acid balance and allow the efficient management of consumable process chemicals with a perfectly matched CMI Chemline fluidised bed or spray roaster acid regeneration plant, thus minimising the environmental impact and maximising operating efficiency. 5 The leading name in chemical processing is also the most improved Thourough analysis Plant investigation Concept development ANALYSIS Minimizing downtime CONCEPT CMI Chemline the partner at your side Growing with the challenge The steel industry of today needs solutions that yield rapid results. In a highly competitive working environment, global competitiveness is crucial to maintaining long-term business viability. Asset performance and reliability are key to your business performance. Unique and innovative solutions, customised engineering and efficient project management enhancing safety, environmental performance and production processes make CMI Chemline the partner of choice. Innovation - A driving force We attach particular importance to selling solutions rather than products. R&D is the driving force behind our organisation. Using our expertise as a springboard, we have been “Leading-edge technology and continuous innovation are designed into all our chemical processing lines, providing a new level of design flexibility. Many of our innovations have set global standards. We offer a substantial track record, with excellent results in all applications.” PROJET EXECUTION Cost effective & reliable solution Revamping and modernisation: A valid alternative Based on many years of experience and numerous references from successful installations, our engineers have developed a systematic approach to the implementation of tailor-made solutions aiming at improving product quality, decreasing operating costs or extending the product mix. Every revamping project starts with a detailed analysis able to develop leading-edge technologies. CMI Chemline makes the First we listen CMI Chemline offers engineering studies, revamping, of the current situation, including an assessment of the existing difference by maximising synergies within our constantly expanding modernisation and training in order to help reduce equipment failure equipment and operating procedures and identification of operational organisation. and operating costs and increase plant availability and safety, while bottlenecks. This analysis is the key to the future success of the project, improving product quality and reducing the ecological footprint of as is the consideration of all boundary conditions and the closest Our centralised technology centre works jointly with our teams of highly your plant. Whether in increased line capacity to satisfy the demand of possible contact with the customer throughout the entire project, from qualified process scientists and engineers in our competence centres downstream finishing lines or modernisation to adapt existing lines to planning to implementation. Our goal is to offer cost-effective solutions around the world, promoting cross-fertilisation and increasing the pace market requirements, CMI Chemline has the optimum solution. as a valid alternative to investment in new equipment, while minimising of market-focused innovation. downtime (e.g. pre-assembly or step by step implementation) and production start-up time, while providing top quality. 6 7 Strip Pickling Lines Modern pickling technology perfectly adapted to our customers’ requirements The better the surface quality at the beginning of the cold rolling process, Our latest Pickling Process Management (PPM) system, together with The modern Push Pull or Semi-Continuous Push Pull Pickling Line the less waste there is in the downstream rolling and coating processes. our fully automated Acid Control Management System, ensures the can easily incorporate additional features to add value to the Scale-free quality achieved through effective pickling produces strip free environmentally safe operation of your plant using the best available finished product. Examples include: from surface impurities. technology. As a market leader, CMI Chemline supplies the full range of pickling Push Pull Pickling Lines are used for processing individual coils solutions for effective removal of mill scale and other surface impurities without strip joining, ensuring excellent operational flexibility in the from hot and cold rolled stainless steel, carbon steel or silicon steel, and face of frequently changing strip dimensions and steel grades, and also from non-ferrous metal strip such as aluminium, brass, etc. Our name non-weldable material. Their specific design makes such lines the only stands for the most modern and effective pickling technology in the practical way of descaling heavy gauge coiled product. steel industry. Our engineers built the world’s first shallow tank pickling line, introducing the turbulent pickling process which improved pickling efficiency and thus replaced the more costly and less efficient deep tank pickling technology. CMI Chemline continues to develop this process and our high turbulence • Entry section: descaling and correct strip shape • Exit section: Our unique v-shaped tank profile facilitates threading the strip through the pickling tank. The fact that there is no strip accumulator in the line makes this technology easy to operate and the most cost-effective method of hot band finishing. Applications range from the typical service centre to the high production requirements of the largest mini mills. • scale breaker/tension leveller to promote efficient • temper rolling mill for improved strip shape and surface Continuous Pickling Lines (CPL) can be part of combined lines. For carbon steel, including silicon steel, a CPL can be sold in combination with: • Tandem Cold Mills (PLTCM) • Temper Rolling Mills • Galvanising Lines • Annealing Lines for Silicon Steel CMI Industry offers tailor-made solutions for all these lines. quality • oil applicator for surface protection during storage • dry lube application for downstream processing such as roll forming and precision stamping For stainless steel a CPL is incorporated into: • Hot Strip Annealing and Pickling Lines (HAPL) • Cold Strip Annealing and Pickling Lines (CAPL) • precision side trimming • Combined Hot/ Cold Strip Annealing Lines (H/CAPL) • automated scrap shopper unloading • Direct Roll Annealing Pickling Lines (DRAP) pickling tank technology is currently among the most efficient and also the most cost effective solutions on the market. Our pickling tanks come in a range of profiles and acid injection systems, suitable for all types of applications and product mixes. In addition, accurate control of the strip and the pickling process optimises scale removal without over-pickling. 8 9 “Every CMI Chemline Pickling Line is specifically configured to the client’s product quality and capacity requirements. This ensures that the installed technology meets production requirements and consistently delivers the best value.” Tank Farm Design features: • Pre-rinse section used for pull back operation • Conventional (steel/ rubber/ brick lined) or polypropylene tank • High turbulence pickling with counter-flow design, decreasing pickling time and thus increasing line capacity by up to 36% • Special alternate lateral acid injection for more efficient use of acid in the system, thus reducing utility consumption • Special cost-effective cover design • Fully automated pickling liquor analysis and acid dosing, reducing acid and utility consumption • Scratch-free strip processing • Highly efficient and fully automated fume absorption and Semi-Continuous- and Continuous Pickling Lines are used for high Annealing and Pickling Lines are used for the treatment of hot rolled The following design features apply specifically to stainless steel capacity production with continuous operation by stitching or welding. (HAPL) and cold rolled (CAPL) stainless steel strip. The work-hardened lines: The strip accumulators, also called loopers, provided at the entry and strip requires annealing and surface scale removal for both the hot and • specially arranged spray beams prevent sludge settlement in the exit sections of the line ensure a consistent product flow during joining, cold rolled material. coiling and removal of the steel coils. In co-operation with leading terminal equipment suppliers, CMI • continuous removal of sludge from the circulation system Chemline has a long history of supplying Continuous Pickling Lines for • modular V-shaped passage through the electrolytic pickling tank pickling tanks • Counter-flow cascade rinse section, decreasing water consumption High Turbulence Pickling Tank – Open Cover • High pressure rinse for improved strip cleanliness • Strip dryer with edge blowing devices Key benefits: In continuous pickling, the line runs at constant speed, while in the Semi- stainless steel. The optimum design of our chemical process section Continuous Line the speed of the strip is reduced during changeover or consists of a combination of electrolytic and mixed acid pickling. The • special design for the prevention of gas bubble formation on the coil joining, due to the lower capacity of the loopers. The installation of need for the quick adjustment of operational parameters and varying strip surface during electrolytic pickling guarantees a uniformly • Maximum pickling efficiency and throughput rates Semi-Continuous Lines is highly cost-effective due to the simpler looper acid concentrations, due to the pickling of different types of austentic, pickled strip • Uniform pickled surface design, while Continuous Pickling Lines provide the highest production ferretic and martensitic stainless steels, requires a highly flexible design, capacity. enabling adjustment to the specific processing requirements of each steel grade. Operational efficiency in the production of top quality lightgauge stainless steel and speciality metals requires the close attention to detail our engineers are able to provide. 10 avoiding electrode damage scrubbing including a special line tank sealing system • Robust, low-maintenance equipment • Lowest possible operating costs, low utility and water consumption • Optimised line design • PPM (Pickling Process Management) guarantees optimised process control • Closed loop circulation of acid, rinse water and fumes for environmentally friendly operation 11 Pickling Lines for Long Products Comprehensive solutions focusing on the individual needs of our customers Pickling Lines for Long Products are a highly specialised group of batch CMI Chemline’s batch pickling plants are designed according to the Sustainable solutions The most modern long product pickling Batch treatment is not only used for the pickling of long products, treatment lines, designed according to the product shape, process efficiency, environmental and low energy demands of today’s market technology, as offered by CMI Chemline, not only means high but can also be used for the full range of chemical surface treatment required and unique parameters defined by the client. for ferrous and non-ferrous metal production: quality products and operator-friendly, safe working conditions, processes for parts of all sizes made from all types of metals (cast • Wire Coil Pickling Lines but also minimum emissions and effluents. CMI Chemline achieves iron, carbon and stainless steel, aluminium, zinc, etc.). Based on Design efficiency and minimum environmental emissions are the • Tube Pickling Lines these objectives by using counter-flow cascade pickling, which many years of experience, CMI Chemline is able to offer the optimum hallmarks of CMI Chemline long product pickling plants. • Bar Pickling Lines reduces acid consumption and, as a result, waste acid and liquid • Plate Pickling Lines effluents. Additional features, such as our closed tunnel system with • Universal Pickling Lines For us, environmental protection starts inside the plant. Consequently, CMI Chemline offers an enclosed vent process, with a dedicated exhaust system and waste air treatment to prevent fumes from escaping from the pickling line. Stand-by essential equipment and an Uninterrupted Power Supply (UPS) to put the plant into a safe mode on power loss are additional features which ensure the continuous safe operation of the plant under extreme working conditions. Our new generation plants feature automated processing using a Level II or Level III control system, multiple fill-drain cycles via an independent transportation function, cascade rinsing using spray and immersion, waste air and waste water treatment aimed at minimising emissions and acid control and management through recovery or regeneration processes. Highly efficient plants producing high quality products Along with high turbulence pickling that ensures uniform pickling conditions and high heat transfer rates, CMI Chemline uses hook vibration for uniform pickling and a high pressure spray rinse arrangement that guarantees a clean surface without residual contamination. Consistent quality and optimised throughput, essential for high capacity lines, are achieved by our automated pickling process. Last, but not least, the individual training of operators and our after-sales service based on long years of experience and many references from successfully operating plants, guarantee continuing safe operation, high productivity and increased separate sections for the appropriate treatment of different fumes, our modern low-temperature phosphating that reduces sludge generation and thus the amount of waste for disposal as well as our total waste acid regeneration and reuse of rinse water, all contribute sequence of chemical treatment steps to address the customer’s specific needs for: • Degreasing • Rinsing • Pickling • Passivation • Anodisation to the pursuit of the same objective – to provide environmentally • Phosphating friendly, high efficiency plants. • Conditioning • Coating Our batch lines are specifically designed to our customers’ needs and comprise the entire range from a single bath installation for a specific treatment, to multi-stage treatment systems and combined lines. This includes handling tools and cranes, instrumentation, electrical components and automation. plant availability. CMI Chemline has supplied special batch treatment lines to many different industries, including the automotive, aerospace and hot dip galvanising sectors. 12 13 “Design efficiency, minimum environmental emissions and low energy consumption are the hallmarks of CMI Chemline Long Product Pickling Lines.” Design features: •H igh turbulence pickling tanks: fibre reinforced plastic (FRP) or polypropylene (PPH) construction with steel framework and special corrosion-proof layer •C losed vent process with dedicated exhaust system and waste air treatment •H igh level of instrumentation and automation with high quality HMI graphics • S pecialised high pressure sprays based on the product profile •C ascade rinsing for low water consumption •P ickling tank arrangement as a counter-flow cascade system •C ontinuous analysis of the pickling solution and dosing via Long product pickling requires a variety of multiple treatment recipes. Reducing the cost of pickling is an important design consideration The closed vent process means that hydrochloric acid, with its significant automated control system Monitoring these different recipes to prevent possible interference is an for CMI Chemline. Acids, cleaning agents or coating chemicals are held operational advantages, such as a lower operating temperature •O ptimised process control through mathematical modelling important consideration in avoiding over-pickling, incorrect coatings or in well insulated tanks made of thick homogenous polypropylene, compared with sulphuric acid, can be used for pickling without fear •C ompact neutralisation plants for waste water loss of efficiency. Consequently, the designs of all of our lines are based enclosed in a tunnel with a closed vent system, thus reducing heating of corrosion of the adjacent equipment and buildings from volatile •R ecovery system for all main chemical consumables on programmes specifically developed by CMI Chemline for various and chemical costs. The tunnel creates an ideal work space, with low emissions. carbon and stainless steel alloys and product dimensions. energy costs compared to lateral tank-side ventilation systems. Central control system CMI Chemline’s central control system with • Highest product quality through uniformly pickled surface Computer simulation model CMI Chemline has developed a dynamic CMI Chemline uses the most modern tunnel pickling technology, which data logging and processing functions is useful in maintaining, records • Highest achievable production rates computer simulation model to test the complete automation system allows the pickling plant to be situated anywhere in the production such as those required for ISO-driven process trending and recording. •O ptimised pickling parameters through mathematical modelling before installation. The automation system is designed on the basis of workshop. This means that the most suitable location can be selected Alarms, instrumentation systems, excellent visual graphics and trend • Low operating costs with controlled utility consumption the simulation model, which is subsequently updated by customer work based on the production workflow, leading to reduced handling costs indicators support the operation of the system. • Environmentally friendly operation instructions, actual plant tests and commissioning data. The results are and optimised material storage. proven and reliable automation systems, for both new installations and Key benefits: • Low maintenance costs • Closed loop systems for acid, water and air treatment revamping. 14 15 Degreasing Lines to prepare surfaces for top quality finishing work From the delivery of complete new installations to productivity and Our modular multi-stage system means that lines can be built to customers’ Spray cleaning section: In order to heat the product to be treated Electrolytic cleaning (for carbon steel only): Direct blistering on the quality improvements in existing lines, for all carbon, stainless and silicon specific line parameters and requirements. to the required temperature and remove coarse contamination, the strip surface results in a deep pore cleaning. CMI Chemline uses low strip is intensively sprayed with a hot alkali cleaning agent. Our special current density cleaning, guaranteeing the same excellent cleaning steel grades as well as all non-ferrous metals, CMI Chemline is recognised across the world for the delivery of technologically advanced cleaning Excellent customer contacts combined with the experience of operating nozzle design, the spray angles used and the optimum velocity of the performance achieved with high current density, but with considerably plants and processes for strip, long products and piece goods. A modular production lines has enabled us to continuously optimise existing process cleaning agents on to the strip result in a high mechanical cleaning lower energy consumption. The specific flow path of the cleaning agent combination of mechanical, chemical and electrolytic processes offers technologies and strive for better solutions, focusing on energy reduction, quality, combined with low fluid evaporation, low maintenance and through the vertical process tank avoids the formation of gas bubbles and the required design flexibility and ensures excellent cleaning efficiency minimised use of chemicals and lower maintenance costs. low energy losses. minimises foam production. The construction of our electrolytic cleaning for the degreasing of all types of metals. CMI Chemline’s cleaning concepts provide integrated or stand-alone solutions for the following lines: • Galvanising Lines • Coating Lines • Annealing Lines • Long Products Processing Lines • Piece Goods Processing Lines For Strip Degreasing or Cleaning Lines CMI Chemline’s multi-stage system combines alkaline spray cleaning, brush cleaning, electrolytic cleaning and a final rinse section including a brush machine and dryer. It is designed to remove almost 100% of surface contaminants before further processing. Vertical spray degreasing and vertical electrolytic degreasing allow for a long effective treatment time within a short facility length, offering space-saving cleaning sections or plants. The final degreasing line arrangement is an assembly of some or all of Surface deposits such as oil, iron fines or other impurities discourage these treatment steps, depending on the initial surface deposits, the adhesion and consequently the functional layer applied to the metal dimensions and the end use of the strip, but also the metal to be treated surface is irregular and easily removable under mechanical pressure and process criteria, such as line speed for example. Brush cleaning section: CMI Chemline’s brush machines are characterised by robust design, long service life and ease of section minimises energy losses and the vertical strip flow ensures a perfect positioning of the strip between the electrodes without sagging. maintenance. Our latest design allows for extremely low downtime Final rinse section: CMI Chemline combines brush rinsing, spray rinsing for brush and roll changes of approximately 15 minutes per unit, and a dryer in this last process step using the latest cascade technology. halving the time for the best technology previously available on the The final brush rinse removes the remaining surface film, before the strip market. Additionally our brushes are equipped with an automated is rinsed in the last rinsing cascade, which is additionally equipped with regulation system to optimise brushing efficiency and provide a final high pressure spraying header in order to remove the cleaning uniform degreasing and constant strip quality. agent completely. Our multi-stage cascade rinse and the continuous regulation and automation of the bath concentrations not only provide excellent flushing, but combine reduced waste water requirements and fresh water consumption with an excellent rinsing effect. In the last step, the combination of strip edge blow-off and strip dryer guarantees the and as a result cannot adequately fulfil its purpose. In preparing for the most efficient and cost effective drying result, preventing the carry-over surface refinement process, an ultra clean base strip or base part surface of fluids to the next process. is essential. CMI Chemline’s cleaning solutions ensure that the functional layer (coating, painting or others) adhere properly and thus guarantee their best performance in service. 16 17 17 “Our long term experience in this field together with our focus on continuing design optimisation and innovation in order to improve the quality of the strip or part to be cleaned are your guarantee that CMI Chemline’s Degreasing Lines provide the essential level of cleanness.” Design features: • E asy service spraying system: possible service during line operation (no downtime) • L ong brush service life through robust design • E asy maintenance of brushing rolls and counter rolls with specific dismounting tool (approx. 15 minutes per roll) •V ibration and leakage-free brush machines •O ptimised electrolyte routing and low current density for deep pore cleaning •C ascading of rinsing water for reduced rinse and fresh water consumption •C ascade guiding of cleaning media ensures maximum For Batch Degreasing Lines CMI Chemline’s expertise offers you the We take responsibility Backed by the combination of our in-house Bearings and seals are removed with the roll in one process step, and the benefit of solutions tailored to produce top quality and performance capabilities in the improvement and further development of process roll change is fully automated. Both of these recent improvements to the and individual environmentally friendly solutions. An optimised bath technologies and our close co-operation with the industry, CMI design enhance operator safety and significantly reduce downtime. operation enhances the efficiency of our Batch Degreasing Lines, using Chemline offers innovative and customised degreasing and cleaning a specially designed agitation system to ensure the homogenous mass lines. Our constant aim is to find better solutions for our customers. exchange of the temperature and the concentration of the degreasing solution, as well as an even rinsing effect in the rinsing section. Our perfectly adapted counter-flow cascade design reduces utility consumption, while a skimmer continuously cleans the degreasing solution to extend its life and avoid cross-contamination of the units leaving the degreasing batch tank. As with our Strip Degreasing Lines, the bath concentrations are constantly monitored and optionally treated in order to optimise consumption, while our leakage-free design and latest fume treatment technology guarantee environmentally and operator friendly operation of our lines. 18 Reliability through in-depth knowledge Our in-depth knowledge in the field of degreasing and cleaning lines enables us to offer advanced efficiency in strip cleaning •A utomated regulation of the cleaning agent concentration •O ptional magnetic filters and ultra-filtration increases maintenance intervals •C losed exhaust treatment system across the line for reduced emissions The redesign of our brushing units solves the leakage problem with this solutions in order to achieve an optimum result, thus providing our type of equipment. Moreover, our newly designed brush positioning customers with the innovative and customised solutions needed to Key benefits: system eliminates vibrations and thus considerably increases brush face today’s challenging market requirements. • E quipment construction and performance results in energy service life and guarantees smooth operation without chatter marks. savings • E nvironmentally friendly lines through reduced consumables The specifically adapted hydraulic dismounting tool is designed for the removal of brushing-, back-up- and wringer rolls. consumption • L ine design adapted to lower maintenance costs • E asy service of major equipment increases uptime •V ertical arrangement of pre-degreasing and electrolytic degreasing for reduced space requirements 19 Acid Regeneration Technology The green solution The better the surface quality at the beginning of the cold rolling CMI Chemline has successfully developed and improved processes process, the more our customers can reduce the waste in down-stream for the regeneration of acids used in the pickling of metals and the rolling and coating processes. Scale free quality is to be achieved though leaching process for the mining industry for decades. All our plant effective pickling, producing strip that is free from surface impurities. layouts are optimised for ease of maintenance and reliable operation, As a market leader, CMI CHEMLINE the full range of pickling guaranteeing the best return on supplies investment, while considerably solutions for the most effective removal of iron oxides from mill scale reducing the ecological footprint of our customers’ plants. and other impurities from hot and cold rolled stainless steel , carbon As a leader in this market segment, CMI Chemline offers a modular steel or silicon steel but also non-ferrous metal strip like, aluminium, design that guarantees our customers the optimal solution for all brass etc. Our name stands for the most modern and effective pickling their individual process requirements and applications, with acid technology in the steel industry. recovery rates of virtually 100%: Our engineers built the world’s first shallow tank pickling line, introducing turbulent process –with thesteel resulting improvement in •the Fluidised bedpickling pyrohydrolysis carbon including silicon steel pickling efficiency and the highest quality on the market, thus replacing applications the more costly and less efficient deep tank pickling technology. • Spray roaster pyrohydrolysis – carbon steel including silicon steel Best available technology for our Hydrochloric Acid (HCl) regeneration process Absorber System and Off-Gas Handling The HCl contained in the Compared to conventional neutralisation plants, TOMAREG® reduces reactor off-gas is then passed through an absorber system using annual costs by 70% and hazardous waste discharged to the environment a counter-current circulation system, in which the rinse water from by more than 98%. Today two pyrohydrolysis processes are available, namely fluidised bed acid, which is then reused in the pickling line. The remaining off- and spray roaster technology, both of which have distinct advantages. gas passes through several treatment steps, including the exhaust Being able to offer either of these processes enables CMI Chemline to fan which regulates the negative pressure in the whole upstream focus fully on our customers’ specific site conditions and help them to system preventing gas leaks, before being released via the stack into choose the best option. Simplified processes such as our quick-change the atmosphere. maintenance free or the most modern plant control system (PCS) are just a few examples of the features provided by the latest generation of our plants. Our Acid Regeneration Plants (ARPs) are equipped with a highly automated control system that minimises field intervention by our high- stainless turbulence pickling tank technology is not only among •today TOMAREG® steel applications the most efficient, but also the most • Pyrohydrolysis - applications other cost thaneffective steel solutions on the the operator and enables safe and reliable daily operation from a single injection systems perfectly adapted to all types of applications as well as the specific product mix to be pickled. In addition accurate control of the strip and the pickling process, guarantees the best possible scale removal without over-pickling. This optimized control of the pickling process based on our latest PPM (Pickling Process Management), as well as our fully automated Acid Control Management System ensure the environmentally safe operation of your plants using the best available technology. 20 20 to 100% of the waste pickle liquor (WPL) is converted back to liquid spray nozzles, the improved design of our venturi rendering it completely CMI Chemline is constantly developing its turbulence pickling and applications market. Our pickling tanks come in different bottom profiles and acid the pickling line absorbs the HCl in the reactor off-gas. Thus close control room. Reactor and Venturi Circulation System For the total regeneration of Hydrochloric Acid (HCl), the waste pickle liquor from the pickling line is concentrated by direct heat and mass exchange in the venturi circulation system, before being injected into the spray roaster or fluidised bed reactor, where it reacts with O2 and H2O to form solid iron oxide and hydrogen chloride gas. Specialized pyrohydrolysis plants for the leaching process In our ongoing effort to create sustainable and responsible solutions, CMI Chemline has also developed plants used in the mineral leaching process, and we are able to supply plants, including test or pilot plants, designed for TOMAREG® - A highly innovative solution for the regeneration of mixed acid the beneficiation of ores of the following non-ferrous metals: • Nickel • Titanium • Magnesium • Zirconium Mixed Acid used for stainless steel pickling consists of Hydrofluoric • Manganese Acid (HF) and Nitric Acid (HNO3), both of which are expensive and • Cobalt problematic in waste streams. TOMAREG® recovers not only these • Chromium expensive acids for reuse in the pickling line but also the valuable metals contained in the waste stream. With TOMAREG®, CMI Chemline Other specialised plants can be developed through working with our offers a system for pickling stainless steel that allows highly flexible customers for other applications. operation of the pickling line, due to the adjustable acid concentration of the regenerated acid. TOMAREG® can produce oxide either in the form of a fine powder or coarse particles, as the plant can be delivered optionally with spray roaster or fluidised bed technology. 21 21 “Continuous awareness of market requirements and the specific needs of our customers makes CMI Chemline the leading company in Acid Regeneration for all types of acid and all available technologies.” Design features: •H igh degree of automation •P roven technology •H igh efficiency combustion systems • E asy start-up sequence •H igh efficiency fume treatment •O xide dust-free, free of trace components (FB-ARP) •O xide fine powder for ferrite industry tailor-made to customers’ requirements (SR ARP) • S tand-by arrangement of essential equipment • L ow maintenance requirement • L ayout optimised for easy access •A ll high pressure lines shielded Process Comparison Spray Roaster vs. Fluidised Bed Both processes, fluidised bed and spray roaster, offer specific advantages. The highest market value is obtained in the soft and hard ferrite industry. The fluidised bed has certain features which make it attractive to a particular However, for an iron oxide to be usable as a raw material ferrite, it needs to market, namely the considerably smaller space requirements, and the meet constant physical and chemical properties with minimal variations, • E nhanced combustion system safety •C ontrol system designed to minimise operator field intervention • S afe operation from control room characteristics of the oxide, which are extremely low residual chloride content requirements that significantly affect the price obtained for the iron oxide, While both technologies are mature, it is not always easy to make the and ease of handling. Consequently, the dust-free fluidised bed oxide can but which are not always easy to achieve, mainly due to the varying waste choice. A number of considerations potentially affect the decision. The cost Key benefits: easily be disposed of in landfill, or can be used as an aggregate or as an pickle liquor quality. Additionally, the saturation rate of the iron oxide market of handling and transport or the distance between the oxide producing • E nvironmental protection due to recovery of hazardous addition to recycled iron used in the steel making process. has a profound impact on the price obtained in the ferrite or pigment plant and the oxide consuming industry are decisive factors when choosing industry and makes the price cyclic. chemicals •V irtually emission-free operation between the two technologies. Additional considerations include energy On the other hand, the spray roaster technology generates an iron oxide or maintenance costs which are higher for the fluidised bed process, or which is a highly valuable by-product. Used in the hard and soft ferrite The above considerations argue against a reductionist approach to •H ighest achievable production rates operating costs which are higher for the spray roaster process. Depending industry and the pigment industry, the oxide can considerably improve the assessing the choice of the most suitable technology. The appropriate •O ptimised pickling due to constant operating parameters on where the acid regeneration plant (ARP) is to be built, the above factors return on investment of the ARP. choice encompasses the need to address a wide set of issues over • Independence from chemical suppliers may differ considerably and some will be decisive in the final choice of different time scales, while accommodating specific customer and market • S hort payback time which technology to install. requirements and constraints. •R ecovery of costs by sale of oxide as high quality by-product •P resent and future legal requirements on emissions are met • L ow maintenance costs •P roven design 22 •A daptable to all types of Pickling Lines 23 Our commitment to sustainability and the environment CMI Chemline helping you build the future Against the background of rising energy prices and increasing environmental awareness, sustainable development has become the driving factor behind our global industrial system. The steel industry is investing billions in becoming a more sustainable and environmentally “Our equipment helps our customers meet the needs of today… without compromising the needs of tomorrow.” Recycling solutions – Clean perspectives Designed to take into account the most modern technical and process parameters, our Cleaning, Degreasing and Pickling Lines support environmental aspirations by significantly reducing Ultra-filtration, magnetic filters and vacuum evaporators are examples of optional add-ons that ensure the highest efficiency of our Degreasing and Cleaning Lines, while offering an environmentally friendly operation by further reducing consumption and waste streams. Our acid fume treatment systems offer the best available technology (BAT) and not only comply with the present emission requirements, but are already designed with reference to more stringent future legislation. consumables and energy consumption. In addition to fail-safe design, we offer key features such as a stand-by friendly industry. This means that steel industry investment is increasingly directed towards reduced energy and consumables consumption CMI Chemline develops and supports sustainable recycling and improved emission control, while increasing production and solutions to minimise waste products – down to zero in the productivity. best case. In addition to our in-line features, such as counterflow cascade technology, closed exhaust treatment systems, exhaust fan and continuous off-gas monitoring. Fumes loaded with NOx from e.g. mixed acid Pickling Lines are treated most efficiently by Selective Catalytic Reactors (SCR-Technology). CMI Chemline supplies highly reliable systems with low maintenance CMI Chemline supports these goals by providing a diverse range of optimised process control, continuous analysis of consumables solutions. Our chemical process design not only helps you to master and high turbulence pickling, CMI Chemline offers optional the increasingly demanding quality requirements imposed by your waste stream treatment solutions providing even more eco- Our Neolyte Purification Systems not only reduce harmful chromium customers, but also addresses increasingly stringent environmental friendly and efficient operation. (+6) to non-toxic chromium (+3), but also regenerate the electrolyte, regulations. CMI Chemline offers a wide range of technologies for the treatment of spent acid, waste water and waste air generated by requirements, low operator attendance and a long lifetime. thus reducing operating costs and the environmental impact of stainless steel Pickling Lines. all types of processing lines, in order to eliminate substances that are harmful to the environment. 24 25 Engineering your global success Closed Loop Recycling Regenerating waste pickle liquor from Pickling Lines to produce regenerated acid and valuable iron oxide is the perfect example of such a system. Based on many years of in-house experience, CMI Chemline offers highly efficient system solutions by matching metal pickling operations with the most adapted Acid Regeneration Technology. Leading technology Tightening environmental standards and stringent air permit policies render it increasingly difficult to operate Pickling Lines without an Acid Regeneration Plant. Ultramodern acid regeneration technology from CMI Chemline not only lays the foundation for optimised productivity and the highest possible level of process safety, but also offers the most environmentally friendly solution. • The waste acid from the pickling process can be recovered completely with a total recovery efficiency > 99% • Rinse water from the pickling process can be utilised, allowing effluentfree operation of the PL + ARP system • Highly efficient dust reduction down to 1 micron particle size • High efficiency self cleaning gas scrubbing and dust separation equipment guarantees Hydrochloric Acid (HCl) and dust emissions below the prescribed emission limits. “CMI Chemline focuses constantly on reducing the impact of industry on the environment and its sustainability. As such, our aim is to deliver significant innovation in processes or technologies for the long term.” Along with CMI Rolling Mills, CMI Processing Lines, CMI Thermline With its strength as an assembler behind it, CMI Industry is also active in and CMI Greenline, CMI Chemline belongs to CMI Industry. the supply of other production installations, and offers solutions in the domain of reducing the environmental footprint of all types of industrial A specialist in industrial processes, CMI Industry designs, modernises installations. and supplies cold steelmaking complexes. Cold rolling mills, steel galvanising lines, thermal and chemical treatment equipment for In addition to supplying equipment, CMI Industry also offers customer steel, specialised equipment, are just some of the specialities in support programs to assist in the start-up of the new or upgraded unit, which CMI Industry possesses expert knowledge and mastery of including complete and flexible customized training sessions, addressing the latest technologies, and for which it has unparalleled references. issues from equipment operation to final product quality. By combining these various skills, CMI Industry holds a position in the vanguard of leading-edge technological innovation for the CMI Industry solutions are available everywhere in the world, either modernization or construction of new integrated plants, including through its operational units in Brazil, China, the United States, Europe, electrical and automation systems. India and Russia, or through its commercial network. Wherever he may be situated, a client thus has a local contact to access a global offer of services. 26 27 Business Units Regional contacts • AMERICA [email protected] Tel +1 330 332 4461 Fax +1 330 332 1853 • BRASIL [email protected] Tel +55 31 3789 5342 Fax +55 31 3789 5319 • CHINA [email protected] Tel +86 10 6561 1126 Fax +86 10 6561 2533 • EASTERN EUROPE AND DEUTSCHLAND [email protected] Tel +43 1 603 34 93 Fax +43 1 603 34 93 • ESPAÑA [email protected] Tel +34 94 415 72 45 Fax +34 94 416 80 28 • FRANCE [email protected] Tel +33 4 42 06 95 36 Fax +33 4 42 06 76 38 • ITALIA [email protected] Tel +39 331 67 97 71 Fax +39 331 63 02 53 • RUSSIA [email protected] Tel +7 495 937 19 20 Fax +7 495 937 19 21 TRAINING CENTER LOCATION • MASTEEL - CMI International Training Center Co., Ltd. Hunanxilu No 8, Maanshan City 243000 Anhui Province China www.magang.com.cn CMI chemline [email protected] • CMI Beugin 26, rue Jules Elby BP 57 F-62150 La Comté France Tel +33 3 21 47 52 00 Fax +33 3 21 47 52 01 • CMI UVK GmbH Robert-Bosch-Straße 12 D-56410 Montabaur Germany Tel +49 2602 99 99 0 Fax +49 2602 99 99 599 • CMI Industry Americas Inc. [email protected] Salem installation 435 W. Wilson St., Salem, OH 44460 USA Tel +1 330 332 4661 Fax +1 330 332 1853 • CMI Brasil Ltda [email protected] Rua Fernandes Tourinho, 147 - sala 1002 - Savassi 30112-000 - Belo Horizonte - MG Tel +55 31 3789 5342 Fax +55 31 3789 5319 • CMI FPE Ltd Mehta House, Stud N°64, Road N°13, MIDC Industrial Area Marol, Andheri (E) 400078 Mumbai Maharashtra India Tel +91 22 6676 2727 Fax +91 22 6676 2737 • CMI Beijing Engineering [email protected] Hanwei Plaza, Room B719 7, Guanghua Road Chaoyang District 100004 Beijing China Tel +86 10 5265 9797 Fax +86 10 5265 9700 CMI Industry (Head Office) Avenue Greiner, 1 BE - 4100 Seraing Belgium Tel. +32 4 330 21 91 Fax +32 4 330 21 10 [email protected] www.cmigroupe.com - • EUROPE [email protected] Tel +32 4 330 21 91 Fax +32 4 330 21 10 • INDIA [email protected] Tel +91 22 667 627 27 Fax +91 22 667 627 37 Printed on FSC paper REGIONAL CONTACTS