Pickling 2 Ton Wire Rod

It's called titration. Your chemical supplier will have the info on how to do it and the parameters for their product, talk to them.

Thanks for your reply :) We have titration measurements in place but sometimes i have read in a book that even with a good concentration value shown in titration measurement still the EFFECTIVENESS of acid goes down after sometime and that cannot be noted by titration method: If this is true, what fool proof arrangement we can have ( a kind of small lab test ) or something which shows us the effectiveness of pickling solution., Thanks in advance

JPool's answered your second question. For the first one- are you using any detergents in the HCl package, and are the tanks agitated?

If you can't release the coil (even slightly) to allow better penetration of the solution then you need to ensure the surface tension of the fluid is low enough to allow it to wet through evenly and quickly, otherwise certain areas may have less time exposure and give you inconsistent results. This would be more likely to be a random occurence, whereas a spent solution would be more likely to give repeatedly poor results that may be more consistent throughout the coil. Agitation also helps solution penetration.

The surfactants also help remove dirt (& oil, as I notice you don't mention an alkaline prewash). Beyond that you have to ask the metal experts.

Hi, thanks for the answer. The tanks are not agitated as HCl can corrode all the blades of agitator(this is the explanation operators have given me) and we dont use any detergent. Any help in such situation ?? thanks in advance again

Plastic agitator blades?

External "ultrasonic" tank agitation on the side of the tanks?

Just random, outside the box, questions. I am by no means an expert!

Agitator blade can be made from stainless steel,very less likely to corrode.

Do you think NAOH and KMNO4 solution (alkaline cleaning) can be of good use here ??

You seem to be in quite a pickle over the processes used to make springs from wire.

This question, and others on the same subject, has already been asked, by you.

You need someone to teach you the fine art of surface treatments for steel. And maybe processes in general.

It's time to quit going to strangers with the same questions and hire a process engineer. A good engineer will pay for themselves with the savings they can give you by reducing losses from improper handling and processing.

HIRE AN ENGINEER! You obviously have no one on staff who knows what to do.

Good luck.

This would involve some work, but I believe it would enable you to keep tight control of your pickling process....

What if you were to run your wire off the original spool, through a feeder, and onto another spool of the same size, with your pickling tanks in between?

It would allow you to make sure that every inch of wire was uniform.

All you would have to do, is adjust the speed of the feed to get it perfect.

It isn't spooled, it's rods strapped into a bundle. But this might save the OP some money because you could use less complicated equipment.

But, it would take some more handling equipment and somebody to run it $$$$, so I predict this will be a non-starter, due to $.

As my old friend "the Frog" used to say, they'd have to break loose with some bucks. So, I say it ain't gonna happen.

Oops! I saw the word coil and jumped the gun.

Since it's going to cost money regardless, I would talk to the supplier and see if I could get them to pickle the rods on site, prior to bundling.

If he offers the supplier some extra $ per bundle, it could be a win-win situation.

Am I correct in reading through your process that you are extruding wire rod down to a smaller size for wire?

Zinc-Phos is a great lubricant, but it seems that everyone wants to get away from it due to environmental issues.

Have you / your company investigated any alternate lubricating processes to get away from prep-dipping altogether? There are a lot of great extruding lubricants out there that can be applied in-line with your wire drawing.

There are also many options for materials and coatings for your drawing dies that will give you more lubricating options.

Esco Engineering The Whys and Hows of Hydrochloric Acid Pickling

Dear Mr.amanmohey,

My posting may not be directly relating to your quiery. After removal of the rods, the sample of the Acid can be tested - for its character, and decide how effective the pickling was.?

Other point is, when you make spring, the rods are to be PEELED, are you following this PEELING, be indicated.

DHAYANANDHAN.S

Hi. We do in fact know many things that are pertinent in your scenario. Our ability to gauge both pH and oxidation down to rate of change by elemental content and stimulus has been around for a long time, and getting more accurate daily. There are a multitude of ways to approach your solution. Your chemistry and electrical activity are very basic by your description, and very well known in industry and academia. Seeing as how you are here on GlobalSpec; I'd be willing to bet to can find your answers right here in this manufacturing database-search engine. Do your homework.