Mechanical Wire Descaling Solutions by SHJLPACK

Mechanical wire descaling machines are essential for cleaning steel wire rods, removing mill scale through bending and brushing techniques. This process significantly improves wire cleanliness, extends the lifespan of drawing dies, and minimizes the necessity for harsh chemical pickling. SHJLPACK provides efficient and eco-friendly descaling equipment, enhancing wire preparation, quality, and the efficiency of wire drawing processes.

Mechanical Type Bending & Brushing Descaler RG-SB7

The SHJLPACK Mechanical Type Bending & Brushing Descaler RG-SB7 is designed to efficiently remove scale from wire rods using a mechanical process. This machine employs a method of periodic kinks in different planes between rollers, followed by a final cleaning stage with steel brushes. This approach is particularly cost-effective and well-suited for cleaning carbon steel, where the scale is relatively brittle and easily removed through bending.

Key Features of RG-SB7

• Mechanical Bending Descaling: Utilizes bending rollers to fracture and loosen mill scale.
• Steel Brush Cleaning: Employs steel brushes for the final removal of scale particles.
• Automated Brush Control: PLC control system manages steel brushes, ensuring gentle scale removal without damaging the wire surface. It includes an automatic brush replacement notification.
• High Cleaning Efficiency: Achieves up to 90% mill scale removal, significantly improving wire cleanliness.
• Reduces Pickling Needs: Minimizes or eliminates the need for pre-pickling, cutting down on acid use and waste disposal costs.
• Versatile Wire Diameter Range: Standard model handles wire diameters from Ø5.5 mm to Ø7.0 mm for medium and low carbon steel. Custom sizes are available upon request.

Mechanical Cleaning Unit with Brushes Details

The brushing unit is designed for consistent and effective cleaning:

• Guiding and Straightening Rollers: Ensures uniform brushing action around the wire circumference.
• Powerful Drive: Equipped with a 12 HP drive for robust performance.
• Alloy Steel Brushes: Features 4 sets of alloy steel brushes, each with its own motor.
• Dedicated Motors: Each brush set is powered by a 3 HP motor (total 4 motors).
• Automatic Brush Adjustment: An electromagnetic switch sensor, managed by the PLC system, automatically adjusts the brushes for optimal cleaning.
• HMI Control: Includes a HMI Control & Monitoring Station for easy operation and monitoring.
• Synchronized Speed: Brush cleaning unit speed is synchronized with the wire drawing line speed.
• Customizable Direction: Direction of operation can be tailored to customer requirements.
• Long-Life Brushes: Alloy steel brushes offer an approximate lifespan of 3000 tons of processed wire.
• Power Supply: Operates on a 380V / 50Hz / 3 Phase power source.

Bending Descaler Components

The bending descaler section is engineered for durability and effective scale removal:

• Tungsten Carbide Rollers: Bending descaling rollers are constructed from pure tungsten carbide, providing an extended lifespan of about 5 years.
• Optimized Roller Alignment: Rollers are arranged both horizontally and vertically at specific angles to maximize descaling efficiency.
• Mill-Scale Collection System: An integrated chute within the descaling machine efficiently collects dislodged mill scale into a waste disposal bag, maintaining a clean working environment.

Integrated Equipment for Mechanical Descaling, Washing, Sub-Lubricant Coating, and Drying

SHJLPACK offers comprehensive equipment lines that integrate mechanical descaling with subsequent processes like washing, coating, and drying. This integrated approach ensures superior surface preparation, crucial for achieving high-quality drawn wire. Effective removal of mill scale and application of a sub-lubricating coating, such as lime or borax, are essential for reducing friction during wire drawing, minimizing drawing force, lowering temperatures, and reducing residual stress in the final wire product.

Importance of Surface Preparation

The quality of wire surface preparation directly impacts the quality of the final wire. Complete removal of mill scale and creation of a suitable surface texture are vital for effective lubricant adhesion. A consistent lubricant layer minimizes friction in the drawing die, leading to improved wire quality and extended die life.

Wire surface before and after processing showcases the effectiveness of mechanical descaling.

Equipment Characteristics

SHJLPACK’s integrated descaling equipment offers several key advantages:

• Versatility: Suitable for high, medium, and low carbon steel wires.
• Environmentally Friendly: Minimizes waste acid emissions compared to traditional pickling lines.
• Cost-Effective: Reduces operational costs associated with acid etching, exhaust gas treatment, and civil engineering infrastructure.

Integrated descaling, washing, coating, and drying equipment by SHJLPACK.

Technological Flow of Descaling Line RS-C Series

The RS-C series descaling line follows a systematic technological flow to ensure optimal wire preparation:

1. Rough Descaling with Bending Rollers: Initial scale removal using bending rollers.

2. Finishing Descaling with Steel Brushes: Further scale removal and surface cleaning using steel brushes.

3. Washing in Water: High-pressure washing to remove any remaining scale particles and debris.

4. Applying a Sub-Lubricating Coating: Application of a coating like borax or lime to aid in subsequent drawing processes.

5. Hot Air Drying: Efficient drying of the wire to prepare it for the next stages of production.

Technical Specifications of the Equipment RS-C Series

| Feature | Specification ```

Mechanical Wire Descaling Solutions for Enhanced Production Efficiency

In the wire manufacturing industry, achieving a clean wire surface is paramount for subsequent processes and the quality of the final product. Mill scale, a layer of iron oxides formed during hot rolling, can negatively impact drawing, coating, and welding processes. SHJLPACK offers advanced mechanical wire descaling machines designed to efficiently remove mill scale, ensuring a superior wire surface and optimizing downstream operations.

The RG-SB7: Precision Bending and Brushing Descaler

The RG-SB7 Mechanical Type Bending & Brushing Descaler stands out as a robust solution for effectively cleaning wire rod. This machine utilizes a two-stage process:

1. Mechanical Bending: The wire rod is subjected to a series of controlled bends in multiple planes as it passes through a set of rollers. This bending action effectively fractures and loosens the mill scale layer from the wire surface.
2. Steel Brush Cleaning: Following the bending stage, the wire rod enters a cleaning unit equipped with high-speed steel brushes. These brushes meticulously remove the fractured scale, ensuring a thoroughly cleaned wire surface.

This mechanical descaling method offers significant advantages, particularly for carbon steel, where the mill scale is relatively brittle and easily detached through bending.

Key Advantages of the RG-SB7:

• Efficient Descaling: Combines bending and brushing for comprehensive scale removal.
• PLC Automation: Features automated control of steel brushes via a Programmable Logic Controller (PLC) system. This ensures gentle and precise scale removal without damaging the wire surface. The system also includes automatic notification for brush replacement, minimizing downtime.
• Superior Cleanliness: Capable of achieving up to 90% removal of mill scale, significantly enhancing wire cleanliness. Cleaner wire leads to improved drawing efficiency and product quality.
• Cost Savings: Reduces or eliminates the need for pre-pickling, resulting in substantial savings on acid consumption and waste treatment costs.
• Extended Consumable Life: By providing cleaner wire, the RG-SB7 helps prolong the lifespan of consumable parts in downstream processes, such as drawing dies.
• Versatile Application: Designed for wire diameters ranging from Ø5.5 mm to Ø7.0 mm, suitable for medium and low carbon steel. Custom solutions are available for other diameters upon request.

Detailed Components of the RG-SB7:

• Mechanical Cleaning Unit with Brushes:

  • Guiding and Straightening Rollers: Ensure consistent wire alignment for uniform brushing.
  • Powerful Drive System: A 12 HP drive powers the brushing unit for efficient operation.
  • Alloy Steel Brushes: Four sets of durable alloy steel brushes, each driven by a dedicated 3 HP motor, provide thorough cleaning.
  • Automatic Brush Adjustment: An electromagnetic switch sensor, integrated with the PLC control system, automatically adjusts the brushes to maintain optimal cleaning pressure.
  • HMI Control & Monitoring: A user-friendly Human-Machine Interface (HMI) allows for easy control and monitoring of the brushing process.
  • Synchronized Speed Control: The speed of the brush cleaning unit is synchronized with the wire drawing line speed for seamless integration and consistent performance.
  • Long Brush Life: Alloy steel brushes offer a long service life, processing approximately 3000 tons of wire before replacement is needed.

• Bending Descaler Unit:

  • Durable Tungsten Carbide Rollers: Bending rollers are made of high-quality tungsten carbide, ensuring an extended lifespan of approximately 5 years.
  • Optimized Roller Configuration: Rollers are strategically aligned both horizontally and vertically at specific angles to maximize descaling effectiveness.
  • Integrated Scale Collection: The descaling machine is equipped with a mill-scale collection chute, channeling removed scale into a waste disposal bag for easy cleanup and disposal.

Integrated Descaling, Washing, Coating, and Drying Lines (RS-C Series)

For operations requiring comprehensive wire surface treatment, SHJLPACK offers the RS-C Series of integrated descaling lines. These lines combine mechanical descaling with washing, sub-lubricant coating application, and drying into a single, efficient system.

Benefits of Integrated Surface Preparation:

• Enhanced Wire Quality: Thorough surface preparation is critical for achieving high-quality drawn wire. Complete removal of mill scale and application of a uniform sub-lubricating coating optimize the wire surface for subsequent drawing processes.
• Reduced Friction and Wear: Proper surface treatment minimizes friction between the wire and drawing dies, reducing drawing force, lowering operating temperatures, and minimizing residual stress in the finished wire.
• Minimized Environmental Impact: Mechanical descaling significantly reduces the need for chemical pickling, minimizing waste acid generation and associated environmental concerns. The RS-C series further minimizes environmental impact and operational costs compared to traditional chemical-based systems.

RS-C Series Technological Flow:

The RS-C series descaling line follows a sequential process to ensure optimal wire surface preparation:

1. Rough Descaling with Bending Rollers: Initial mill scale removal using bending rollers.
2. Finishing Descaling with Steel Brushes: Further cleaning and scale removal with steel brushes.
3. Washing in Water: High-pressure washing with an aqueous solution to remove any remaining scale particles and processing residues. The washing system includes filtration and a magnetic filter to maintain water quality.
4. Applying a Sub-Lubricating Coating: Application of a chemical coating, such as borax, sodium tetraborate, or lime, to facilitate drawing. The coating process includes automatic temperature control, with a maximum temperature of 120°C.
5. Hot Air Drying: High-efficiency hot air drying using a high-pressure blower (up to 600°C) to thoroughly dry the wire before further processing. The drying system features automatic controls for consistent performance.

RS-C Series Technical Specifications:

| Feature | Specification |
| :-------------------- | :------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------```