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Machines & equipment for sale

Delmet Anopol Acid Pickling Line

Direct From Site Clearance

Direct Site Clearance Price [?]
£ 25,000 (+ VAT)
Clearance ends
25 February 2021 16:00 GMT while stocks last
Decommissioning,
Moving & Loading Contribution [?]
£ 5,000 (+ VAT) will be added to your invoice
Part of a Direct Site Clearance
Heatrae Sadia
Condition
From a working environment, Seen working by RSW, Excellent Condition
Location
Norwich, Norfolk, UK
Stock No
HEA500
Manufacturer
Delmet
Model
Acid Pickling
Year of Manufacture
2000
Condition
From a working environment, Seen working by RSW, Excellent Condition
Work Envelope (WxDxH mm)
4800 x 1500 x 1500
Process Stages
7
Location
Norwich, Norfolk, UK

Description

Anopol Acid Pickling Line

The line was designed by Anopol and built in Italy by Delmet. It is about 20 years old and is still in use 24/7 with the only weekly down time from 22:00 on a Saturday night to 06:00 on Sunday morning. The plant was subject to a major refurbishment 10 years ago with replacement of the solution holding and pumping tanks and fume scrubbing system.

Process Description

The line has been utilised in the treatment post welding of their Heatrae Sadia and Megaflo cylinders manufactured from duplex stainless steel.
In stainless steel fabrication process oxides are formed on the stainless steel surface of the heat affected zone during welding.

Under these oxides layers chromium is depleted, and the steel has lost a significant amount of corrosion resistance. Thus, removal of the oxide scale is necessary. Best performance and quality are reached by using chemical cleaning of the surface.

This is done with an acid pickling process, where mixtures of hydrofluoric acid (HF), nitric acid (HNO3) are used to remove the oxides and to enrich the chromium depleted areas again.

The stainless steel cylinders which have an outside diameter of 450mm are loaded into a purpose made work carrier.
The number of cylinders per load depends on the length of the cylinder presented to the line.
The work carrier is easily adjustable to suit the different lengths being manufactured.
Each load could be six medium (as shown above) or eight shorter or four longer cylinders.
The internal length of the work carrier is 3600mm.

The work carrier incorporates pipework and valve connections to enable the inside of the stainless steel cylinders to be sprayed with the pickling acid and rinse waters which are pumped from holding tanks located in an adjacent plant room.
The work carrier also incorporates an integral tank lid to seal the top of the treatment tank whilst processing is taking place.
When the work carrier is automatically located into the treatment tank by the transporter a pipe on the work carrier makes connection with the supply pipe from the pumping stations.

Transporter & Gantry System
The line is served by an automatic transporter with motorised lift and traverse. The transporter structure is manufactured in 316 stainless steel and has a SWL of 500kg.
The transporter runs on a parallel twin track gantry system. The gantry system is self-supporting from the factory floor with painted mild steel RHS legs complete with all necessary cross braces. The transporter running rails are stainless steel and are positioned at 5.7 metre centres with a track length of 20 metres.
Both sides of the gantry have a raised GRP access and maintenance walkway with 820 mm wide GRP griding positioned 1040mm above factory floor level.
Both sides have handrails and kick strips, and one side has a set of access steps. The support structure and handrails are painted mild steel.

Plant Layout.
The process line has nine stations as detailed below arranged in a straight line serviced by an automatic stainless steel transporter running on a twin track gantry system which is self- supporting from the factory floor.


Station Number (On Line)        Function
1                                                   Jig Loading Station
2                                                   Jig Collection Station
3                                                   Treatment Tank
4                                                   Treatment Tank
5                                                   Treatment Tank
6                                                   Treatment Tank
7                                                   Treatment Tank
8                                                   Treatment Tank
9                                                   Treatment Tank


Station Number (Off Line)       Function
12                                                 Pickle Storage Tank
13                                                 Pickle Swill Water Storage Tank
14                                                 Pickle Swill Water Storage Tank
15                                                 Pickle Swill Water Storage Tank

Each treatment tank on the line is identical with the process solutions being automatically pumped in the correct sequence and time from seven identical sets of pumps mounted above the solution holding tanks in the plant room.

Each work carrier remains in its treatment tank for 42 minutes in the current set up, so with seven stations this gives a nominal cycle time of six minutes.

If we take an allowance for transporter time and typical efficiency factor of 80% utilisation, this suggests a production output of 8 loads per running hour or 64 cylinders of the shorter length.

The process times and sequences are PLC controlled so could be adjusted to suit alternative applications.

Process Flow Schematic
The attached flow diagram shows the set up nominally as installed. The post pickle passivation stage has now been converted to a rinse stage.
The nominal internal dimensions of each treatment tank on the line is 4800mm long x 1500mm wide x 1500mm deep.
The treatment tanks are fitted with spray bars to wash the outside of the cylinders and fume extraction to atmosphere via a vertical tower scrubber.
The extraction system is complete with range of polypropylene manifold ductwork and centrifugal fan. 
The capacity of the system is 12,000 M3/HR or 7,000 CFM.
The system is fully protected with level control and monitoring as detailed in the diagram above.
The fume scrubber has automatic pH control and dosing.

Production: 200 - 230 off (longer cylinders) per 8 hour shift

Cycle Time: Approx. 8 - 10 mins

Process Time: (Pickling): Approx. 15 minutes

Process Envelope: 3600 x 600 mm ( Ø)

Process Sequence:
• Load (Polypropylene fixtures)
• Pickle (Anopol Fluorinox)
• Rinse (Recycled Pickle Rinse Water)
• Rinse (Recycled Passivation Water)
• Passivation / Desmut (Anopol PA)
• Rinse (Recycled Passivation Rinse Water)
• Rinse (Fresh Water)
• Unload

Total Cycle Time: Approx. 50 mins

** Please note the above process sequence is as originally supplied. The Passivation Stage has now been converted to an additional rinsing stage. However, it is quite possible the plant could revert back to its original two stage treatment, Pickling and Passivation rather that Pickling only as it is now configured.

Design: Single lane installation with dual track overhead transporter. Load and unload from same end.

Heating Up Time: Approx. 8 hours to working temperature. (Controlled by a 7 day 24 hour timer)

Electricity: 3 x 415 volts @ 50Hz approx. 60 kW

Compressed Air: Clean and dry, low pressure. High pressure with lubrication

Water: Clean fresh approx. 1.8 m³/hr

Extraction: Approx. 12,000 m³/hr

Dimensions: 2000mm diameter x 7750mm high

EQUIPMENT

Transport Equipment
The transporter is used for the manual and automatic conveyance of the flight bars through the process stations of the installation.

• 1 x Transporter
• Type: Dual rail manufactured in mild steel (suitably protected)
• Carrying capacity: 500 kg
• Lifting device: Lifting power transmission with geared motor, brake and lifting gear. Controlled by frequency inverter (fully variable).
• Lifting locators manufactured in stainless steel.
• Transverse motion: By geared motor on stainless steel guide rail with friction rollers.
• Fitted with manual buttons for manual use. Emergency stop and anti collision device.
• Proximity switches are fitted for lifting, lowering and transverse motion positioning.
• The transporter is operational in 3 modes (Automatic, Manual & Emergency)

Framework and Guide Rails
The complete installation is mounted on a mild steel frame suitably protected. The transporter guide rail is manufactured from stainless steel approx. 25,000 mm.

Electrical Equipment
1 x Switch cabinet: Wired in accordance to British Standard regulations including:-
1 x Main switch
1 x DC power supply (24 VDC)
Circuit Breakers Safety Relays
Connecting terminals as designated and labelled according to the wiring diagram
1 x Frequency Inverter
1 x PLC with I/O cards for the control of various electromechanical devices
2 x Temperature controllers
8 x Level controllers
1 x 24 hour 7 day timer

Safety Devices
The main switch cabinet is fitted with an emergency stop button.
The transporter is fitted with an emergency stop button.
The transporter is fitted with switches either side to prevent derailing.
The transporter is fitted with switches to detect something lying in its path.
The operators side of the installation is fitted with a pull cord emergency stop.
The control cabinet is fitted with leakage breakers to protect power going to ground.

Programming
The PLC is programmed to enable user friendly process cycle sequencing via a computer interface.
Input of component part numbers is possible through the computer interface for process sequence and data.

Tanks and Equipment
1) Load/Unload station
Description: Working station for loading and unloading of flight bars with drip tray.
Equipment: 1 x Polypropylene drip tray (4800 x 1500 x 200 mm)
1 x Drain valve
2 x Flight bar supports

2) Set Down Station ( x 2)
Description: Working station for set down of flight bars
Equipment: 1 x Polypropylene drip tray (4800 x 1500 x 200 mm)
1 x Drain valve
2 x Flight bar supports
1 x Rotation device (for loading & unloading of jigs)

3) Process Station ( x 7)
Description: A station to carry out the complete process sequence
Tank Material: 15 mm Polypropylene with encased supports
Dimensions: 4800 x 1500 x 1000 mm
Temperature: 50°C
Equipment:  Fume extraction 
2 x Flight bar supports
2 x Pneumatic Pump ( 1 as spare)
3 x 3 way pneumatic ball valves
5 x Pneumatic ball valves
1 x Pipe work manifold 4

4) Pickle Storage
Description: A heated station for storage of pickle solution
Tank Material: 15 mm Polypropylene with encased supports
Dimensions: Compartmentalised storage tank in plant room 
Equipment: 1 x Temperature control probe
1 x Lip extraction 
2 x Level control probe
3 x 4.5 kW PVDF heating elements
1 x Set of interconnecting pipework

5) Passivation / Desmut Storage (now converted to recycled rinse water )
Description: A heated station for storage of passivation / desmut solution
Tank Material: 15 mm Polypropylene with encased supports and lid
Dimensions: Compartmentalised storage tank in plant room 
Temperature: 35 °C
Equipment: 1 x Temperature control probe
2 x Level control probe
1 x Lip extraction 
2 x 4.5 kW PVDF heating elements
1 x Set of interconnecting pipework

6) Recycled Water Storage  (Pickle & Passivation)
Description: A recycled water storage station
Tank Material: 15 mm Polypropylene with encased supports and lid
Dimensions: Compartmentalised storage tank in plant room 
Temperature: Ambient
Equipment: 2 x Level control probe
1 x Set of interconnecting pipework

7) Fresh Water Storage (Pickle & Passivation)
Description: A fresh water storage station
Tank Material: 15 mm Polypropylene with encased supports and lid
Dimensions: Compartmentalised storage tank in plant room 
Temperature: Ambient
Equipment: 2 x Level control probe
1 x Set of interconnecting pipework

8) Carriage Fixtures
8 off Polypropylene carriage fixtures capable of holding vessels detailed in the technical specifications. Complete with pipe work manifolds and spray jet assemblies.

9) Flight Bars
8 off Flights bars complete with polypropylene hood and lifting locators.

10) Extraction System
A complete extraction system  from each treatment station and  the process solution holding tanks. Including extraction fan, fume scrubbing unit, ducting and extraction stack.

 

 

 

pdf icon Print / Download Delmet Anopol Acid Pickling Line Datasheet

Additional files

Schematic Drawing

Photographs taken prior refurbishment. Our refurbishment service is not available on all machines.