winter internship report (1)

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Technology Group, Global Wires & Longs, Tata Steel Limited

Winter Internship Report

Report

no.

WTG/ITR/FY14-15

Tarapur Wire Plant 1, Tata

Steel Wire Division,

Tarapur

Date of

report

18-1-14

Subject

Model development and validation in patenting fumeless pickling and bronze plating line for the auto dosing of chemicals.

Submitted by

SABBAN

RUSHIKESH

KAILAS

3rd year METALLURGY & MATERIALS

SCIENCE

COLLEGE OF ENGINNERING PUNE

Duration

8TH December to 14TH January

Guided by

Mr. Shaishav Upadhyay Manager, wire technology group

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ACKNOWLEDGEMENT

I would like to take this opportunity to express a deep sense of

gratitude to my guides- Mr.Dinesh Gudadhe, Technology group, Tata

Steel Wire Division Ltd, Tarapur and Mr. Shaishav Upadhyay, Manager,

wire technology group, Tata Steel Wire Division Ltd, Tarapur. Their

continuous encouragement and competent guidance motivated me and

instilled a sense of confidence in me.

I would like to express my profound gratitude to - Mr. Shishir Desai,

Head, Technology group, Tata Steel Wire Division Ltd, Tarapur for

giving me a chance to work in an esteemed organization like Tata Steel.

I would also like to thank Mr.Pradnyil Karande, Mr. Satish Kadu, Ms.

Apeksha Runwal, Manager, wire technology group, Tata Steel Wire

Division Ltd for their selfless help and support. The study presented in

this project would not have accomplished without their help and support.

Finally, I would like to acknowledge my heartfelt gratitude to

Mr.Arjun Dige, QA lab assistant for being there for me and supporting

me.

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Abstract-:

TATA WIRON is the largest MTB wire producer in India. MTB wires

comprises of bronze coating for adhesion between steel wire and tyre rubber

material, coating quality of Bead wires is rather important and it cannot be

compromised , at any cost.

The following project report includes predictive dosing and

consumption patterns of following chemicals

1) HCl tanks in the fumeless pickling,

2) Borax (Na2B4O7. 5H2O) on patenting line

3) Gardoclean, NaOH, CuSO4, H2SO4 on plating line.

This project emphasises more upon collecting data points of

concentrations of above mentioned chemicals, their consumption per hour,

addition of chemicals and water, tracing of acid content in rinsing water,

tonnage of wire passing per hour, etc. The consumptions of the chemicals

gram/hour were calculated and some recommendations were suggested to

maintain concentration of the chemicals constant.

This project is industrially significant as with the help of auto-dosing of

chemicals we can avoid excess use of chemicals. The concentration values

should be maintained in an acceptable range because they also affect the

properties like uniformity of coating, lifetime of the coating. It drastically

affects the quality of the product.

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Table of Contents

ACKNOWLEDGEMENT ................................................................................... 2

ABSTRACT ....................................................................................................... 3

1.INTRODUCTION ......................................................................................... 10

1.2. What is patenting treatment?.................................................... Error! Bookmark not defined.

1.2.1 significance ............................................................................. Error! Bookmark not defined.

1.2.2 overall process flow ................................................................ Error! Bookmark not defined.

1.2.3 Plating process........................................................................ Error! Bookmark not defined.

1.2.4 Need of plating process ........................................................... Error! Bookmark not defined.

1.2.5 Overall Process Flow ............................................................... Error! Bookmark not defined.

2. PROJECT OBJECTIVES............................................................................... 16

2.1.Understanding the project ................................................................................. 15

3. LITERATURE REVIEW ............................................................................... 17

3.1 chemicals used in Patenting Process ......................................................................................... 17

3.2 chemicals used in plating process ............................................................................................ 19

4. EXPERIMENTAL PROCEDURE .................................................................. 21

4.1 Tracing of concentrations of chemicals on patenting line .................................................. 21

4.1.1 Acid and Fe concentrations in Tank 1 and Tank 2 of fumeless pickling ................... 21

4.1.2 The acid consumption of HCl in the fumeless pickling ............................................. 21

4.4.3 Concentration of borax bath ....................................................................................... 22

4.4.4 Acid concentration tracing in all three rinsing baths and water curtains .................... 22

4.2 Tracing of concentrations of chemicals on patenting line ................................................... 23

4.2.1 Gardoclean, NaOH, Sulphuric acid, Copper Sulphate baths concentrations .................. 23

4.4.2.Tracing of addition of chemicals ......................................................................................... 24

5. RESULTS AND DISCUSION

5.1 trend charts ............................................................................................................................ 25

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6. CONCLUSIONS .......................................................................................... 32

7. Recommendation and way forward ...................................................... 34

List of Figures

Figure 1 Spool of MTB wires

Figure 2 Various parts used in tyre

Figure 3 Patenting process flow

Figure 4 Plating process flow

Figure 5 Turbulent flow of concentrated acid around the wire

Figure 6 Cascade rinsing

Figure 7 Different forms of borax

Figure 8 Electrolytic pickling for H2SO4

Figure 9 Leakage in HCl tanks

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COMPANY PROFILE

“TATA STEEL LTD. WIRE DIVISION”

INTRODUCTION Established in 1958, Tata SSL Ltd. (formerly known as Special Steels Ltd.), is a

pioneer in the manufacture of steel wires in the country. It is the acknowledged market leader

in the steel wire category, with a 30 per cent market share of the organized wire market. It has

an integrated, IQMS certified facility for steel and wire rod manufacture. It is the country's

largest exporter of steel wires. The company also produces narrow width CR-strips and high

precision hot rolled profiles and sections. The company exports its products to over 40

countries around the world, including USA, Australia and New Zealand.

TWP is TS 16949, ISO 9001:2008, EMS 14001 certified plant.

TSWD is the first wire company having a wire manufacturing unit certified under

EMS in India. Many of the company’s products are certified as per BIS standards. The

company as whole is awarded with ISO 9001 by TUV Germany since Dec 1994.

This plant is equipped with modern high-speed wire drawing m/c, heat treatment

furnaces, and galvanizing and copper coating facilities. Most of the raw materials for wire

manufacturing plant is obtained from companies own steel making facilities located at

Jamshedpur. It covers almost all types of steel wires in the different size ranges in single and

standard form, and in coated and in uncoated form.

The company was incorporated in the year 1958 as a private manufacture of wires

and got into the business of making the umbrella, rib wires. The plant was set up at Borivali,

northern suburban of Mumbai. The company went to public in 1961 and subsequently took

up manufacture of many other wires, which were being imported at that time, in 1976. The

company set up another wire plant at Tarapur in Maharashtra for production of tyre bead

wire. The company integrated backward in 1980 by setting up a Wire Rod Mill at Tarapur.

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All the plants have well equipped laboratories and quality assurance departments.

The company believes in continuously modernizing its manufacturing facilities and

upgrading technology. The company is successfully exporting its products to countries like,

USA, IRAN, and UAE etc. with the help of TATA STEEL EXPORT DIVISION.

Company’s corporate office is located at Goregaon, Mumbai. In additional, there

are regional sales offices at Delhi, Chennai and Calcutta and sales offices at Ludhiana,

Faridabad, Hyderabad and Bangalore.

TATA STEEL GLOBAL WIRE BUSINESS

Tata Steel Wires Business is a major player in the wire industry servicing the discerning

needs of its customers across the global markets. Tata Steel's Global Wires Business has manufacturing facilities spread across the geographies of India, China, Thailand and Sri

Lanka. The Group manufactures a variety of wires catering for the Automobile, Construction, Power

and General Engineering Industry sector needs. It manufactures wires in black and coated varieties in both single and stranded forms.

Tata Steel's Global Wires Business:-

Has fully integrated manufacturing, from Iron Ore mining to Steel Wires. Is amongst the 'Top Wire Manufacturers in the World. Has a wealth of expertise and experience in Wire drawing, coupled with the latest

manufacturing facilities Has the ability to meet the exacting specifications and varied needs of the customers.

Has established its products across its domestic markets of India, Thailand, Sri Lanka and China and in markets of USA, Europe, Australia and Middle East

Asia.

Tata Steel's Global Wires Business spans the following companies: Tata Steel Wire Division, India The Siam Industrial Wire Co., Ltd, Thailand

Indian Steel & Wire Products, India Lanka Special Steel Limited, Sri Lanka

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CHAPTER 1

1. INTRODUCTION

PRODUCTS AND APPLICATIONS

A) PRODUCT

Tyre bead wires are needed to be

tough and high in durability. The high-

carbon steel wire rod is given regulative

cooling after being hot-rolled if need be,

and the resultant wire rod of pearlite

structures having a diameter in a range of

5.5-6.5 mm is repetitively subjected to

wiredrawing processes and patenting

treatments to become a diameter in a

range of 3.0-2.0 mm for a final

wiredrawing. The wire rod of this

diameter, after being subjected to the

final wiredrawing, is then subjected to

copper coating and is coiled.

B) APPLICATION

Motor Tyre Bead (MTB) Wire

It is used in motor tyres for providing necessary strength and grip onto the

tyre’s rim.

Fig1. Spool of MTB wires

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Fig2. Various parts used in tyres

2. PATENTING PROCESS

Patenting Advantages-:

1. Improve drawability of wire rods

2. Reclaim ductility and drawability

3. Improve strength and uniformity of mechanical properties.

Wire Drawing results in:

1. Work hardening

2. Loss of Ductility

3. Elongated grains in tensile stress’s direction

If It needs to be further drawn ,the process used to Regain the ductility is

PATENTING

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PATENTING PROCESS FLOW

Pay off – Turntable type

Bogies lined with refractory

Burners for heating

75% heating+25% soaking time

31 m length having 3.25 mm diameter wires

Austenitisation furnace

Lead Bath

11.2 m

temp.zone1=617-634 deg. celcius

temp.zone2=611-628deg.celcius

Quenching bath water quenching

HCl fumeless pickling tanksHCl tanks with turbulrnt flow of acid around wire

by pumps

A

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Fig3.patenting process flow

Cascade rinsing

3 rinsing zones with

decreasing acid content

borax tank

3.4 m length and used for neutralizing the acid and as a

Lubricant Carrier

Drying oven Scale reduction+ handling

Take up unit for final drawing Horizontal coilers as a take ups

A

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1.3 plating process

1.3.1 What is the need of plating process?

To provide strength to automobile tyres, they must be reinforced with steel wire.

To facilitate good adhesion between tyre material and steel wire, steel wires are

often coated with bronze.

1.3.2. Overall plating process

FINISHED DRAWING

STESS RELIEVING LEAD BATH

Charcoal wiper & cooling tank

Gardoclean tank for cleaning

NaOH electrolytic pickling for Removal of foaming agents

Conc.40-71 gm/lit

Current/wire=34-45 Amp

Temp.40-60 deg.

A

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Rinsing tank Combinations of cells in series with +

& -ve electrode alternatiely

H2SO4 Electrolytic pickling

Cascade rinsing

Conc. 220-270 gm/lit Current/wire=20 Amp

Temp=45 degree

CuSO4 Solution 1

CuSO4 CONC. 4-8 gm/lit

H2SO4 conc.=25-40 gm/l i t

SnSO4 CONC.=0.08-0.17 gm/L

CuSO4 Solution 2CuSO4 CONC. 20-40 gm/lit

H2SO4 conc.=15-35 gm/l i t

SnSO4 CONC.=0.08-0.17 gm/L

Drying oven at 180-200 degress, Graflon rollers, Xylene tank, Take -

up, final packing

A

Fig4.Plating process

flow

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CHAPTER 2

2. 1 PROJECT OBJECTIVES To determine the consumption of chemicals on patenting and bronze plating line for

development of model for auto dosing of the chemicals.

Reuse of rinsing water in cascade to reduce the total water consumption during bronze

plating.

Understanding of objectives

The need of model for auto dosing of various chemicals is that concentration of chemicals

will always show readings around the average value reading (5 gm/lit) as shown in the

graphs .Using this model we can avoid excess use of chemicals. E.g. for NaOH the

concentration range is 27-40 gm/lit. With the help of auto dosing concentration will

always remain around 34 gm/lit.

Fig. Graph showing variation in con

0

2

4

6

8

10

1 2 3 4 5 6

Concetration(g/lit)

0

2

4

6

8

10

1 2 3 4 5 6

concentration(g/lit)

Graph showing variation in conc.

From avg. value without auto dosing

Graph showing readings near average

value due to auto dosing

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CHAPTER 3

3. LITERATURE REVIEW

3.1 Chemicals used in patenting line

HCl fumeless pickling -:

The Fumeless HCl Pickling System eliminates the need for a Scrubber. In any pickling

system with a scrubber, there is the possibility of escaping acid fumes due to such

factors as: 1) HCl Over temperature 2) High Acid Concentration 3) Incorrect Water Tray

Depth 4) Incorrect Fan Pressure or Capacity within the Scrubber.

The above factors can be caused either by operator error or equipment malfunction. The

release of acid fumes can result in building and property damage and more importantly

environmental code violations

Fig5. Turbulent flow of concentrated acid around the wire

The Fumeless HCl Pickling System is designed to introduce the hydraulic jump of acid

counter flow to the direction of the wire field. This unique turbulent technology increases

the effectiveness of the pickling HCl by effectively disturbing the laminar flow layer, which

normally surrounds the wire in a static HCl pickle. The Reaction takes place as follow-:

OHFeClHClFeO 222

Cascade Rinsing-:

When the wire rods are pickled in the Acid the considerable amount of acid will carry

over along with the wire rod, this carry over Acid will contaminate the other pre coating

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tanks, to remove this acid the cleaning is carried with water and this cleaning process is

called as Rinsing.

The water required to clean the wire is 10,000 times of Acid, if the Rinsing is done in one

water bath the water consumption will be more , so to minimize the water consumption

Rinsing is done in series of water Tanks.

Water of pH 1-2 Water of pH 3-5 Water of pH 6-7

Fig6. Cascade rinsing

Borax-:

Sodium tetra borate, Na2B4O7.5H2O called as pentahydrate due to 5 molecules of water.

Fig7. different forms of borax

Wire Rod Coil Movement

Fresh water addition

Water flow direction

Role of Borax:

1) It neutralizes the phosphate (acidic).

2) Lubricant Carrier

Operating parameters:

Conc. –:100-125 g/l

Temperature-: >95oC, Time-: 3-5 min

Pentahydrate Borax is a good lubricant

carrier. Borax coating is mechanical

deposition on the wire rod. It helps in

lubricant pick up in first few passes which is

carry forward till the last pass. It is

transparent glassy finish coating on wire

rod surface.

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3.2 Chemicals used in plating line

Gardoclean-: Gardoclean is a highly-alkaline liquid designed to effectively clean steel drawn wire in

preparation for bronze plating. This highly alkaline product is effective in removing

most scrap associated with steel wire. It is effective at temperatures as low as 120°F

(49°C).

NaOH Electrolytic Pickling-: NaOH is used for following purposes-:

1) To avoid base metal loss

2) To avoid hydrogen embrittlement.

3) To remove the stearates associated with the wires.

Method is slower than acid pickling and is commonly used for steel at lower temperatures.

Hydrogen embrittlement and acid residues can be avoided using alkaline pickling. Using

alkaline pickling at higher temperatures can cause caustic embrittlement.

H2SO4 Electrolytic Pickling-: Electrolytic pickling is faster than normal pickling in cleaning oxides. By this method, a

cleaner surface can be achieved. Special equipment is needed, and the method is

mainly used in continuous pickling lines.

Fig8. Electrolytic pickling for H2SO4

The equipment is built up of number of cells, which are separated by plastic walls with

slots for the wires. In the bottom of every cell is a lead electrode. Every second electrode

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is connected to the minus pole of a rectifier and the other electrodes to the plus pole. That

part of the wire that is in opposite position to a cathode will acts as an anode and oxygen

will be evolved on its surface. In next moment the same wire part acts as a cathode and

hydrogen gas will be given off. The evolution of this hydrogen and oxygen contributes to

the cleaning of the wire by “gas brushing”.

CuSO4 Solutions-:

This setup comprises of two plating solution tanks. One for primary coating and second is

for final coating. The difference between the solutions is in their concentrations. First one

is of lower (4-8 gm/lit) copper concentration and second one is of higher (20-40 gm/lit)

copper concentration.

It is then followed by drying oven at 180-200 deg, graflon rollers, Xylene tank, Take –

up spools and final packing.

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CHAPTER 4

4. EXPERIMENTAL PROCEDURE

The Whole project was divided into 2 parts as follows- :

4.1 First part consists of tracing of concentrations of chemicals on patenting line-:

a) Acid and Fe concentrations in Tank 1 and Tank 2 of fumeless pickling were

noted every two hours for a week.

b) The acid consumption of HCl in the fumeless pickling was tracked on daily

basis

c) Concentration of borax bath every two hours for a week was tracked.

d) Acid concentration tracing in all three rinsing baths and water curtains was done

every two hours for a week.

e) HCl tank levels and flow of both inlet and outlet water curtain were noted down

on daily basis.

4.2 Second part consists of tracing of concentrations of chemicals on plating line-:

a) Gardoclean, NaOH, Sulphuric acid, Copper Sulphate baths concentrations were

noted every two hours for a week.

b) Addition of the chemicals to the baths in the plating line was noted down with

quantity and time.

c) Copper and tin concentrations of first copper sulphate tank solution before and

after addition of proline addition were calculated for 3 days..

Section 4.1-:

A) Acid and Fe concentration determination in Tank 1 and Tank 2 of fumeless pickling- :

1. Acid Determination-:

A known concentration of a strong base solution is titrated (measured) into a known

volume of acid sample solution until the acid solution is neutralised. The amount of

base solution needed to neutralise the acid is proportional to the amount of acid in the

sample solution.

2. Procedure-:

1. 1 ml of sample into a 250 ml beaker was exactly taken.

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2. 30 to 50 ml of water (distilled if possible) was added.

3. 3 to 5 drops Methyl-Orange indicator was added.

4. While swirling the solution constantly, it was titrated from 50 ml burette 1N

sodium carbonate solution until a colour change occurs in the solution (from red to

orange).

5. Volume of sodium carbonate used in ml was noted down and calculation was

carried out as: ml sodium carbonate used x 36.5 = HCl concentration in gm/lit.

2. Fe Determination-:

A known concentration of a reagent readily reacting with iron is titrated into a known

volume of iron sample solution until all the iron in the sample solution has reacted

with the reagent solution. The amount of reagent solution needed to react with all the

iron is proportional to the amount of iron in the sample solution.

Procedure-:

1. 5 ml of sample was taken into a 250 ml beaker.


3. Few drops of concentrated sulphuric acid was added which acts as self indicator.


potassium permanganate solution until the colour changes in the solution (from clear

to violet) and remains for 30 seconds. (The solution may clear again after 30

seconds).


carried out as: ml sodium carbonate used x 5.6 = Fe concentration in gm/lit

B) Acid concentration determination in rinsing tanks and water curtains-:

Procedure-: 1.100 ml of sample into a 250 ml beaker was exactly taken.




orange).


carried out as: (ml sodium carbonate used x 36.5)/100 = acid concentration in gm/lit

C) Borax concentration determination of patenting line-:

Procedure-:



3. Few drops of methyl orange were added.

4. While swirling the solution constantly, it was titrated from 50 ml burette 1 N HCl

solution until the colour changes in the solution (from orange to pink).


carried out as: ml HCl used x 29.2 = borax concentration in gm/lit

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Section 4.2

A) Gardoclean concentration determination of plating line-:

Procedure-:




4. While swirling the solution constantly, it was titrated from 50 ml burette 1 N

H2SO4 solution until the colour changes in the solution (from orange to pink).

5. Volume of H2SO4 used in ml was noted down and calculation was carried out as:

(ml H2SO4 used*2) x 0.074 = Gardoclean concentration in %.

B) NaOH concentration determination of plating line-:

Procedure-:




4. While swirling the solution constantly, it was titrated from 50 ml burette 1 N HCl

solution until the colour changes in the solution (from orange to pink).


carried out as: ml HCl used x 8 = NaOH concentration in gm/lit

C) H2SO4 concentration determination of plating line-:

A known concentration of a sodium carbonate solution is titrated (measured) into a

known volume of H2SO4 acid sample solution until the H2SO4 solution is neutralised.

The amount of base solution needed to neutralise the acid is proportional to the

amount of acid in the sample solution.

2. Procedure-:






orange).


carried out as: ml sodium carbonate used x 9.8 = H2SO4 concentration in gm/l

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D) Copper concentration determination of CuSO4 Solutions-:

A known concentration of a sodium thiosulphate solution is titrated (measured) into a

known volume of CuSO4 sample solution. The amount of sodium thiosulphate

solution needed to react with the CuSO4 solution is proportional to the amount of

copper in the sample solution. It is also known as iodometric titration because iodine

is used up in this reaction.

2. Procedure-:



3. 1 gram of KI indicator along with starch was added.


sodium thiosulphate solution until a colour change occurs in the solution (from dark

black to milky white).

5. Volume of sodium thiosulphate used in ml was noted down and calculation was

carried out as: ml sodium thiosulphate used x 5 = copper concentration in gm/L.

E) Tin concentration determination of CuSO4 Solutions-:

Procedure-:


2. 2-3 drops of starch were added as an indicator.

3. While swirling the solution constantly, it was titrated from 50 ml burette 1N KIO3

solution until a colour change occurs in the solution (from light blue to dark blue).

5. Volume of KIO3 used in ml was noted down and calculation was carried out as:

ml sodium thiosulphate used x 2.1= tin concentration in gm/L.

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CHAPTER 5

5. RESULTS AND DISCUSION

At the starting of this study, the concentration of chemicals in different baths was taken at

five times in a day. That concentration data is available but to avoid confusion only graphs of

average concentration drop in gram/hr are given in this report.

The following graphs show the readings of average concentration drop for different

chemicals taken in 15 days. The graphs clearly show that there are little variations in the

average concentration readings. So for the auto dosing purpose, we must exactly know how

much drop in concentration of chemicals is there. Taking into consideration of this average

value for consumption of chemicals, we can add that much amount of chemicals in the

solution.

1)

Graph showing Total acid in tank 1 consumed (lit/hr)

2)

.

Graph showing total acid in tank 2 consumed (lit/hr)

1 2 3 4 5 6 7 8 9

total acid tank 1 con

lit/hr0.807 0.857 0.857 0.857 1.229 0.988 0.804 1.310 1.310

0.000

0.200

0.400

0.600

0.800

1.000

1.200

1.400

lit

con

sum

ed

/hr

1 2 3 4 5 6 7

total acid tank 2 cons

lit/hr1.54 2.68 1.13 2.71 2.03 2.45 2.45

0.00

0.50

1.00

1.50

2.00

2.50

3.00

lit

con

sum

ed

/h

r

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3)

Total borax consumed gm/hr

4)

Total NaOH consumption in gm/hr

5)

Total tank 1 Cu consumption in gm/hr

1 2 3 4 5 6 7 8 9

total borax

consumed/hr7786 8760 7786 8760 7786 8760 7786 7786 8760

7200

7400

7600

7800

8000

8200

8400

8600

8800

9000

Con

cen

trat

ion

dro

p g

m/h

r

1 2 3 4 5 6 7

total NaOH consum/hr 5280 5500 5280 5500 5280 5280 5500

5150

5200

5250

5300

5350

5400

5450

5500

5550

Co

nce

ntr

atio

n d

rop

gm

/hr

1 2 3 4 5 6 7 8

totalCu consump./hr 2826.24 3200 3600 3200 3600 3200 3200 3200

2500

2700

2900

3100

3300

3500

3700

Con

cen

trat

ion

dro

p g

m/h

r

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6)

Total tank 2 Cu consumption in gm/hr

7)

Total tank 1 Sn consumed in gm/hr

8)

Total tank 2 Sn consumption in gm/hr

1 2 3 4 5 6 7 8

totalCu consump./hr 3840 3200 3600 3200 3200 2400 3360 3200

0

500

1000

1500

2000

2500

3000

3500

4000

4500C

once

ntr

atio

n dr

op g

m/h

r

1 2 3 4 5 6 7

totalSn consum/hr 320 64 320 48 64 320 64

0

50

100

150

200

250

300

350

Co

nce

ntr

atio

n d

rop

gm

/hr

1 2 3 4 5 6 7 8

totalSn consum/hr 64 51.692308 64 64 64 48 60 64

0

10

20

30

40

50

60

70

Co

nce

ntr

atio

n d

rop

gm

/hr

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9)

Total tank 1 H2SO4 consumption in gm/hr

10)

Total tank 2 H2SO4 consumption in gm/hr

11)

Total pickling H2SO4 consumed in lit/hr

1 2 3 4 5 6 7

total SO4 CONS./hr 5340 6528 5340 6272 5644.8 7056 6272

5000

5500

6000

6500

7000

7500

Con

cen

trat

ion

drop

gm

/hr

1 2 3 4 5 6 7

total SO4 CONS./hr 5804.3077 6272 5804.3077 6272 5856 6272 6272

5500

5600

5700

5800

5900

6000

6100

6200

6300

6400

Con

cent

rati

on d

rop

gm/h

r

1 2 3 4 5 6

TOTAL H2SO4

CON.lit/hr5.4192935 5.2550725 5.4192935 5.2550725 5.2081522 5.2550725

5.1

5.15

5.2

5.25

5.3

5.35

5.4

5.45

Con

sum

pti

on

in li

t/h

r

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12)

All of the above graphs show that there is slight variation in consumption pattern and concentration drop is not uniform. This is due to many factors like a) Variation in number of wires b) Manual addition of chemicals c) Stoppages in wires etc

1 2 3 4 5 6 7 8 9 10 11 12

Series1 320 353 400 353 353 353 400 353 353 353 400 400

0

50

100

150

200

250

300

350

400

450

con

sum

pti

on

in g

m.h

r

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CHAPTER 6

6. CONCLUSIONS

Owing to the results in section 5 we can see that there are some variations in consumption

values due to many factors like improper judgement of addition by an operator etc. Based

upon the results we got, we can conclude the average concentration drop line for each

chemical for auto-dosing purpose and based upon the results we developed auto dosing

working models for patenting and plating line.

To keep the concentration of the chemicals near the average value, following

amount (gm/hr OR lit/hr) should be added for auto dosing purpose-:

Name of chemical

Amount

consumed/hr

HCl tank 1 1.002 lit

HCl tank 2 2.14 lit

Borax 8.218 lit

Gardoclean 366.11 gm

NaOH 5.374 kg

Pickling H2SO4 5.301 lit

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Cu tank 1 3253.28 gm

Cu tank 2 3250 gm

H2SO4 tank 1 6064.68 gm

H2SO4 tank 2 6078 gm

Sn tank 1 156 gm

Sn tank 2 59.96 gm

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CHAPTER 7

Recommendations and way forward-:

1)

Fig9. Leakage in HCl tanks

The leakage of HCl from tank needs to be prevented because it will cause errors in tank level

Reading and in concentration reading also.

2) The flow of water curtain 1 need to be controlled so that it should exceed much and giving

Nearly zero acid content.

of 32


REFERENCES 1. Per Enghag, “Steel wire technology” 2. B. Qlkave, “The metallurgist in the steel wire industry” 3. Hydrochloric whys n hows 4. http://www.frpblower.com/fumeless-picking.html 5. Steel_Pickling_in_Challenging_Conditions_2014_Thesis_Mika_Maanonen 6. http://www.britannica.com/EBchecked/topic/564627/steel/81444/Pickling

http://www.frpblower.com/fumeless-picking.html

http://www.britannica.com/EBchecked/topic/564627/steel/81444/Pickling

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