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STEEL PICKLING / HCl SCRUBBER

STEEL PICKLING

Steel strip and other steel or stainless forms are pickled by continuous or batch processing to remove scale and oxides. This is done by treating the metal surface with hydrochloric acid (HCl) or other acid solutions. HCL Scrubber and HCL Acid Fume Absorber systems are essential for controlling emissions during the pickling process of steel or stainless forms using hydrochloric acid (HCl). HCL Scrubber and HCL Acid Fume Absorber systems from Kimre Inc. provide high efficiency mist elimination and gaseous emissions control for continuous, semi- continuous and batch process systems.

Continuous steel pickling processing consists of pressurized liquids sprays and motive air handling systems. A push/pull air draw off system is more complex than that for a ducting hood draw-up that is typically found in batch pickling systems.

Mist and droplet sizes can vary based on the motive air system. Usually with more air/liquid energy input, smaller acid mist particle size is generated, making higher removal efficiency more difficult. For any pickling process the mist abatement must conform to current statutory controls using systems like hydrochloric acid fume scrubber.

Kimre technology provides “Best Available Technology” for new as well as retrofits of current and/or systems out of compliance. Kimre™ Technology has demonstrated efficient and economical emission controls in this industry for over 40 years. Many original equipment manufacturers (OEM) design their scrubbing systems with Kimre’s B-GON® Mist Eliminators, KON-TANE® Tower Packing, and Fiber Bed Diffusion Filters to meet any performance level required.

Kimre Technology™ products attain mist and particulate recovery from both cool and warm laden air streams. Kimre Technology™ scrubbers can provide capture and neutralization of acid particles ranging from the smallest sub-micron aerosols to large dust-laden droplets.

While providing the lowest emission levels, Kimre technology also offers other significant advantages to other technologies, including:

  • Less Susceptible to fouling
  • Easy to Clean
  • Able to be retro-fitted and modified to meet ever-changing emission standards

Let Kimre’s experienced engineering staff and industry specialists review your process application and allow us to custom design the most optimal, cost-effective separation solution based upon your needs, limitations, and requirements.

Use Case History: Steel Pickling / HCI

In steel manufacturing, pickling is a critical process used to remove scale and oxides from steel or stainless steel surfaces. This process involves treating the metal with hydrochloric acid (HCl) or other acid solutions, which creates hazardous gases, mist, and particulate emissions that must be effectively managed. Kimre Inc. provides high-efficiency mist elimination and gaseous emissions control for continuous, semi-continuous, and batch steel pickling processes.

  • The Most Common Method of Steel Pickling:

    The most common method of steel pickling is acid pickling, which involves using a mixture of acids, typically hydrochloric acid (HCl) or sulfuric acid (H₂SO₄), to remove impurities such as rust, scale, and oxides from the surface of steel.
    Here's how it works:

    • Preparation: Steel parts are first cleaned to remove grease, oil, or other contaminants.
    • Pickling: The steel is then submerged in an acid bath, which dissolves the iron oxides (rust and scale) from the surface, leaving a clean metal surface. This is what I have seen in the field.
    • Post-treatment: After pickling, the steel is usually rinsed with water and sometimes neutralized with a base (such as sodium hydroxide) to stop the acid reaction. In some cases, it is coated with a protective layer to prevent re-rusting.
  • Mist Formation and Challenges:

    In any pickling process, the mist particles vary in size based on the energy input from the motive air system. Smaller acid mist droplets, resulting from higher energy input, are more difficult to remove efficiently. As mist abatement must conform to stringent environmental regulations, advanced mist elimination technologies are necessary to ensure compliance and maintain operational efficiency.

  • Mist Emissions
    • Health and Safety: Exposure to acid mist in the air can lead to respiratory issues for workers and cause equipment corrosion, reducing overall operational lifespan.
    • Environmental Impact: Acid mist emissions can contaminate the surrounding environment, potentially violating air quality standards and incurring regulatory penalties.
    • Operational Efficiency: Mist accumulation on equipment can impair machinery performance, increasing maintenance costs and downtime.
  • Regulatory Compliance
    • Steel pickling operations must adhere to strict air quality regulations. Failure to meet these standards can result in fines, shutdowns, and damage to reputation. The mist abatement systems must not only capture particles effectively but also neutralize harmful pollutants to meet emission limits.

  • Kimre’s Mist Eliminators

    Kimre provides proven “Best Available Technology” for mist abatement in steel pickling. Kimre’s B-GON® Mist Eliminators, KON-TANE® Tower Packing, and Fiber Bed Diffusion Filters are specifically designed to meet the demanding needs of steel pickling applications. These solutions effectively capture and neutralize acid mist and gaseous emissions, ensuring both compliance with regulatory standards and the protection of equipment and personnel.

    • B-GON® Mist Eliminators: Designed to handle both fine sub-micron particles and larger droplets, these mist eliminators ensure high-efficiency removal, improving air quality and worker safety.
    • KON-TANE® Tower Packing: This innovative packing solution enhances scrubbing and neutralization efficiency, optimizing the removal of acidic vapors, mist, and particulate matter.
    • Fiber Bed Diffusion Filters: These filters provide additional filtration capacity, ensuring efficient removal of even the finest sub-micron particles while handling high volumes of air.

  • Efficient Emission Control

    Kimre’s mist eliminators and filtration systems remove acid mist and particulate matter from the air, reducing airborne contaminants to below statutory limits. This not only helps steel manufacturers meet environmental standards but also minimizes health risks for workers.

    Enhanced Equipment Longevity

    By removing mist and acid particles from the air, Kimre’s solutions prevent the buildup of corrosive residues on machinery. This reduces equipment wear, enhances system performance, and lowers maintenance costs.

    Regulatory Compliance

    Kimre’s mist elimination technologies help ensure that steel pickling operations comply with the latest environmental and health regulations, avoiding fines and maintaining a positive industry reputation.

    Reduced Downtime and Maintenance Costs

    The durability and low-maintenance nature of Kimre’s systems significantly reduce the frequency and costs of maintenance. Additionally, the systems are designed for easy cleaning and retrofitting, which is particularly beneficial for facilities that need to upgrade or replace older systems.

    Customizable Solutions

    Kimre offers tailored mist elimination systems that can be customized to the unique demands of specific steel pickling processes. Whether a facility requires a continuous or batch system, Kimre’s engineering team works closely with clients to design an optimal solution that meets their specific needs, performance requirements, and regulatory constraints.

Kimre’s mist eliminators and emission control systems can be integrated into new installations or retrofitted into existing pickling systems to upgrade performance and ensure compliance. The integration of these systems is seamless, requiring minimal downtime, and they can be modified to accommodate evolving emission standards.

Kimre’s technology has been successfully implemented in steel pickling operations worldwide, demonstrating significant improvements in air quality, worker safety, and equipment efficiency. In one particular case, a large steel manufacturer retrofitted their existing pickling line with Kimre’s B-GON® Mist Eliminators and KON-TANE® Tower Packing. The result was a substantial reduction in airborne acid mist levels, ensuring compliance with local environmental regulations and improving the overall operational efficiency of the facility.

Kimre’s mist elimination and emission control technologies play a vital role in improving the environmental impact and operational efficiency of steel pickling processes. By utilizing Kimre’s advanced mist eliminators and filtration systems, manufacturers can reduce mist-related health risks, extend equipment life, and ensure compliance with stringent air quality regulations. With over 40 years of experience in the industry, Kimre’s solutions provide the most efficient, cost-effective mist abatement technologies available.

Contact Kimre today to learn how our technology can enhance the performance of your steel pickling operations and ensure compliance with environmental standards.

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