STEEL PICKLING / HCl SCRUBBER

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.