The next Generation of Surface Treatment Solutions

The next Generation of
Surface Treatment Solutions
Content
Lifecycle partnership: a trusted partner .............................................................................................................................. 4
Innovation: a driving force ..................................................................................................................................................................... 6
Revamping and modernisation: a valid alternative ............................................................................................. 7
Strip Pickling Lines ........................................................................................................................................................................................... 8
Pickling Lines for Long Products . .............................................................................................................................................. 12
Degreasing Lines . ........................................................................................................................................................................................... 16
Acid Regeneration Technology .................................................................................................................................................... 20
Our commitment to sustainability and the environment ........................................................................ 24
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The most trusted name in metal
surface treatment
PICKLING LINE
WASTE PICKLE LIQUOR
RINSE WATER
REGENERATED ACID
TANK FARM
WASTE PICKLE LIQUOR
FRESH WATER
FUEL
CMI Chemline engineering
your success worldwide
Lifecycle partnership Our worldwide team provides support throughout
the entire project life cycle, from design, construction and
commissioning to our after-sales and consultancy services. Our goal
is to deliver comprehensive solutions based on the individual needs
of our customers.
Customer focus Our products are designed and manufactured to offer
maximum value, from the delivery of complete new installations, to
productivity and quality improvements to existing lines.
A trusted partner As a wholly owned subsidiary of the CMI Group, CMI
Chemline has access to the resources and financial strength of a large,
international company, while remaining largely independent and thus
able to react quickly to changes and new challenges.
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“CMI Chemline has assembled
a worldwide team of over
100 scientists, engineers and
technicians. We have planned,
designed, automated,
financed, erected and
commissioned chemical
processing lines in every
international steel market.
Our proven reliability has
earned us the confidence
and respect of leading steel
companies around the
world. Our global presence
guarantees local contacts
wherever you are.”
Why trust us with your
investment… ?
Our project design focuses on your requirements. Costeffectiveness and versatility make CMI Chemline one of the best
qualified suppliers in the business. Our tailor-made solutions
and long years of experience guarantee:
• Optimised design
• Continuous innovation
• Environmentally friendly operation
• Low operating cost
• Controlled utility consumption
• Cost effective maintenance
• Easy to service
RINSE WATER
REGENERATED ACID
ACID REGENERATION
PLANT
EXHAUST AIR
OXIDE
Environment:
Our goal, clean solutions
Stringent environmental standards and permit policies mean that capital
expenditure in the steel industry is increasingly directed towards
environmental improvements. CMI Chemline’s products and services
enable its customers to face the challenges of reducing, or even eliminating, emissions and minimising consumption.
Closed loop CMI Chemline offers experience-based pickling knowhow, process automation and operating technology, including fully
integrated pickling systems that close the loop on acid balance and
allow the efficient management of consumable process chemicals with
a perfectly matched CMI Chemline fluidised bed or spray roaster acid
regeneration plant, thus minimising the environmental impact and
maximising operating efficiency.
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The leading name in chemical processing
is also the most improved
Thourough
analysis
Plant
investigation
Concept
development
ANALYSIS
Minimizing
downtime
CONCEPT
CMI Chemline the partner at
your side
Growing with the challenge The steel industry of today needs solutions
that yield rapid results. In a highly competitive working environment,
global competitiveness is crucial to maintaining long-term business
viability. Asset performance and reliability are key to your business
performance. Unique and innovative solutions, customised engineering
and efficient project management enhancing safety, environmental
performance and production processes make CMI Chemline the partner
of choice.
Innovation - A driving force We attach particular importance to
selling solutions rather than products. R&D is the driving force behind
our organisation. Using our expertise as a springboard, we have been
“Leading-edge technology
and continuous innovation are
designed into all our chemical
processing lines, providing a
new level of design flexibility.
Many of our innovations have
set global standards. We offer
a substantial track record,
with excellent results in all
applications.”
PROJET
EXECUTION
Cost effective &
reliable solution
Revamping and
modernisation:
A valid alternative
Based on many years of experience and numerous references from
successful installations, our engineers have developed a systematic
approach to the implementation of tailor-made solutions aiming at
improving product quality, decreasing operating costs or extending
the product mix. Every revamping project starts with a detailed analysis
able to develop leading-edge technologies. CMI Chemline makes the
First we listen CMI Chemline offers engineering studies, revamping,
of the current situation, including an assessment of the existing
difference by maximising synergies within our constantly expanding
modernisation and training in order to help reduce equipment failure
equipment and operating procedures and identification of operational
organisation.
and operating costs and increase plant availability and safety, while
bottlenecks. This analysis is the key to the future success of the project,
improving product quality and reducing the ecological footprint of
as is the consideration of all boundary conditions and the closest
Our centralised technology centre works jointly with our teams of highly
your plant. Whether in increased line capacity to satisfy the demand of
possible contact with the customer throughout the entire project, from
qualified process scientists and engineers in our competence centres
downstream finishing lines or modernisation to adapt existing lines to
planning to implementation. Our goal is to offer cost-effective solutions
around the world, promoting cross-fertilisation and increasing the pace
market requirements, CMI Chemline has the optimum solution.
as a valid alternative to investment in new equipment, while minimising
of market-focused innovation.
downtime (e.g. pre-assembly or step by step implementation) and
production start-up time, while providing top quality.
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Strip Pickling Lines
Modern pickling technology perfectly adapted to
our customers’ requirements
The better the surface quality at the beginning of the cold rolling process,
Our latest Pickling Process Management (PPM) system, together with
The modern Push Pull or Semi-Continuous Push Pull Pickling Line
the less waste there is in the downstream rolling and coating processes.
our fully automated Acid Control Management System, ensures the
can easily incorporate additional features to add value to the
Scale-free quality achieved through effective pickling produces strip free
environmentally safe operation of your plant using the best available
finished product. Examples include:
from surface impurities.
technology.
As a market leader, CMI Chemline supplies the full range of pickling
Push Pull Pickling Lines are used for processing individual coils
solutions for effective removal of mill scale and other surface impurities
without strip joining, ensuring excellent operational flexibility in the
from hot and cold rolled stainless steel, carbon steel or silicon steel, and
face of frequently changing strip dimensions and steel grades, and also
from non-ferrous metal strip such as aluminium, brass, etc. Our name
non-weldable material. Their specific design makes such lines the only
stands for the most modern and effective pickling technology in the
practical way of descaling heavy gauge coiled product.
steel industry.
Our engineers built the world’s first shallow tank pickling line,
introducing the turbulent pickling process which improved pickling
efficiency and thus replaced the more costly and less efficient deep tank
pickling technology.
CMI Chemline continues to develop this process and our high turbulence
• Entry section:
descaling and correct strip shape
• Exit section:
Our unique v-shaped tank profile facilitates threading the strip through
the pickling tank. The fact that there is no strip accumulator in the line
makes this technology easy to operate and the most cost-effective
method of hot band finishing. Applications range from the typical
service centre to the high production requirements of the largest mini
mills.
• scale breaker/tension leveller to promote efficient
• temper rolling mill for improved strip shape and surface
Continuous Pickling Lines (CPL) can be part of combined lines.
For carbon steel, including silicon steel, a CPL can be sold in
combination with:
• Tandem Cold Mills (PLTCM)
• Temper Rolling Mills
• Galvanising Lines
• Annealing Lines for Silicon Steel
CMI Industry offers tailor-made solutions for all these lines.
quality
• oil applicator for surface protection during storage
• dry lube application for downstream processing such as
roll forming and precision stamping
For stainless steel a CPL is incorporated into:
• Hot Strip Annealing and Pickling Lines (HAPL)
• Cold Strip Annealing and Pickling Lines (CAPL)
• precision side trimming
• Combined Hot/ Cold Strip Annealing Lines (H/CAPL)
• automated scrap shopper unloading
• Direct Roll Annealing Pickling Lines (DRAP)
pickling tank technology is currently among the most efficient and
also the most cost effective solutions on the market. Our pickling tanks
come in a range of profiles and acid injection systems, suitable for all
types of applications and product mixes. In addition, accurate control
of the strip and the pickling process optimises scale removal without
over-pickling.
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“Every CMI Chemline Pickling Line is specifically configured to the
client’s product quality and capacity requirements. This ensures that the
installed technology meets production requirements and consistently
delivers the best value.”
Tank Farm
Design features:
• Pre-rinse section used for pull back operation
• Conventional (steel/ rubber/ brick lined) or polypropylene
tank
• High turbulence pickling with counter-flow design, decreasing
pickling time and thus increasing line capacity by up to 36%
• Special alternate lateral acid injection for more efficient use of
acid in the system, thus reducing utility consumption
• Special cost-effective cover design
• Fully automated pickling liquor analysis and acid dosing,
reducing acid and utility consumption
• Scratch-free strip processing
• Highly efficient and fully automated fume absorption and
Semi-Continuous- and Continuous Pickling Lines are used for high
Annealing and Pickling Lines are used for the treatment of hot rolled
The following design features apply specifically to stainless steel
capacity production with continuous operation by stitching or welding.
(HAPL) and cold rolled (CAPL) stainless steel strip. The work-hardened
lines:
The strip accumulators, also called loopers, provided at the entry and
strip requires annealing and surface scale removal for both the hot and
• specially arranged spray beams prevent sludge settlement in the
exit sections of the line ensure a consistent product flow during joining,
cold rolled material.
coiling and removal of the steel coils.
In co-operation with leading terminal equipment suppliers, CMI
• continuous removal of sludge from the circulation system
Chemline has a long history of supplying Continuous Pickling Lines for
• modular V-shaped passage through the electrolytic pickling tank
pickling tanks
• Counter-flow cascade rinse section, decreasing water
consumption
High Turbulence Pickling Tank – Open Cover
• High pressure rinse for improved strip cleanliness
• Strip dryer with edge blowing devices
Key benefits:
In continuous pickling, the line runs at constant speed, while in the Semi-
stainless steel. The optimum design of our chemical process section
Continuous Line the speed of the strip is reduced during changeover or
consists of a combination of electrolytic and mixed acid pickling. The
• special design for the prevention of gas bubble formation on the
coil joining, due to the lower capacity of the loopers. The installation of
need for the quick adjustment of operational parameters and varying
strip surface during electrolytic pickling guarantees a uniformly
• Maximum pickling efficiency and throughput rates
Semi-Continuous Lines is highly cost-effective due to the simpler looper
acid concentrations, due to the pickling of different types of austentic,
pickled strip
• Uniform pickled surface
design, while Continuous Pickling Lines provide the highest production
ferretic and martensitic stainless steels, requires a highly flexible design,
capacity.
enabling adjustment to the specific processing requirements of each
steel grade. Operational efficiency in the production of top quality lightgauge stainless steel and speciality metals requires the close attention
to detail our engineers are able to provide.
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avoiding electrode damage
scrubbing including a special line tank sealing system
• Robust, low-maintenance equipment
• Lowest possible operating costs, low utility and water
consumption
• Optimised line design
• PPM (Pickling Process Management) guarantees optimised
process control
• Closed loop circulation of acid, rinse water and fumes for
environmentally friendly operation
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Pickling Lines for Long Products
Comprehensive solutions focusing on the
individual needs of our customers
Pickling Lines for Long Products are a highly specialised group of batch
CMI Chemline’s batch pickling plants are designed according to the
Sustainable solutions The most modern long product pickling
Batch treatment is not only used for the pickling of long products,
treatment lines, designed according to the product shape, process
efficiency, environmental and low energy demands of today’s market
technology, as offered by CMI Chemline, not only means high
but can also be used for the full range of chemical surface treatment
required and unique parameters defined by the client.
for ferrous and non-ferrous metal production:
quality products and operator-friendly, safe working conditions,
processes for parts of all sizes made from all types of metals (cast
• Wire Coil Pickling Lines
but also minimum emissions and effluents. CMI Chemline achieves
iron, carbon and stainless steel, aluminium, zinc, etc.). Based on
Design efficiency and minimum environmental emissions are the
• Tube Pickling Lines
these objectives by using counter-flow cascade pickling, which
many years of experience, CMI Chemline is able to offer the optimum
hallmarks of CMI Chemline long product pickling plants.
• Bar Pickling Lines
reduces acid consumption and, as a result, waste acid and liquid
• Plate Pickling Lines
effluents. Additional features, such as our closed tunnel system with
• Universal Pickling Lines
For us, environmental protection starts inside the plant. Consequently,
CMI Chemline offers an enclosed vent process, with a dedicated exhaust
system and waste air treatment to prevent fumes from escaping from
the pickling line. Stand-by essential equipment and an Uninterrupted
Power Supply (UPS) to put the plant into a safe mode on power loss are
additional features which ensure the continuous safe operation of the
plant under extreme working conditions.
Our new generation plants feature automated processing using a Level
II or Level III control system, multiple fill-drain cycles via an independent
transportation function, cascade rinsing using spray and immersion, waste
air and waste water treatment aimed at minimising emissions and acid
control and management through recovery or regeneration processes.
Highly efficient plants producing high quality products Along with
high turbulence pickling that ensures uniform pickling conditions and
high heat transfer rates, CMI Chemline uses hook vibration for uniform
pickling and a high pressure spray rinse arrangement that guarantees
a clean surface without residual contamination. Consistent quality and
optimised throughput, essential for high capacity lines, are achieved
by our automated pickling process. Last, but not least, the individual
training of operators and our after-sales service based on long years of
experience and many references from successfully operating plants,
guarantee continuing safe operation, high productivity and increased
separate sections for the appropriate treatment of different fumes,
our modern low-temperature phosphating that reduces sludge
generation and thus the amount of waste for disposal as well as our
total waste acid regeneration and reuse of rinse water, all contribute
sequence of chemical treatment steps to address the customer’s
specific needs for:
• Degreasing
• Rinsing
• Pickling
• Passivation
• Anodisation
to the pursuit of the same objective – to provide environmentally
• Phosphating
friendly, high efficiency plants.
• Conditioning
• Coating
Our batch lines are specifically designed to our customers’ needs
and comprise the entire range from a single bath installation for a
specific treatment, to multi-stage treatment systems and combined
lines. This includes handling tools and cranes, instrumentation,
electrical components and automation.
plant availability.
CMI Chemline has supplied special batch treatment lines to many
different industries, including the automotive, aerospace and hot
dip galvanising sectors.
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“Design efficiency, minimum environmental emissions and low energy
consumption are the hallmarks of CMI Chemline Long Product Pickling
Lines.”
Design features:
•H
igh turbulence pickling tanks: fibre reinforced plastic (FRP)
or polypropylene (PPH) construction with steel framework
and special corrosion-proof layer
•C
losed vent process with dedicated exhaust system and waste
air treatment
•H
igh level of instrumentation and automation with high
quality HMI graphics
• S pecialised high pressure sprays based on the product
profile
•C
ascade rinsing for low water consumption
•P
ickling tank arrangement as a counter-flow cascade system
•C
ontinuous analysis of the pickling solution and dosing via
Long product pickling requires a variety of multiple treatment recipes.
Reducing the cost of pickling is an important design consideration
The closed vent process means that hydrochloric acid, with its significant
automated control system
Monitoring these different recipes to prevent possible interference is an
for CMI Chemline. Acids, cleaning agents or coating chemicals are held
operational advantages, such as a lower operating temperature
•O
ptimised process control through mathematical modelling
important consideration in avoiding over-pickling, incorrect coatings or
in well insulated tanks made of thick homogenous polypropylene,
compared with sulphuric acid, can be used for pickling without fear
•C
ompact neutralisation plants for waste water
loss of efficiency. Consequently, the designs of all of our lines are based
enclosed in a tunnel with a closed vent system, thus reducing heating
of corrosion of the adjacent equipment and buildings from volatile
•R
ecovery system for all main chemical consumables
on programmes specifically developed by CMI Chemline for various
and chemical costs. The tunnel creates an ideal work space, with low
emissions.
carbon and stainless steel alloys and product dimensions.
energy costs compared to lateral tank-side ventilation systems.
Central control system CMI Chemline’s central control system with
• Highest product quality through uniformly pickled surface
Computer simulation model CMI Chemline has developed a dynamic
CMI Chemline uses the most modern tunnel pickling technology, which
data logging and processing functions is useful in maintaining, records
• Highest achievable production rates
computer simulation model to test the complete automation system
allows the pickling plant to be situated anywhere in the production
such as those required for ISO-driven process trending and recording.
•O
ptimised pickling parameters through mathematical modelling
before installation. The automation system is designed on the basis of
workshop. This means that the most suitable location can be selected
Alarms, instrumentation systems, excellent visual graphics and trend
• Low operating costs with controlled utility consumption
the simulation model, which is subsequently updated by customer work
based on the production workflow, leading to reduced handling costs
indicators support the operation of the system.
• Environmentally friendly operation
instructions, actual plant tests and commissioning data. The results are
and optimised material storage.
proven and reliable automation systems, for both new installations and
Key benefits:
• Low maintenance costs
• Closed loop systems for acid, water and air treatment
revamping.
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Degreasing Lines
to prepare surfaces for top quality finishing work
From the delivery of complete new installations to productivity and
Our modular multi-stage system means that lines can be built to customers’
Spray cleaning section: In order to heat the product to be treated
Electrolytic cleaning (for carbon steel only): Direct blistering on the
quality improvements in existing lines, for all carbon, stainless and silicon
specific line parameters and requirements.
to the required temperature and remove coarse contamination, the
strip surface results in a deep pore cleaning. CMI Chemline uses low
strip is intensively sprayed with a hot alkali cleaning agent. Our special
current density cleaning, guaranteeing the same excellent cleaning
steel grades as well as all non-ferrous metals, CMI Chemline is recognised
across the world for the delivery of technologically advanced cleaning
Excellent customer contacts combined with the experience of operating
nozzle design, the spray angles used and the optimum velocity of the
performance achieved with high current density, but with considerably
plants and processes for strip, long products and piece goods. A modular
production lines has enabled us to continuously optimise existing process
cleaning agents on to the strip result in a high mechanical cleaning
lower energy consumption. The specific flow path of the cleaning agent
combination of mechanical, chemical and electrolytic processes offers
technologies and strive for better solutions, focusing on energy reduction,
quality, combined with low fluid evaporation, low maintenance and
through the vertical process tank avoids the formation of gas bubbles and
the required design flexibility and ensures excellent cleaning efficiency
minimised use of chemicals and lower maintenance costs.
low energy losses.
minimises foam production. The construction of our electrolytic cleaning
for the degreasing of all types of metals.
CMI Chemline’s cleaning concepts provide integrated or stand-alone
solutions for the following lines:
• Galvanising Lines
• Coating Lines
• Annealing Lines
• Long Products Processing Lines
• Piece Goods Processing Lines
For Strip Degreasing or Cleaning Lines CMI Chemline’s multi-stage
system combines alkaline spray cleaning, brush cleaning, electrolytic
cleaning and a final rinse section including a brush machine and dryer.
It is designed to remove almost 100% of surface contaminants before
further processing. Vertical spray degreasing and vertical electrolytic
degreasing allow for a long effective treatment time within a short
facility length, offering space-saving cleaning sections or plants. The
final degreasing line arrangement is an assembly of some or all of
Surface deposits such as oil, iron fines or other impurities discourage
these treatment steps, depending on the initial surface deposits, the
adhesion and consequently the functional layer applied to the metal
dimensions and the end use of the strip, but also the metal to be treated
surface is irregular and easily removable under mechanical pressure
and process criteria, such as line speed for example.
Brush cleaning section: CMI Chemline’s brush machines are
characterised by robust design, long service life and ease of
section minimises energy losses and the vertical strip flow ensures a
perfect positioning of the strip between the electrodes without sagging.
maintenance. Our latest design allows for extremely low downtime
Final rinse section: CMI Chemline combines brush rinsing, spray rinsing
for brush and roll changes of approximately 15 minutes per unit,
and a dryer in this last process step using the latest cascade technology.
halving the time for the best technology previously available on the
The final brush rinse removes the remaining surface film, before the strip
market. Additionally our brushes are equipped with an automated
is rinsed in the last rinsing cascade, which is additionally equipped with
regulation system to optimise brushing efficiency and provide
a final high pressure spraying header in order to remove the cleaning
uniform degreasing and constant strip quality.
agent completely. Our multi-stage cascade rinse and the continuous
regulation and automation of the bath concentrations not only provide
excellent flushing, but combine reduced waste water requirements and
fresh water consumption with an excellent rinsing effect. In the last step,
the combination of strip edge blow-off and strip dryer guarantees the
and as a result cannot adequately fulfil its purpose. In preparing for the
most efficient and cost effective drying result, preventing the carry-over
surface refinement process, an ultra clean base strip or base part surface
of fluids to the next process.
is essential. CMI Chemline’s cleaning solutions ensure that the functional
layer (coating, painting or others) adhere properly and thus guarantee
their best performance in service.
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“Our long term experience in this field together with our focus on
continuing design optimisation and innovation in order to improve the
quality of the strip or part to be cleaned are your guarantee that CMI
Chemline’s Degreasing Lines provide the essential level of cleanness.”
Design features:
• E asy service spraying system: possible service during line
operation (no downtime)
• L ong brush service life through robust design
• E asy maintenance of brushing rolls and counter rolls with
specific dismounting tool (approx. 15 minutes per roll)
•V
ibration and leakage-free brush machines
•O
ptimised electrolyte routing and low current density for
deep pore cleaning
•C
ascading of rinsing water for reduced rinse and fresh water
consumption
•C
ascade guiding of cleaning media ensures maximum
For Batch Degreasing Lines CMI Chemline’s expertise offers you the
We take responsibility Backed by the combination of our in-house
Bearings and seals are removed with the roll in one process step, and the
benefit of solutions tailored to produce top quality and performance
capabilities in the improvement and further development of process
roll change is fully automated. Both of these recent improvements to the
and individual environmentally friendly solutions. An optimised bath
technologies and our close co-operation with the industry, CMI
design enhance operator safety and significantly reduce downtime.
operation enhances the efficiency of our Batch Degreasing Lines, using
Chemline offers innovative and customised degreasing and cleaning
a specially designed agitation system to ensure the homogenous mass
lines. Our constant aim is to find better solutions for our customers.
exchange of the temperature and the concentration of the degreasing
solution, as well as an even rinsing effect in the rinsing section.
Our perfectly adapted counter-flow cascade design reduces utility
consumption, while a skimmer continuously cleans the degreasing
solution to extend its life and avoid cross-contamination of the units
leaving the degreasing batch tank. As with our Strip Degreasing Lines,
the bath concentrations are constantly monitored and optionally
treated in order to optimise consumption, while our leakage-free design
and latest fume treatment technology guarantee environmentally and
operator friendly operation of our lines.
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Reliability through in-depth knowledge Our in-depth knowledge in
the field of degreasing and cleaning lines enables us to offer advanced
efficiency in strip cleaning
•A
utomated regulation of the cleaning agent concentration
•O
ptional magnetic filters and ultra-filtration increases
maintenance intervals
•C
losed exhaust treatment system across the line for reduced
emissions
The redesign of our brushing units solves the leakage problem with this
solutions in order to achieve an optimum result, thus providing our
type of equipment. Moreover, our newly designed brush positioning
customers with the innovative and customised solutions needed to
Key benefits:
system eliminates vibrations and thus considerably increases brush
face today’s challenging market requirements.
• E quipment construction and performance results in energy
service life and guarantees smooth operation without chatter marks.
savings
• E nvironmentally friendly lines through reduced consumables
The specifically adapted hydraulic dismounting tool is designed for the
removal of brushing-, back-up- and wringer rolls.
consumption
• L ine design adapted to lower maintenance costs
• E asy service of major equipment increases uptime
•V
ertical arrangement of pre-degreasing and electrolytic
degreasing for reduced space requirements
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Acid Regeneration Technology
The green solution
The better the surface quality at the beginning of the cold rolling
CMI Chemline has successfully developed and improved processes
process, the more our customers can reduce the waste in down-stream
for the regeneration of acids used in the pickling of metals and the
rolling and coating processes. Scale free quality is to be achieved though
leaching process for the mining industry for decades. All our plant
effective pickling, producing strip that is free from surface impurities.
layouts are optimised for ease of maintenance and reliable operation,
As a market leader,
CMI CHEMLINE
the full
range
of pickling
guaranteeing
the best
return on supplies
investment,
while
considerably
solutions for the most effective removal of iron oxides from mill scale
reducing the ecological footprint of our customers’ plants.
and other impurities from hot and cold rolled stainless steel , carbon
As a leader in this market segment, CMI Chemline offers a modular
steel or silicon steel but also non-ferrous metal strip like, aluminium,
design that guarantees our customers the optimal solution for all
brass etc. Our name stands for the most modern and effective pickling
their individual process requirements and applications, with acid
technology in the steel industry.
recovery rates of virtually 100%:
Our engineers built the world’s first shallow tank pickling line, introducing
turbulent
process –with
thesteel
resulting
improvement
in
•the
Fluidised
bedpickling
pyrohydrolysis
carbon
including
silicon steel
pickling efficiency and the highest quality on the market, thus replacing
applications
the more costly and less efficient deep tank pickling technology.
• Spray roaster pyrohydrolysis – carbon steel including silicon steel
Best available technology for
our Hydrochloric Acid (HCl)
regeneration process
Absorber System and Off-Gas Handling The HCl contained in the
Compared to conventional neutralisation plants, TOMAREG® reduces
reactor off-gas is then passed through an absorber system using
annual costs by 70% and hazardous waste discharged to the environment
a counter-current circulation system, in which the rinse water from
by more than 98%.
Today two pyrohydrolysis processes are available, namely fluidised bed
acid, which is then reused in the pickling line. The remaining off-
and spray roaster technology, both of which have distinct advantages.
gas passes through several treatment steps, including the exhaust
Being able to offer either of these processes enables CMI Chemline to
fan which regulates the negative pressure in the whole upstream
focus fully on our customers’ specific site conditions and help them to
system preventing gas leaks, before being released via the stack into
choose the best option. Simplified processes such as our quick-change
the atmosphere.
maintenance free or the most modern plant control system (PCS) are
just a few examples of the features provided by the latest generation
of our plants. Our Acid Regeneration Plants (ARPs) are equipped with a
highly automated control system that minimises field intervention by
our high- stainless
turbulence
pickling
tank technology is not only among
•today
TOMAREG®
steel
applications
the
most
efficient,
but
also
the
most
• Pyrohydrolysis - applications other cost
thaneffective
steel solutions on the
the operator and enables safe and reliable daily operation from a single
injection systems perfectly adapted to all types of applications as well
as the specific product mix to be pickled. In addition accurate control
of the strip and the pickling process, guarantees the best possible scale
removal without over-pickling.
This optimized control of the pickling process based on our latest PPM
(Pickling Process Management), as well as our fully automated Acid
Control Management System ensure the environmentally safe operation
of your plants using the best available technology.
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to 100% of the waste pickle liquor (WPL) is converted back to liquid
spray nozzles, the improved design of our venturi rendering it completely
CMI
Chemline is constantly developing its turbulence pickling and
applications
market. Our pickling tanks come in different bottom profiles and acid
the pickling line absorbs the HCl in the reactor off-gas. Thus close
control room.
Reactor and Venturi Circulation System For the total regeneration
of Hydrochloric Acid (HCl), the waste pickle liquor from the pickling
line is concentrated by direct heat and mass exchange in the venturi
circulation system, before being injected into the spray roaster or
fluidised bed reactor, where it reacts with O2 and H2O to form solid iron
oxide and hydrogen chloride gas.
Specialized pyrohydrolysis plants
for the leaching process
In our ongoing effort to create sustainable and responsible solutions, CMI
Chemline has also developed plants used in the mineral leaching process,
and we are able to supply plants, including test or pilot plants, designed for
TOMAREG® - A highly
innovative solution for the
regeneration of mixed acid
the beneficiation of ores of the following non-ferrous metals:
• Nickel
• Titanium
• Magnesium
• Zirconium
Mixed Acid used for stainless steel pickling consists of Hydrofluoric
• Manganese
Acid (HF) and Nitric Acid (HNO3), both of which are expensive and
• Cobalt
problematic in waste streams. TOMAREG® recovers not only these
• Chromium
expensive acids for reuse in the pickling line but also the valuable
metals contained in the waste stream. With TOMAREG®, CMI Chemline
Other specialised plants can be developed through working with our
offers a system for pickling stainless steel that allows highly flexible
customers for other applications.
operation of the pickling line, due to the adjustable acid concentration
of the regenerated acid. TOMAREG® can produce oxide either in the
form of a fine powder or coarse particles, as the plant can be delivered
optionally with spray roaster or fluidised bed technology.
21 21
“Continuous awareness of market requirements and the specific needs
of our customers makes CMI Chemline the leading company in Acid
Regeneration for all types of acid and all available technologies.”
Design features:
•H
igh degree of automation
•P
roven technology
•H
igh efficiency combustion systems
• E asy start-up sequence
•H
igh efficiency fume treatment
•O
xide dust-free, free of trace components (FB-ARP)
•O
xide fine powder for ferrite industry tailor-made to
customers’ requirements (SR ARP)
• S tand-by arrangement of essential equipment
• L ow maintenance requirement
• L ayout optimised for easy access
•A
ll high pressure lines shielded
Process Comparison
Spray Roaster vs. Fluidised Bed
Both processes, fluidised bed and spray roaster, offer specific advantages.
The highest market value is obtained in the soft and hard ferrite industry.
The fluidised bed has certain features which make it attractive to a particular
However, for an iron oxide to be usable as a raw material ferrite, it needs to
market, namely the considerably smaller space requirements, and the
meet constant physical and chemical properties with minimal variations,
• E nhanced combustion system safety
•C
ontrol system designed to minimise operator field
intervention
• S afe operation from control room
characteristics of the oxide, which are extremely low residual chloride content
requirements that significantly affect the price obtained for the iron oxide,
While both technologies are mature, it is not always easy to make the
and ease of handling. Consequently, the dust-free fluidised bed oxide can
but which are not always easy to achieve, mainly due to the varying waste
choice. A number of considerations potentially affect the decision. The cost
Key benefits:
easily be disposed of in landfill, or can be used as an aggregate or as an
pickle liquor quality. Additionally, the saturation rate of the iron oxide market
of handling and transport or the distance between the oxide producing
• E nvironmental protection due to recovery of hazardous
addition to recycled iron used in the steel making process.
has a profound impact on the price obtained in the ferrite or pigment
plant and the oxide consuming industry are decisive factors when choosing
industry and makes the price cyclic.
chemicals
•V
irtually emission-free operation
between the two technologies. Additional considerations include energy
On the other hand, the spray roaster technology generates an iron oxide
or maintenance costs which are higher for the fluidised bed process, or
which is a highly valuable by-product. Used in the hard and soft ferrite
The above considerations argue against a reductionist approach to
•H
ighest achievable production rates
operating costs which are higher for the spray roaster process. Depending
industry and the pigment industry, the oxide can considerably improve the
assessing the choice of the most suitable technology. The appropriate
•O
ptimised pickling due to constant operating parameters
on where the acid regeneration plant (ARP) is to be built, the above factors
return on investment of the ARP.
choice encompasses the need to address a wide set of issues over
• Independence from chemical suppliers
may differ considerably and some will be decisive in the final choice of
different time scales, while accommodating specific customer and market
• S hort payback time
which technology to install.
requirements and constraints.
•R
ecovery of costs by sale of oxide as high quality by-product
•P
resent and future legal requirements on emissions are met
• L ow maintenance costs
•P
roven design
22
•A
daptable to all types of Pickling Lines
23
Our commitment to sustainability
and the environment
CMI Chemline helping you
build the future
Against the background of rising energy prices and increasing
environmental awareness, sustainable development has become the
driving factor behind our global industrial system. The steel industry is
investing billions in becoming a more sustainable and environmentally
“Our equipment helps
our customers meet the
needs of today… without
compromising the needs of
tomorrow.”
Recycling solutions –
Clean perspectives
Designed to take into account the most modern technical and
process parameters, our Cleaning, Degreasing and Pickling Lines
support environmental aspirations by significantly reducing
Ultra-filtration, magnetic filters and vacuum evaporators are
examples of optional add-ons that ensure the highest efficiency of our
Degreasing and Cleaning Lines, while offering an environmentally friendly
operation by further reducing consumption and waste streams.
Our acid fume treatment systems offer the best available technology
(BAT) and not only comply with the present emission requirements, but
are already designed with reference to more stringent future legislation.
consumables and energy consumption.
In addition to fail-safe design, we offer key features such as a stand-by
friendly industry. This means that steel industry investment is increasingly
directed towards reduced energy and consumables consumption
CMI Chemline develops and supports sustainable recycling
and improved emission control, while increasing production and
solutions to minimise waste products – down to zero in the
productivity.
best case. In addition to our in-line features, such as counterflow cascade technology, closed exhaust treatment systems,
exhaust fan and continuous off-gas monitoring.
Fumes loaded with NOx from e.g. mixed acid Pickling Lines are treated
most efficiently by Selective Catalytic Reactors (SCR-Technology).
CMI Chemline supplies highly reliable systems with low maintenance
CMI Chemline supports these goals by providing a diverse range of
optimised process control, continuous analysis of consumables
solutions. Our chemical process design not only helps you to master
and high turbulence pickling, CMI Chemline offers optional
the increasingly demanding quality requirements imposed by your
waste stream treatment solutions providing even more eco-
Our Neolyte Purification Systems not only reduce harmful chromium
customers, but also addresses increasingly stringent environmental
friendly and efficient operation.
(+6) to non-toxic chromium (+3), but also regenerate the electrolyte,
regulations. CMI Chemline offers a wide range of technologies for
the treatment of spent acid, waste water and waste air generated by
requirements, low operator attendance and a long lifetime.
thus reducing operating costs and the environmental impact of stainless
steel Pickling Lines.
all types of processing lines, in order to eliminate substances that are
harmful to the environment.
24
25
Engineering
your global
success
Closed Loop Recycling Regenerating waste pickle liquor from Pickling
Lines to produce regenerated acid and valuable iron oxide is the perfect
example of such a system. Based on many years of in-house experience,
CMI Chemline offers highly efficient system solutions by matching
metal pickling operations with the most adapted Acid Regeneration
Technology.
Leading technology Tightening environmental standards and stringent
air permit policies render it increasingly difficult to operate Pickling Lines
without an Acid Regeneration Plant.
Ultramodern acid regeneration technology from CMI Chemline not only
lays the foundation for optimised productivity and the highest possible
level of process safety, but also offers the most environmentally friendly
solution.
• The waste acid from the pickling process can be recovered completely
with a total recovery efficiency > 99%
• Rinse water from the pickling process can be utilised, allowing effluentfree operation of the PL + ARP system
• Highly efficient dust reduction down to 1 micron particle size
• High efficiency self cleaning gas scrubbing and dust separation
equipment guarantees Hydrochloric Acid (HCl) and dust emissions
below the prescribed emission limits.
“CMI Chemline
focuses constantly on
reducing the impact of
industry on the environment
and its sustainability.
As such, our aim is to deliver
significant innovation in
processes or technologies
for the long term.”
Along with CMI Rolling Mills, CMI Processing Lines, CMI Thermline
With its strength as an assembler behind it, CMI Industry is also active in
and CMI Greenline, CMI Chemline belongs to CMI Industry.
the supply of other production installations, and offers solutions in the
domain of reducing the environmental footprint of all types of industrial
A specialist in industrial processes, CMI Industry designs, modernises
installations.
and supplies cold steelmaking complexes. Cold rolling mills, steel
galvanising lines, thermal and chemical treatment equipment for
In addition to supplying equipment, CMI Industry also offers customer
steel, specialised equipment, are just some of the specialities in
support programs to assist in the start-up of the new or upgraded unit,
which CMI Industry possesses expert knowledge and mastery of
including complete and flexible customized training sessions, addressing
the latest technologies, and for which it has unparalleled references.
issues from equipment operation to final product quality.
By combining these various skills, CMI Industry holds a position in
the vanguard of leading-edge technological innovation for the
CMI Industry solutions are available everywhere in the world, either
modernization or construction of new integrated plants, including
through its operational units in Brazil, China, the United States, Europe,
electrical and automation systems.
India and Russia, or through its commercial network. Wherever he may
be situated, a client thus has a local contact to access a global offer of
services.
26
27
Business Units
Regional contacts
• AMERICA
america@cmigroupe.com
Tel +1 330 332 4461
Fax +1 330 332 1853
• BRASIL
brasil@cmigroupe.com
Tel +55 31 3789 5342
Fax +55 31 3789 5319
• CHINA
china@cmigroupe.com
Tel +86 10 6561 1126
Fax +86 10 6561 2533
• EASTERN EUROPE
AND DEUTSCHLAND
deutschland@cmigroupe.com
Tel +43 1 603 34 93
Fax +43 1 603 34 93
• ESPAÑA
espana@cmigroupe.com
Tel +34 94 415 72 45
Fax +34 94 416 80 28
• FRANCE
france@cmigroupe.com
Tel +33 4 42 06 95 36
Fax +33 4 42 06 76 38
• ITALIA
italia@cmigroupe.com
Tel +39 331 67 97 71
Fax +39 331 63 02 53
• RUSSIA
russia@cmigroupe.com
Tel +7 495 937 19 20
Fax +7 495 937 19 21
TRAINING CENTER LOCATION
• MASTEEL - CMI
International Training Center Co., Ltd.
Hunanxilu No 8, Maanshan City
243000 Anhui Province
China
www.magang.com.cn
CMI chemline
chemline@cmigroupe.com
• CMI Beugin
26, rue Jules Elby BP 57
F-62150 La Comté
France
Tel +33 3 21 47 52 00
Fax +33 3 21 47 52 01
• CMI UVK GmbH
Robert-Bosch-Straße 12
D-56410 Montabaur
Germany
Tel +49 2602 99 99 0
Fax +49 2602 99 99 599
• CMI Industry Americas Inc.
industry.americas@cmigroupe.com
Salem installation
435 W. Wilson St.,
Salem, OH 44460 USA
Tel +1 330 332 4661
Fax +1 330 332 1853
• CMI Brasil Ltda
brasil@cmigroupe.com
Rua Fernandes Tourinho, 147 - sala
1002 - Savassi
30112-000 - Belo Horizonte - MG
Tel +55 31 3789 5342
Fax +55 31 3789 5319
• CMI FPE Ltd
Mehta House, Stud N°64,
Road N°13, MIDC
Industrial Area Marol, Andheri (E)
400078 Mumbai
Maharashtra
India
Tel +91 22 6676 2727
Fax +91 22 6676 2737
• CMI Beijing Engineering
beijing.engineering@cmigroupe.com
Hanwei Plaza, Room B719
7, Guanghua Road
Chaoyang District
100004 Beijing
China
Tel +86 10 5265 9797
Fax +86 10 5265 9700
CMI Industry (Head Office)
Avenue Greiner, 1
BE - 4100 Seraing
Belgium
Tel. +32 4 330 21 91
Fax +32 4 330 21 10
industry@cmigroupe.com
www.cmigroupe.com
-
• EUROPE
industry@cmigroupe.com
Tel +32 4 330 21 91
Fax +32 4 330 21 10
• INDIA
india@cmigroupe.com
Tel +91 22 667 627 27
Fax +91 22 667 627 37
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REGIONAL CONTACTS