Andy Ruan new General Manager in Scanacon Shanghai
by adopting optimized process control.
Consistent acid finishing process requires consistent process conditions. Variations in the key variables that govern the finishing process can negatively affect product quality.
Scanacon offers stainless, titanium, zirconium and specialty alloy producers and fabricators the opportunity to achieve consistent product quality by eliminating process variations in their finishing processes. Surface defects resulting from over or under pickling can be significantly reduced. For titanium cast or forged parts manufacturing, over-milling and scrapping expensive parts can be eliminated.
Gain control of your process, improve product quality and reduce the need for re-working or scrapping valuable material.
Optimum management of the pickling or milling line has a tremendous impact on productivity.
During production, when the pickling or milling rate decreases a threshold limit, periodic stoppages to dump and replenish the pickling or milling solution is necessary, a process that costs valuable production hours. Moreover, a non-optimized process operates less efficiently as the waste products that inhibit the pickling or milling process continually increase in concentration.
Eliminate process dumping with Scanacon and achieve maximum line availability for production – not maintenance. We offer our customers our experience, knowledge and technology to achieve the most productive pickling or milling line possible.
During metal finishing activities, Sulphuric, Nitric and/or Hydrofluoric acid are consumed in the pickling and chemical milling process. However, a certain proportion – in some instances, over half - are wasted.
Acid loss from dumping to control suspended solids, dissolved metals and drag-out into the rinses can equal 50% or more of the total acid purchased. This high percentage of waste significantly increases the total quantity and cost of the acid(s) necessary for operating a pickling, chemical milling or etching line.
By reducing the total quantity of acid lost as waste, significant quantities of other chemicals – alkaline, flocculants and polymers - used for the treatment and disposal of these acids at the waste treatment plant can also be minimized.
Minimize acid waste and reduce treatment chemicals with Scanacon. We offer our customers our experience, knowledge and technology to achieve the most efficient pickling or milling line possible.
Non optimized pickling or milling can result in excessive base metal loss and an unnecessary high consumptions of acid, significantly increasing the cost per tonne of finished product. Variations in pickling or milling chemistry can cause unacceptable product variations or surface defects that may necessitate re-working or scraping the material.
When it comes to production and economics of pickling or milling, the goal is simple – the greatest production throughput with the lowest specific consumption of acids and the highest quality finish.
Reducing the percentages of lost acids, liquid waste volumes, solid waste volumes, neutralisation chemicals and water while simultaneously improving production throughput significantly reduces the costs associated with finishing activities. Reducing re-work, scrap or product rejects means more finished product leaves the door, and not on the shop floor.
We offer our customers our experience, knowledge and technology to achieve the most economical and efficient pickling or milling line possible.
Scanacon gives the stainless, speciality alloy, titanium and zirconium producer the ability to minimize energy and other resources.
With optimized picking or chemical milling, energy lost to dumping process baths and the energy inputs required to maintain process temperatures are minimized, directly reducing the quantity of energy needed to operate the finishing line.
Water is a precious resource. With a cleaner pickling or milling process, water demands and optimized rinsing practice can be minimize fresh water volumes by 90% or more, helping you achieve a leaner and greener finishing operation!
On-site storage and routine handling of hazardous Sulphuric, Nitric and/or Hydrofluoric acid represent significant liabilities given the risks of spillage and accidental contact to personnel and property. By virtue of their highly acidic composition, pickling wastes also pose risks to personnel during their handling, treatment and disposal.
Scanacon understands that while acids cannot be realistically eliminated from the production area, minimizing the quantity of acids used in the pickling, milling or cleaning process reduces the volume of acids stored on-site, and minimizes the workers potential for occupational exposure from fresh acids or acidic wastes.
Scanacon competency includes engineering of acid storage and handling systems and establishing safe operational protocols – thus minimizing health and safety liabilities.
We offer our customers our experience, knowledge and technology to achieve the safest pickling or milling line possible.
A managed and optimized pickling or milling process with Scanacon reduces the overall amount of waste resulting from the pickling or chemical milling line. Reducing the primary by-products of pickling and milling – metal oxide sludge’s, waste liquor, acid gasses and acidic waste water from rinses – reduces the quantity of hydroxide sludge that results from it’s treatment by 40% or greater.
Pickling and milling results in the production of environmental pollutants in the form of solids, liquids and gasses, all of which require appropriate treatment prior to disposal or discharge. In some instances stainless and speciality alloy producers are coming under increased regulatory pressure to limit releases of nitrogen bearing wastes such as NO /NO2 gas and nitrate (NO3-) ions into the environment. Reducing overall water usage and it’s discharge is quickly becoming a focus of stainless steel and speciality alloy producers, worldwide.
A closed loop pickling or milling line while technologically possible remains at present a challenge given the complexity and economics to achieve it. Nevertheless, reductions of 90% or greater in fresh water usage and up to 60% of the nitrate (NO3-) associated with the pickling line is economically achievable with existing technology today.
Increased productivity by gaining control over the main variables that govern the pickling, etching or milling reaction ensures consistent and repeatable processing times.