Scale Breaker for 1850 mm Pickling Lines
A tension leveler installed in front of the pickling tank is called a scale breaker. Hot rolled strip is plastically deformed by continuous alternating stretching and bending, while the oxide surface layer does not deform plastically, so it fractures and the acid does far less work.
- Installed in front of the pickling tank
- For 1850 mm wide pickling lines
- Core component is the bending and correcting roll units
- Saves acid and corrects strip shape in one pass
Key Benefits
Two results from one pass.
Large Acid Saving
When the oxide layer fractures under stretching and bending, the acid no longer has to dissolve an intact scale, which saves a great deal of acid.
Shape Correction Included
The hot rolled strip also receives better shape correction at the same time, so a separate leveling step is not needed before cold rolling.
Proven Configuration Across Lines
The same tension leveler technology is used in galvanizing, acid rolling and colour coating lines, with the roll units configured for each duty.
Where It Is Used
Line types.
- 1850 mm hot strip pickling lines
- Acid rolling lines
- Feed preparation for cold rolling
- Wide strip processing for automotive sheet
Who It Is For
- Pickling line operators running wide strip
- Mills tracking acid consumption cost
- Plants correcting shape before cold rolling
- Project teams specifying pickling line equipment
Problems It Solves
- High acid consumption in the pickling tanks
- Uneven descaling across wide strip
- Shape defects carried into cold rolling
- Slow throughput through the acid section
Technical Features
How the unit is built.
Bending And Correcting Roll Units
The core component of the tension leveler is the bending and correcting roll unit, which delivers both the scale fracture and the shape correction.
Alternating Stretch And Bend
Continuous alternating stretching and bending plastically deforms the strip while the oxide layer, which cannot deform plastically, fractures.
Wide Line Configuration
Roll length, drive and frame are sized for 1850 mm line width.
Specifications
Configuration follows the pickling line. Scope is confirmed per project.
| Line Width | 1850 mm pickling line |
|---|---|
| Position | In front of the pickling tank |
| Principle | Continuous alternating stretching and bending |
| Core Component | Bending and correcting roll units |
| Material | Hot rolled strip |
| Related Lines | Galvanizing, acid rolling and colour coating lines |
Materials
- Welded and stress relieved frame
- Alloy steel bending and correcting rolls
- Sealed bearing units for the acid area
Manufacturing Process
Line Survey
Strip width, thickness, scale condition and line speed are reviewed.
Frame Fabrication
Housings are welded, stress relieved and machined for roll position accuracy.
Roll Unit Production
Bending and correcting roll units are produced and ground.
Assembly And Test
Roll parallelism and drive alignment are verified before shipment.
Quality Control
- Frame machining inspection
- Roll hardness and runout records
- Bearing seal verification for acid exposure
- Assembly parallelism report
Customization Options
- Line width and roll length to your pickling line
- Roll unit configuration for scale condition
- Drive package and automation interface
- Spare roll units and cassettes
Use Guide
- Set elongation from the scale condition of the incoming coil
- Check roll gap parallelism after each roll change
- Watch bearing seals in the acid fume area
- Track acid consumption as an indicator of scale breaker performance
How It Compares
Against relying on acid alone.
| Pickling without a scale breaker | Fracturing the oxide layer mechanically saves a large amount of acid and shortens tank residence time. |
|---|---|
| Separate leveler after pickling | Shape correction happens in the same pass, saving line length and handling. |
| Narrower units | The 1850 mm configuration covers wide strip that narrower equipment cannot process. |
Related Products
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Related Technical Articles
How Scale Breakers Optimise Surface Quality Before Cold Rolling
Dry and wet scale breakers, the elongation window that matters, and why the first processing step decides the last.
Read MoreTension Control In Push Pull Pickling Lines Section By Section
Typical tension ranges for entry, pickling, rinse, dry and exit sections, and what each one is protecting.
Read MoreScale Breaker for 1850 mm Pickling Lines FAQ
Why is it called a scale breaker?
It is a tension leveler installed in front of the pickling tank. In that position the job is to fracture the oxide surface, so the same machine is called a scale breaker.
How does it save acid?
Under alternating stretching and bending the strip deforms plastically but the oxide surface does not, so it fractures. Acid then penetrates instead of having to dissolve an intact layer.
Does the strip shape improve as well?
Yes, the hot rolled strip also receives better correction during the same pass.
What is the core component?
The bending and correcting roll units. Their configuration decides both scale fracture and shape correction.
Can you supply for other line widths?
Yes. Send your line width, strip range and layout and we configure accordingly.
What do you need to quote?
Line width, strip thickness range, scale condition, line speed and whether this is new or a replacement.
Cut Your Acid Consumption
Send your pickling line data and our engineers come back with a scale breaker configuration.