Innovative application of soap-free emulsion in aluminum casting and rolling mill
In the field of metal processing, especially in the process of aluminum casting and rolling and tandem rolling, the application of soap-free emulsion is gradually becoming the key technology to improve production efficiency and product quality. Soap-free emulsion, as a kind of high performance metal processing liquid, plays an irreplaceable role in aluminum processing with its unique advantages.
No advantage of soap emulsion
The main advantage of soap-free emulsions is their excellent cooling and lubrication properties. Compared with the traditional emulsion, the soap-free emulsion does not need to rely on soap additives to form a lubricating film, but through the Base Oil in the emulsion and the additive in the rolling process to form a stable oil film, to achieve anti-friction and anti-wear. This soap-free formula not only reduces the environmental pollution of the emulsion, but also improves the stability of the rolling process and the quality of the product.
In the process of aluminum casting and continuous rolling, the non-soap emulsion can significantly increase the thickness of the intermediate billet at the inlet of the finishing mill or reduce the thickness at the outlet, which is of great significance to improve the production efficiency and reduce the cost. For example, in the first Hazelett aluminum plate production line in Longquan, Henan Province, designed by MCC East, the relative reduction rate reached 63% after using Quaker soap free emulsion, which was much higher than 43% when using traditional emulsion. This improvement not only improves the flexibility of the production line, but also significantly improves the shape and surface quality of the aluminum sheet.
Application case and effect
On the 1650 production line of CVAB in Spain, soap-free emulsions also demonstrate excellent performance. At the rolling speed of 90-150m/min, the reduction rate of the finishing mill reaches 63%, 58%, 83%, respectively, and the outlet thickness is controlled between 1.4mm and 3.0mm. In this process, the soap-free emulsion ensures a good cooling effect and avoids the phenomenon of thermal scars and sticky rolls caused by excessive temperature during the rolling process. At the same time, its excellent lubrication performance also extends the service life of the mill work roller and reduces the maintenance cost.
In addition, the soap-free emulsion also has the characteristics of long-term use without replacement and without adding on-site additives. In the application of Southwest Aluminum, soap-free emulsion has been used continuously for 8 years, and the fuel consumption of tons of aluminum has been reduced from 12 to 1.45L/t to 0.6L/t, which significantly reduces the production cost. At the same time, the corrosion of the emulsion to the equipment is only 1/3 of the conventional emulsion, which further guarantees the long-term stable operation of the production line.
Performance specifications and stability
The performance indexes of soap-free emulsion mainly include physical indexes and chemical indexes. Among them, stability is one of the key indexes to evaluate the quality of emulsion. Soap-free emulsion, through its unique formulation design, can maintain the stability of oil and water stratification during long-term use, avoiding precipitation and stratification. In addition, its high saponification value also ensures that the emulsion has excellent lubrication properties and can meet the needs of complex and variable conditions during aluminum casting and continuous rolling.
Conclusion
The application of soap-free emulsion in aluminum casting and rolling mill not only improves production efficiency and product quality, but also reduces production cost and maintenance difficulty. With the continuous progress of metal processing technology and the increasing environmental protection requirements, soap-free emulsion will become an important development direction in the field of metal processing in the future. Through continuous optimization of formulation and process, soap-free emulsion will show its unique advantages and value in more fields.
