OPTIMIZATION OF THE EMULSION CIRCUIT FOR ALUMINUM ROLLING MILLS (EA9)

ISSUE

An aluminum product rolling mill is experiencing a clogging problem in the rolling mill emulsion circuit.

A cohesive gel builds up in the rolling mill emulsion circuit and causes the filter to clog. The factory has requested an investigation to assess and select a method to stop the formation of this gel.

TECHNOLOGICAL CHALLENGE

The customer operates 13 aluminum rolling mills. The gel formation problems are new to the plant. A critical analysis of the additives and chemical reactions in the emulsion circuit was a key strategy to introduce a sustainable solution.

RECOMMENDED SOLUTION

The determination of the nature of the gel building up in the circuit was conducted through an analytical investigation. The application of various methods to control bacterial formation were tested and evaluated to select the most efficient method and compatible material. An evaluation of the effectiveness of the solution adopted on the bacterial population was carried out in laboratory.

RESULTS

The results of the analytical investigation shown a high level of bacteria present in the gel and the emulsions. This observation allowed to conclude that bacterial control method in place in the factory had low efficiency which explained the bacterial growth in the circuits well.

Laboratory tests allowed to identify an effective method to control bacterial growth and achieve very good bacteria kill rates. This method allows simple, safe use and at a reasonable price compared to the former method.

The recommended method was implemented in the plant in 2016 and shows good performance in ensuring the control of bacterial growth.