1.What are the core selection principles?
Process Compatibility: Meets the lubrication, cooling, cleaning, and rust prevention requirements of the rolling process.
Quality Compliance: Ensures the surface quality of the strip steel (cleanliness, gloss, and color uniformity).
Equipment Compatibility: Compatible with the rolling mill's circulation system, filtration system, and sealing materials.
Cost-Effectiveness: Comprehensively considers initial costs, maintenance costs, consumption, and wastewater treatment costs.
Environmental Protection and Safety: Complies with environmental regulations, is easy to handle, and is safe for operators.
2.How to determine the process and equipment parameters?
Rolling Mill Types and Processes:
Rolling Mill Types: Single-stand reversible rolling mills, continuous rolling mills, silicon steel rolling mills, stainless steel rolling mills, etc., each have different requirements for emulsions.
Rolling Speed: High-speed rolling (>1200m/min) requires extremely high emulsion cooling and stability.
Rolling Pressure and Deformation: Large reductions require higher extreme pressure lubrication.
Rolling Oil System: Understanding tank capacity, filtration accuracy (magnetic filtration, paper filtration, ceramic membrane, etc.), skimming system, and temperature control capabilities is crucial.
3.What types of product outlines are there?
Steel grades: Plain carbon steel, high-strength steel, silicon steel, stainless steel, etc. Silicon steel requires extremely low residual carbon and high cleanability; stainless steel may require special oils.
Finish thickness: The thinner the finish, the higher the lubricity requirement.
Surface quality requirements: High-grade surfaces (such as O5 plates) require good emulsion cleaning properties, without producing stains or sludge.
4.How to determine the performance requirements of emulsions?
Lubricity:
Base Oil Type: Mineral oil, ester oil, synthetic hydrocarbons. Ester oils offer the best lubricity but are prone to hydrolysis; synthetic hydrocarbons exhibit good stability.
Additive Package: Extreme pressure anti-wear agents (e.g., phosphate esters, sulfides), oiliness agents (e.g., fatty acids, alcohols). Selection is based on rolling force.
Reflecting Indicators: Coefficient of friction, rolling force reduction rate, annealing detergency (residual carbon content).
Cooling and Heat Dissipation:
Depends on the specific heat capacity, thermal conductivity, and particle size of the emulsion. Small particle size (typically 0.5-2 μm) results in good stability and uniform cooling.
Stability and Separability:
Balance: Stability is required during rolling, but rapid oil-water separation is necessary during skimming and settling to facilitate oil removal.
Particle Size Distribution: Must remain stable within the target range. Too fine a particle size makes separation difficult, while too coarse a particle size results in uneven lubrication.
5.How to choose the type of emulsion?
Standard Emulsions:
Mineral oil-based, suitable for low-to-medium speed rolling of plain carbon steel with general surface requirements. Low cost.
High-Efficiency Emulsions:
Contain esters or synthetic esters, excellent lubrication, suitable for high-speed, high-force rolling of thin-gauge or high-strength steel. Annealing cleaning properties are generally better.
Long-Life Emulsions:
Polysesses excellent resistance to oxidation and bacterial spoilage, longer replacement intervals, and potentially lower overall maintenance costs.
Specialty Emulsions:
Silicon Steel Emulsion: Extremely low residual carbon, high cleaning power.
Stainless Steel Emulsion: May be chlorine- and sulfur-free to prevent corrosion.
Aluminum Rolling Oil: A completely different system; please distinguish carefully.