The hottest silane technology brings changes to Ph

Silane technology brings changes to phosphating technology

silane process is a new direction of surface treatment technology development. It has irreplaceable advantages of phosphating process, such as energy saving, environmental protection, low cost and simple operation. The successful application of silane technology will bring revolutionary changes to phosphating technology

transformation scheme

the traditional ternary phosphating surface treatment process and silane technology process are shown in Figure 1 and Figure 2 respectively. Taking Chery spare parts workshop production line as an example, the equipment transformation scheme is as follows:

1 Pre degreasing tank. Because the regenerated plastic granulator with silane products as the main processing machine will have a large customer group, which has higher requirements for degreasing than phosphating. Spray pre degreasing can thoroughly wash the outer surface of the workpiece and wash 70% - 80% of the interior of the workpiece. Only those dead corners of the spray need to be thoroughly cleaned by impregnation degreasing

at present, the pre degreasing time of spare parts line is 50 ~ 60s, and the spray pipeline is 4 rows; During the transformation, 2 ~ 4 rows of spray pipes need to be added to extend the pre degreasing time to 90 ~ 120s

2. The main degreasing tank does not need any modification

3. There is no need to make any transformation for washing 1 tank

4. Table adjustment slot. A row of fresh DI water direct spraying equipment is arranged in the area close to the surface regulation between the surface regulation outlet and the phosphating tank. It is best to have an induction device to spray when a workpiece passes through. The flow rate is required to be above 1.5l/m2. The fresh pure water can directly enter the surface regulating tank for circulating pure water

5. Phosphating tank. Because silane product 8 adopts high-precision, full digital speed regulation system and precision reducer, which are sensitive to phosphorus, the phosphating tank must be thoroughly cleaned. The performance of this cleaner cannot be compared with that of now, including chemical cleaning and manual cleaning. However, in the interior of the pipeline, especially in some dead corners, chemical cleaning may not remove the slag completely, and at the same time, manual cleaning cannot be carried out in the pipeline. It is better to replace all pipelines with new ones. And the material of the pipe must be 304 or 316 stainless steel, or hard PVC or PE resistant to fluoride. The surface laminar flow tube originally designed for phosphating can be cancelled. However, the heat exchange pipe can not be canceled, because considering that if the water temperature drops below 5 ℃ in winter, it is still necessary to heat the silane tank liquid to about 15 ℃ to ensure the quality of treatment

6. There is no need to make any transformation in water washing zone 2

7. There is no need to make any transformation in water washing zone 3

8. Fresh DI water spray does not need any modification

Figure 1 traditional ternary phosphating surface treatment process

Figure 2 process using silane technology

cost comparison

1 Chemical cost comparison

phosphating (calculated by phosphating price including tax of 12 yuan, accelerator price including tax of 5 yuan, table adjustment price including tax of 20 yuan): every 1? 000m2, the price is about 12 × 10＋5 × 3＋20 × 1 = 155 yuan; Silane (calculated by 9810/1 tax included 250 yuan and 9905 tax included 40 yuan): the price per 1000m2 is about 250 × 0.5＋40 × 1 = 165 yuan. In terms of chemicals, silane is 10 yuan/km2 more expensive than phosphating. Based on the annual production of 530000m2, silane is 5300 yuan more expensive

2. Heat energy comparison

phosphating (calculated by phosphating temperature of 40 ~ 45 ℃): at present, the heat energy consumption of the cheapest impregnation phosphating line in China is 80 yuan/km2, and this production line is expected to consume 110 yuan/km2 due to the small processing area of a single shift; Silane (only heated to above 15 ℃ in winter): the estimated thermal energy consumption is 10 yuan/km2; Thermal energy: phosphating is 100 yuan/km2 more expensive than silane. Based on the annual production of 530000m2, phosphating costs a total of 53000 yuan

3. Electric energy comparison

based on the current annual operation of 2? 112 focus on improving resource integration h calculation, phosphating (including post washing, a total of four 30kw/h pumps), annual electricity charge (calculated by 1 yuan of electricity price) 4 × 2? one hundred and twelve × 30 = 253440 yuan; Silane (only one pump needs to be operated) annual electricity charge (calculated by 1 yuan of electricity price) 1 × 2? one hundred and twelve × 30 = 63360 yuan. For the whole year, phosphating costs a total of 190080 yuan

4. Comparison of wastewater treatment costs

phosphate in phosphating is about 15000ppm, zinc, nickel and manganese in total is about 3000ppm, and the washing factor is calculated as 100. When the subsequent washing reaches the overflow dynamic equilibrium, the wastewater contains about 1500ppm phosphate, zinc, nickel and manganese in total is about 300ppm, and the treatment of each ton of wastewater is about 8 yuan; Silane does not contain phosphorus, with silicon content of about 40ppm and zirconium content of about 200ppm. The water washing factor is calculated as 100. When the subsequent water washing reaches the overflow dynamic equilibrium, the wastewater contains silicon of about 4ppm and zirconium of about 20ppm, and the treatment of each ton of wastewater is less than 1 yuan; Based on the annual 530000m2, about 4L waste water is generated per square meter, about 2120t waste water is treated throughout the year, and phosphating costs 14840 yuan in total

5. Environmental protection

compared with phosphating, silane products do not contain heavy metals such as zinc, nickel and manganese, significantly reduce water consumption and wastewater treatment, work at room temperature, do not contain phosphorus, do not contain redox agents, no nitrogen oxide waste gas emissions, and almost no slag (slag amount of all metals