ecoat korea
DESCRIPTION
A electrocoat technical presentation in Korea talking about the specs of the process.TRANSCRIPT
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E-Coat Seminar. 2008
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A.
Neutralization ( )Electro-deposition Reaction Mechanism Electro Deposition Section Parameter ED Trends of Future
6. Trouble Shooting
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1. Neutralization ( )
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2. Electro-deposition Reaction Mechanism , , H+, OH- . , . ( +) . . OH- . H+ OH- H2O . . . () () (Electrolysis) (Electrophoresis) (Electro deposition) (Electro endosmosis)
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(Cathode)- Electrolysis of water( ) 4 HO + 4 e- 2 H + 4 OH- Film deposition( )
4 RNH+ + 4 OH- 4 RN + 4 HO- p H : 12 ~ 14 (Anode)- Electrolysis of water( ) 2 HO 4 H+ + O + 4 e- 4 CH3COO- + 4 H+ 4 CH3COOH- p H : 1 ~ 3 (Electrochemical Reaction)
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3. Electro Deposition Section ( ) . (Electro deposition, E-Coat, ELPO) Bath . , . . UF (Ultra Filtration Rinse Section)
. UF . Spray immersion . UF #1 UF #2 UF #3 95% (Deionized Water Rinse) (Cure)
UF () . , .
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4. Parameter
UF Module / / 1 / UF 70% ~ 80% Module .Electrode(Anode) 50% 1 / 2 Anolyte Flow .- Anode ( SUS 316 L ) Membrane . / P - Bath 28 ~ 34Ripple 5% - Max. Filter 1 / Cartridge / Bag Filter Bag : 2~3 pH Module : 1/2Ion Change :2- R/O Module / Ion Resin
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UF System (Ultra Filtration) : . Bath UF Module UF (Permeate) UF Permeate UF Rinse ( ) , , . Bath , UF Permeate Bath fresh . 1/min UF Permeate : 1.3L /min
UF Module Filter - : Bag Filter Cartridge Filter UF Module . UF Permeate Flux() - Bath Carry Over - Bath p H ( pH Flow ) - Membrane . - (Filter Clog )/ . Permeate Back Pressure - Parameter (NV,)
4. Parameter
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Foulant Membrane Membrane Support
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UF Module Type - Spiral Wound Type - Hollow Fiber Type- Multi Tubular Type - Plate Type UF Module Spiral Wound Type . UF Module . . UF Module 2.50.5 Kg.f/( P 2.0 Kg.f/ ) 100 L/Min , : 35 .
Membrane PVDF (Polyvinylidene Fluoride) . Molecular Weight Cut Off (MWCO) (NV,)4. Parameter
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SpiralWoundMulti Tubular Hollow Fiber
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Electrode (Anode : )
(+) . Box Cell Tubular Cell 1 4 ~ 6 . (-) Fresh Bath Electrode System Membrane Anode(SUS 316L) . Membrane , Anode . Electrode .
Anode , Anolyte() .
Anode 1 8L/min Membrane Surface Resistance : Max. 25000. 4. Parameter
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(Heat Exchange) : (30 2)
Pump . Pump Bath . Bath 35 . , Line . 34 . IN Put - OUT Put (P )0.5 ~ 1.0 Kg.f/ . (Rectifier)
: / 0V ~ 350V : Continues Type : (21 Amp.min/ / min) : UP-Down Program hoist Type : 75 A / m2 : Ramp Time : 1sec ~ 60 sec : Ripple : Max. 5%4. Parameter .
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(Deionized Water System)
Line Raw Material (Water). 90% (Water) . Material . () Mineral pH . 100 . - (Conductivity : /), ( Resistivity : .) p H ( ) . - p H 5.0 ~ 6.5 , - 10 / , ( 0.1 . ) 1 / ( 1 . ) .
4. Parameter
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, R/O (Reverse Osmosis : ) EDI . 4. Parameter
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Filtration - Cartridge Filter : , (2.0 Kg.f/ )
- Bag Filter : , 1.0 Kg.f/ (Oil Magnetic Filter).
,SEED Cartridge Filter Bag Filter . Conveyor System
(Continuous) Type Conveyor Speed . Line Space . .(P & F Conveyor type)
Up-Down Type (Programmable hoist) - .- PARAMETER .- Line . ( : min 45 sec) 4. Parameter
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ED Zone Grounding System ( Electro coat 2000 / Electrocoat for advanced users )
, Bath Bath FRP Coating . .
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(wt %)15 ~ 20 - , ( ) 1 /1 . p H 5.9 ~ 6.3 - . - p H . p H (25%: ADJ-002) . p H p H .(/) 1000 ~ 1800 - , UF Drain . 30 2 - . 36 34 .
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(%) : : BATH LEVEL : : : UF RUPTURE VOLTAGE ( )THROW POWER ROUGH FILMPHOSPHATE SENSITIVITY UF (UF ) SYSTEM BATH
P/B Ratio PASTE BINDER Rough , DIRT ,UF THROW POWER CRATER THROW POWER PASTE BINDER BINDER PASTE
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% BINDER % UF Rough ( )RUPTURE VOLTAGE THROW POWER Rough THROW POWER UF ( ) System UF
pH PASTE Leak DIRT FILTER CLOGT/POWER UF , , Rough FILM GAS PINHOLE TANK SYSTEM
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Improvement of Economic Advantages ( ) - Excellent Film Uniformity and Control ( ) - Low Applied Cost ( ) : Reduce Film density / Heat weight loss : Low Temperature Cure - Low Maintenance Cost ( )
Improvement of Environmental Advantages ( )
- VOC(Volatile Organic Compounds)& HAPs(Hazardous Air Pollutants) Free Formulations - Lower BOD/COD in Waste Streams5. ED Trends of Future
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5. ED Trends of FutureGen. 4pigment = 33 binder= 100Gen. 5 pigment = 17 binder = 100Gen.6 pigment = 12 binder = 100Future pigment = 4 binder = 100120 mg/h50 mg/h30 mg/h1 mg/hSedimentation VelocityReduced Pigment
- Lower Dry Film Density- Improved Usage- Lower Applied Cost
Low P/B RatioPowercron 640Powercron 648Powercron 643Powercron 6000CXPowercron 659ElectroClear 2700
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6.Introduction of New ED Products
PropertyPowercron 659Electroclear 2700Resin TypeEpoxyAcrylicCR 659 - CP 506CR 955 Solid (%)18 ~ 2211~ 13P/B ratio0.02 0.010.02 0.01p H5.0 ~ 604.5 ~ 6.0Conductivity2100 ~ 2900400 ~ 500Bath Temperature30 230 2Coat Volt / Time225 V / 120 sec60 V ~ 100 V / 60 secBake schedule121 20 Minutes (Metal Temperature)160 20 Minutes (140 ~190 )
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6.Introduction of New ED Products
PropertyPowercron 659Electro Clear 2700ColorBlackClearFilm Thickness0.4 - 1.2 Mils0.4 - 1.2 MilsGloss - 60 Degree55 75%Full GlossPencil Hardness2H Minimum2H MinimumCrosshatch Adhesion100%100%Salt spray500 Hours Minimum500 Hours MinimumHumidity500 Hours Minimum500 Hours MinimumWater Soak250 Hours Minimum-UV Durability-750 Hours MinimumThrow power11 13 inches-
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B.
1. 2.
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(Hot Water Rinse) (Degreasing) (Rinse) (Activation) (Phosphates) (Rinse/Pure Water)
~ , , . ( , ) .1.(PRETREATMENT)
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(- : - : Blaster ) ~ . . Line Alkali . , . (Saponification) + , , , . . CH2-OOC-R - CH-OOC-R - CH2-OOC-R (fat) + 3NaOH (or KOH) heated CH2-OH -CH-OH - CH2-OH (glycerol) + 3 R-CO2-Na (soap)
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~ . , Alkali . .
. Ca,Mg ( ) . Scale ( ) , .
1000cc CaCO3 1mg 1ppm .
40 ppm 120 ~180ppm 40 ~ 80 ppm 180 ~ 300ppm 80 ~ 120 ppm 300ppm
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~ . Etching . Etching , . (Ti- Colloid) Etching
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~ Phosphophyllite [Zn2Me(PO2)4] Hopeite [Zn3(PO2)4] Hopeite Phosphophyllite Zn Mn, Ni Tri cationic . Tri cationic P/P+H Ratio (Phosphophyllite / Hopeite) , , . 2Fe + 2H3PO4 Fe(H2PO4)2 1 + H2 Fe(H2PO4)2 + [O]/(NaNO2) FePO4 (Sludge) + H3PO4 + H20 Zn + 2H3PO4 Zn(H2PO4)2 + H2 3Zn(H2PO4)2+ 4H2O Zn3(PO4)2.4H2O Hopeite+ 4H3PO4 Fe(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Fe(PO4)2.4H2O Phosphophyllite + 4H3PO4 Ni(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Ni(PO4)2.4H2O Phosphonickelite + 4H3PO4Mn(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Mn(PO4)2.4H2O Phosphomangollite + 4H3PO4
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. 160 ~ 170 . : 1.5g ~ 3g/ ( 8% )
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BeforeAfter CRS GA SEM of Zinc Phosphates
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SEM of Zinc PhosphatesBeforeAfter MG
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2.
() . . . : - : CHECK. : CHECK .( ) - . - - - Sludge . Sludge . . Sludge Sludge Sludge .( UF Module ) - p H / p H : 5.0 ~ 7.0 ,- : Max 25/ .
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The Solubility of Zinc Phosphates Phosphophyllite[Zn2Me(PO2)4] Hopeite[Zn3(PO2)4] . Phosphophyllite[Zn2Me(PO2)4] Hopeite [Zn3(PO2)4] . (Immersiong Type) Phosphophyllite[Zn2Me(PO2)4] .
. , .
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pH
(dm2) = (kg) (mm) x 2 x 100
pHpHZn10.0Al10.0Sn11.0Cu11.5Fe13.0
Fe7.876Al2.7Zn7.13Mg1.74Mn7.3Bi9.8Sn7.28Pt21.45
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