Full Surface. Influencing flux parameters with flux treatment. Flux eng

Transcription

1 Full Surface Influencing flux parameters with flux treatment Flux eng

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3 Erik van der Staaij Sales & service manager 25 years of experience in surface treatment With the Fluxcleaner since 2006

4 General short story of company We are an innovative full service-oriented manufacturer in the surface treatment industry, with a unique combination of market knowledge in Galvanizing, Powder Coating, Anodizing, Electroplating and E-coat. Based on 25 years knowledge and experience, we provide quality, sustainable solutions, cost effective technical and logistical solutions and lean processes.

5 General our company in Emmen, The Netherlands

6 General facts Grounded in 1991 Owned Han Kleijn 25 full time employees Company surface m² R&D budget 2-3% of annual turn-over Installations throughout Europe.

7 General quality ISO 9001 DVS, Deutsche Verein für Schweißtecnik TÜV, Anerkennung Fachbetrieb Continuous training of employees

8 General social media Linkedin Twitter You Tube

9 General portfolio Galvanizing Powder Coating Anodizing Plating E-coat

10 Fluxcleaning 1.0

11 Fluxcleaning 1.0 Goals Getting the iron out Compact unit Easy to maintain & service Transportable Online servicing

12 Fluxcleaning 1.0 The Unit

13 Fluxcleaning 1.0 Results Prototype 6 months trial Still up & running Learning curve

14 Fluxcleaning 1.0 Facts Standard chemistry No overdosing H 2 O 2 No sludge in your tank Fe on constant level

15 Fluxcleaning 2.0

16 Process control & Quality improvement of galvanized steel

17 Fluxcleaning 2.0 Temperature Concentration & Ratio ph Fe content Surface tension Fluxparameters

18 Fluxcleaning 2.0 Fluxparameters temperature Important but not influenced by flux treatment Minor drop during proces in external unit Heater can be installed in unit Drying is very important!

19 Fluxcleaning 2.0 Fluxparameters concentration Concentration in between g/l total salt Although lower concentrations are mentioned Ratio Mono, double, triple, quadra salts Influenced by flux treatment NH 4 OH ph correction will influence ratio and density Correction with ZnCl 2 is necessary Possible through ZnCl 2 solution or stripping acid Flux treatment can keep Ratio and density balanced!

20 Fluxcleaning 2.0 ph The least discussed parameter What is your ph? 4,5 Why ph 4,5? Because we ve done so for ages Less agressive/active flux built up less Fe What are the possible benefits of lower ph (like 2,3)? More active flux Will polish the surface Fe building is not an issue when using flux treatment Dry filter cake, faster reaction, no Zn oxidation You decide what your ph will be within the 2-4,5 range!

21 Fluxcleaning 2.0 Fe content Drag in of Fe gives higher dross and ash production Iron content < 5 g/l is recommendable Hard to achieve without flux treatment Each gram Fe binds 25 gr of Zn (theoretically) Main reason to start with flux treatment! Concentrations < 1 g/l are quite achievable Amount of rinses between pickle and flux 1 or none Oxidation with hydrogen peroxide is most common

22 Fluxcleaning 2.0 Surface tension Important for an equally fluxed surface Modern wetting agents are stable towards H 2 O 2 Automated dosing of wetting agent in small amounts is recommendable and can be performed in the flux treatment

23 Fluxcleaning 2.0 Quality improvement Case 1, proto type Dutch general galvanizer 7 metres Case 2, crash barriers, extremely high Fe content German crash barriers, extremely high Fe content 13 metres Case 3, advantages low ph German general galvanizer 15 metres

24 Fluxcleaning 2.0 Case 1 Prototype Fluxcleaner tons/year capacity 30 m 3 flux ph at start 3,9 Fe content 19 g/l Start up at October 27th 2006, no cure no pay Stable situation from february 2007 Status April 2007 ph 2,3 Iron content < 5 g/l Savings 30 m³ Flux, disposal 30 m³ old Flux and sludge, Better quality

25 Fluxcleaning 2.0 Quality improvement, case 2 Extremely high Fe content tons/year capacity 48 m 3 flux ph at start < 0,5 Fe content 78 g/l Start up February 2009 Status June 2009 ph 2,3 Iron content < 1g/l Savings 48 m 3 Flux, disposal 48 m³ old flux and sludge. Less dross( 0,35% 0,24%). Less ashes( 0,54% 0,48%)

26 Fluxcleaning 2.0 Quality improvement, case 3 Advantages low ph tons/year capacity 92 m 3 flux ph at start 4,5 Fe content 1,3 g/l Test started Oktober 2012 Status May 2013 ph 2,3 Iron content approx. 0,5 g/l Savings Considerable quality improvement Less rework or extra work

27 Fluxcleaning 2.0 Fluxcleaner 2.0 proposition Knowhow and experience with the unit since 2006 Not only de-ironing, complete process control Best ROI (always under 2 years!!) Never dump system Lowest chemistry consumption Usage of basic chemistry only Online monitoring & service Will clean up existing flux with high iron content Corrosion resistance, only plastic Fully automated Easy to maintain Short delivery times 30 units in the market Compact, up to tons /year

28 Fluxcleaning 2.0 The container

29 Fluxcleaning 2.0 Netherlands Belgium Germany Austria Hungary Italy Greece United Kingdom Ireland Morocco Iraq References

30 Fluxcleaning 2.0 Fluxcleaner 2.0 will give you Lower ash production Lower dross production Less Zinc pick up Higher quality of Galvanized steel No sludge in tank left

31 Thank you for your Attention