Khaled El Deeb Aquence 866 Process_Manual

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Created By

Mr.Khaled El-Deeb

Autophoretic /Aquence Consultant

[email protected]

Tel:-+2019.3000.833 /+2010.886.7714

Autophoretic® 866 Alex Plant Development

Date 19/10/2010

www.autophoretic.net

mailto:[email protected]

http://www.autophoretic.net/

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Introduction:-

The AUTOPHORETIC® coating process has been in commercial use since 1973. Since then, continuing development of new latex polymers in the 1980's has led to greatly improved appearance, performance and ease of use, and has greatly expanded the applications for the process. The increasing emphasis on environmental issues has also made autodeposition a very attractive process because of its lack of organic solvents. Since 1986, over 30 production lines have been installed using AUTOPHORETIC coating chemicals to coat parts as diverse as small brackets to full automotive leaf spring assemblies.

Process Description

Both Nano-Ceramic and ACC866 process could be used on the same production line so that it’s called dual technology process production line.

work package

(work package capacity =21 scissors =21m²)

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Process Sequence

Stage No Description Comment 1 Alkaline Clean Spray 2 Degreasing Immersion 3 Plant Water Rinse Immersion 4 Hcl Picking Immersion 5 Plant Water Rinse Immersion 6 Neutralization Immersion 7 Plant Water Rinse Immersion 8 D.I Water Rinse Immersion 9 Nano-Ceramic Closed

10 DI or R.O. Water Rinse Closed 11 Autophoretic

®800, Coating Immersion

12 Plant Water Rinse Immersion 13 Reaction Rinse 2150 Immersion 14 Curing Oven (one Zone)

(Production capacity = 42 scissors/h)

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Warning Before starting in nano-Ceramic Process ensure that you closed the ACC

coating Bathes (11-12-13) with good cover

Before starting in The ACC coating Process ensure that you closed the nano-Ceramic Bathes (9-10) with a good cover

Hot Spray

Overview

1 Purpose

2 Room Dimensions (cm)

Width LengthHeight

3 Tools 4 Chemicals content

5 Temperature C° 6 Concentration 7 Pressure

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Stage No (1)

Hot Spray Alkaline Cleaning

Pre Cleaning 305

Length 380 Height 300

Karcher Machine ,items rack Progal D 346 TF ,Ridosol Operating parameters

75-90 C° 2-3% Pa

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Stage No (2)

Degreasing Bath

Tank overview

1 Purpose Degreasing

2 Bath Dimensions (cm)

Width 240 Length 120 Height 100 Volume 2.88m³

3 Materials of construction Mild steel Thermally isolated 4 Agitation method Pump with Eductors 5 Chemicals content Progal D 346 TF ,Ridosol

Operating parameters 6 Temperature C° 70-95 C° 7 Concentration 30-100 g/l 8 Reference Mark ml 4.6-6.6 ml 9 Immersion time 5-20 min Based on oil/wax rust level

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Control Sheet (Degreasing Bath )

Bath Volume =2.88m³

Build-up

Chemical Quantity 1 Progal D 346 TF 144 kg 2 Ridosol 14 L 3 Deionized Water 2733 L

- Use a separate drum to dissolve the Progal D completely in hot D.I water then transfer it into your tank

- Add ridosol directly to your tank in three period 4 L /H - Leave the tank to be agitate for one hour - Check up the Operation parameter - Start in production

Note

- For a new bath adjusted to 50 g/l , this reference mark should be approx. 5.6 ml

Operation

Reference Mark : 4.6 - 6.6 ml

Time : 5 - 20 min

Temperature : 70 - 95°C

Application : Immersion

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TESTING AND CONTROL (Degreasing Bath )

Never pipette by mouth, use a pipette filler.

The Progal D 346 TF bath is controlled in the plant by the reference mark (FA)

Method

1-pipette a sample of exactly 10 ml from the bath into 250 ml conical flask

2-dilute with 100 ml D.I water

3-add few drops of indicator # 3 homogenize the solution

4-The sample will turn pink

5-Using the 25 ml burette filled to the “0” mark with titration solution 27

6-titrate the sample until the pink coloration disappears

7-Record the number of ml of titration solution 27 used which represent the reference mark

Note

-For a new bath adjusted to 50 g/l , this reference mark should be approx. 5.6 ml

-keep the concentration within 5.6 ± 1 ml

-for subsequent titrations add 25.6 kg of progal D 346 TF to the bath per point below reference mark

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Stage No (3)

Plant water Rinse Bath

Tank overview

1 Purpose Tap water Rinsing



3 Materials of construction

Mild Steel inside of the bath be shot blasted and coated with a good quality 2K epoxy paint

4 Agitation method Air agitation 5 Chemicals content Tap Water

Operating parameters 6 Temperature C° ambient 7 Reference Mark 0.46-0.66 ml 8 Conductivity K 400 µs 9 Immersion time 60 Sec

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Kindly follow up your instrument manual for . Electrode cleaning , and calibration

Control point (Tap water Rinse Bath )


Build-up

Chemical Conductivity 1 Tap Water D 200µs

Operation

Conductivity : K 400µs

Reference Mark : 0.46-0.66 ml

Time : 60 Sec

Temperature : ambient


TESTING AND CONTROL(Tap water Rinse Bath )

This rinsing bath controlled by two parameter . bath conductivity and Reference mark

-Conductivity measurement

Use your appropriate conductivity meter for direct measuring conductivity value

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-Reference mark measurement


The water rinse bath is controlled in the plant by the reference mark FA to determine the amount of Degreasing chemicals escaped to the water rinse so that we are going to use the same degreasing control process .

Method








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Stage No(4)

Pickling Bath

Tank overview

1 Purpose Pickling



3 Materials of construction Mild Steel Lined by polypropylene OR good Quality anti acid Fiber

4 Agitation method Air agitation 5 Chemicals content Hcl

Operating parameters 6 Temperature C° ambient 7 Concentration 60-80% by volume 9 Immersion time 5-10 min Based on the rust and corrosion level

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CONTROL METHOD Pickling Bath

Transfer 5 mls of the bath solution to a 250ml beaker by means of a safety pipette. Dilute with approximately 100ml of distilled water. Place the probe of a suitably calibrated pH meter into the solution and titrate against 1N. Sodium Hydroxide until pH 3.8 is reached. (Care must be taken during titration after pH 2.0 is reached as beyond this point the pH changes very quickly with small additions of the titrant) Note burette reading - this is the titration value. Record this Value to be your reference mark

IRON VALUE

The point at which the solution should be discarded is reached when the iron content exceeds 70 grams per litre. The method of determining the iron content is as follows:

Transfer 2 mls of the solution to a 150 ml flask by means of a safety pipette. Dilute with approximately 50 ml of distilled water; carefully add 5 ml of concentrated Phosphoric Acid, followed by 3 drops of diphenylamine indicator solution. Titrate against N/10 Potassium Dichromate solution until a violet blue colour is produced. 1 ml of N/10 Potassium Dichromate is equivalent to 0.0056 grams of iron - therefore, 70 grams/litre of iron will give a titration value of 25.0 mls N/10 Potassium Dichromate per 2 ml sample.

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Stage No(5)


Tank overview





Mild Steel lined with fiber OR inside of the bath be shot blasted and coated with a good quality anti acid 2K epoxy paint


Operating parameters 6 Temperature C° ambient 7 Conductivity K 400 µs 8 Immersion time 60 Sec

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Stage No (6)

Neutralization Bath

Tank overview

1 Purpose Degreasing



3 Materials of construction Mild steel Thermally isolated 4 Agitation method Pump with Eductors 5 Chemicals content Progal D 346 TF ,Ridosol

Operating parameters 6 Temperature C° 70-75 C° 7 Concentration 30-100 g/l 8 FA ml 4.6-6.6 ml 9 Immersion time 5 min

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Control Sheet (Neutralization Bath )


Build-up

Chemical Quantity 1 Progal D 346 TF 144 kg 2 Ridosol 3 L 3 Deionized Water 2880 L

- Use a separate drum to dissolve the progal completely in hot D.I water then transfer it into your tank

- Add ridosol directly to your tank in three period 1 L /H - Leave the tank agitation for one hour then start in production

Operation

Reference Mark : 4.6 - 6.6 ml

Time : 5 - 20 min



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TESTING AND CONTROL(Neutralization Bath )


The Progal D 346 TF bath is controlled in the plant by the reference mark FA

Method








Note

-For a new bath adjusted to 50 g/l , this reference mark should be approx. 5.6 ml

-keep the concentration within 5.6 ± 1 ml

-for subsequent titrations add 25.6 kg of progal D 346 TF to the bath per point below reference mark

References

-International training manual (Henkel ACC)

-Progal D 346 TF technical data sheet

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Stage No (7)


Tank overview







Operating parameters 6 Temperature C° ambient 7 Reference Mark 0.46-0.66 ml 8 Conductivity K 400 µs 9 Immersion time 60 Sec

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Build-up


Operation


Reference Mark : 0.46-0.66 ml

Time : 60 Sec



TESTING AND CONTROL(Tap water Rinse Bath )

This rinsing bath controlled by two parameter . bath conductivity and Reference mark

-Conductivity measurement


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-Reference mark measurement


The water rinse bath is controlled in the plant by the reference mark FA to determine the amount of Degreasing chemicals escaped to the water rinse so that we are going to use the same degreasing control process .

Method








References


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Stage No(8)

D.I Bath

Tank overview

1 Purpose D.I Rinsing



3 Materials of construction Mild steel Lined with fiber with polyester or Stainless Steel

4 Agitation method Air agitation 5 Chemicals content D.I Water

Operating parameters 6 Temperature C° ambient 7 Conductivity K 50µs 8 Immersion time 60 Sec

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Control point (D.I Bath )


Build-up

Chemical Conductivity 1 Deionized Water 5-10 µs

Operation


Time : 60 Sec



TESTING AND CONTROL


References


-Design Manual (Henkel )

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Stages No (9), (10)

Nano-Ceramic and D.I Bathes

Both have to be closed

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Stage No(11)

Autophoretic®866 Coating Bath

Tank overview

1 Purpose Black Coating


Width 320 Length 160 Height 160 Volume 8.192 m³

3 Materials of construction Mild steel lined with fiber with polyester 4 Agitation method 4 Mixers with 2 fan each connected to VFD 5 Temperature control tools Schaller +heater with coil and hot/cold D.I water 6 Chemicals content ACC866 Rpl , HF , H2O2 , FeF3 , D.I

Operating parameters 7 Temperature C° 20-22 C° 8 Solid content % 5-7 % 9 101 ( F - activity ) µA 125-300 10 ORP mV 350-400 11 Starter level ml 27-36 12 Immersion time 90

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Control Sheet (ACC866 Bath )


Build-up

Chemical Quantity 1 AUTOPHORETIC 866 Replenisher 1097.7 kg ( 925.7 L ) 2 Deionized Water 6856.7 L 3 AUTOPHORETIC 300 Starter 434.2 kg ( 409.6 L ) 4 AUTOPHORETIC 35 Activator 30 L 5 AUTOPHORETIC 24 Oxidizer 20 L

Build-up technique

Add one to two inches of deionized water to the tank. For each 100 litres of final bath volume, add 13.4 kg (11.3 litres) of AUTOPHORETIC 866 while adding deionized water and mix thoroughly without generating any foam. While mixing, add more deionized water to bring the volume to three-fourths full. Now add 5.3 kg (5 litres) of AUTOPHORETIC 300 Starter per 100 litres of bath. Finally, add sufficient water to bring the solution up to the operating level. Allow bath to agitate for approximately 2 hours and check all bath parameters. Add Oxidizer, Activator or Replenisher as necessary to adjust levels.

Operation

Redox Value 375 ± 25 mV

Fluoride Meter Reading 125 to 300 micro amperes

Total Solids 5.0 - 7.0%

Starter Titration 36 ml, maximum

Temperature 20 - 22°C

Time : 1.5 minutes



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Kindly follow up your instrument manual for . Electrode cleaning , storage solution and calibration

TESTING AND CONTROL (ACC866 Coating Bath)


The AUTOPHORETIC 866 bath is controlled in the plant by a Redox Control measurement a Fluoride meter measurement, a Total Solids determination and a Starter Titration.

Redox Control

1-Pick up your ACC866 sample in a 200ml plastic biker

2- clean up your Electrodes with D.I water

3-put the Electrodes in the sample

4-turn on your mV instrument

5-Wait for reading stability

6-Record your ORP value

7-Remove the electrodes from the sample and clean it up

8-turn off the mV

9-Put the electrodes into the storage solution

The redox potential is constantly monitored with an appropriate instrument and electrodes. The specification value is maintained by additions of AUTOPHORETIC 24 Oxidizer. The frequency of additions is dependent on the amount of work being processed per unit time and bath volume.

Should it be necessary to add AUTOPHORETIC 24 Oxidizer manually, add 0.4 litres per 100 square metres of metal processed. AUTOPHORETIC 24 Oxidizer should be slowly added to maintain the redox potential within the specified range of operation.

Our Representative will recommend appropriate equipment required.

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Kindly follow up your instrument manual for . Electrode cleaning , storage solution and calibration

101 Fluoride Meter Reading

1- Rinse and fill sample cup on the 101 D meter with bath.

2- Press “Start Timer” button. 3- The meter will time itself for 6 minutes, during which time the yellow “Timing” light will blink. 4- At the end of 6 minutes, the yellow light will become constant and the green “Timer Finished” light will also be lit. The reading on the digital display will freeze, write down this number as the 101 value.

A Fluoride meter reading is made every 2 hours.. The specification value is maintained by additions of AUTOPHORETIC 35 Activator. The frequency of additions is dependent on the amount of work being processed per unit time and bath volume. The Fluoride meter reading should be maintained within the specified limits. To raise the reading by about 100 microamperes, add 32 liters of AUTOPHORETIC 35 Activator. Our Representative should be consulted for appropriate equipment recommendations and operating instructions.

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Kindly follow up your instrument manual for . calibration

Total Solids

The solids content is measured daily by the following method :

a) On a balance capable of weighing to 1.0 milligrams, weigh a small sample dish. Record the weight of the sample dish.

b) To the sample dish add about 3 ml of bath sample.

c) Quickly re weigh the sample dish with the bath sample. Record the measurement

d) Place the sample dish with bath into an oven set at 100°C for 60 minutes. Remove the dish and allow to cool to room temperature.

e) Re weigh the sample and record the value

f) Calculate the % total solids :

weight of dry sample = B-A x 100 = % Total Solids

weight of wet sample C-A

A = weight of sample dish

B = weight of dry sample and sample dish

C = weight of wet sample and sample dish

g) Run 2 tests by the above method and average the results.

To raise the Total Solids level 0.1%, add 18.84 litres of AUTOPHORETIC 866.

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Starter titration

The Starter Titration is performed on a shift basis. The value is obtained by the following method :

1- Place a 10 ml sample of coating bath into flask. 2- Add 25 ml of ATS 32 (50 % HCl) 3- Under the hood, heat and boil solution for 1 minute.

4- Dilute with DI water to approximately 100 ml.

5- Cool Solution to room Temperature.

6- Add ATS 35, 1 ml at a time. Solution will go from the present yellow to clear then to a light salmon color. Note: After solution turns clear, add ATS 35 slowly. Generally, 10 to 20 ml of ATS 35 is needed for the color change.

7- Add approximately 1 ml of RS 22. This will cause the solution to turn deep purple.

8- Stir solution and let sit for 1 minute.

9- Titrate with TS 86 (0.01 M EDTA) until the solution changes from purple to a faint orange to a light yellow. Titrate slowly after solution becomes faint orange.

10- Record mils of TS 86 used.

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Testing Reagents:

Composition in order of Addition

Auxiliary Solution 32 (1000g):

460g Deionized Water

540g HCL-37%, AR, ACS

Reagent Solution 22 (1000g):

606,07g Isopropyl alcohol, purified plus

160,0 g Salicylic Acid, 99%

233,93g DI Water

Titrating Solution 86 (1000g):

600g DI Water

3,7g Disodium EDTA, 2H2O

396.3g DI Water

Auxiliary Test Solution 35 (1000g):

350g DI Water

650g Ammonium Acetate crystals-tech

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Check Sheet (ACC866 Bath )

Check point Date /2010 /2010 /2010 /2010 2010

Op. Range 1 Temperature C° 20-22 2 Solid content % 5-7 3 Rpl add (L) 4 101 ( F ) µA 125-300 5 HF add (L) 6 ORP mV 350-400 7 H2O2 add (L) 8 Starter level ml D34 1 Temperature C° 20-22 2 101 ( F ) µA 125-300 3 HF add (L) 4 ORP mV 350-400 5 H2O2 add (L) 1 Temperature C° 20-22 2 101 ( F ) µA 125-300 3 HF add (L) 4 ORP mV 350-400 5 H2O2 add (L) 6 Total area (m²) 7 Part NO 8 Stabilization Don or N

12 Note

Lab Manager Quality Dept

Name :………………………..….. Name :………………………..…..

Signature :-……………………… Signature :-………………………

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Stage No(12)


Tank overview






4 Agitation method Two mixers connected to VFD 5 Chemicals content Tap Water

Operating parameters 6 Temperature C° ambient 7 Conductivity K 400 µs 8 Immersion time 60 Sec

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Build-up


Operation


Time : 60 Sec



TESTING AND CONTROL


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Stage No(13)

R.R 2150 Bath

Tank overview

1 Purpose Reaction Rinsing


Width 320 Length 130 Height 160 Volume 6.656 m³

3 Materials of construction Mild steel lined with fiber with polyester OR stainless 4 Agitation method 2 Mixers with 1 fan each connected to VFD 5 Chemicals content Reaction Rinse 2150

Operating parameters 6 Temperature C° ambient

7 Functional conductivity m mhos

1000-3000 m mhos

8 Immersion time 60

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Control Sheet (R.R 2150 Bath )


Build-up

Chemical Quantity 1 AUTOPHORETIC® 2150 Reaction Rinse 100 L 2 Deionized Water 6556L

Operation

Functional conductivity 1000-3000 mmhos

Time : 60 Sec

Temperature : ambient - 27°C


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TESTING AND CONTROL(R.R 2150 Bath )


The AUTOPHORETIC 2150 bath is controlled in the plant by the functional conductivity

1. Determine the conductivity of the ACC 2150 RR processing bath by following the instructions for using your specific type of meter. Record the value obtained , Total Conductivity.

2. Measure 50 ml of bath into a graduated cylinder.

3. Transfer bath into a 250 ml Erlenmeyer flask.

4. Heat solution to a boil and continue to boil for 15 minutes.

5. Cool and transfer liquid contents to a graduated cylinder. Wash the flask several times with small amounts of DI water. Transfer water into graduated cylinder.

6. Bring the volume in the graduated cylinder to the 50 ml mark with DI water.

7. Determine the conductivity of this solution.

8. The conductivity value determined in step 7 above represents the contamination level in the bath.

9. Subtract the value in step 7 from the value obtained in step 1. This represents the Functional Conductivity.

To increased conductivity value 100 mmhos add 6.65 L R.R 2150 to the bath

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Stage No(14)

Curing Oven

Overview

1 Purpose Curing

3 Temperature prop 6 prop distributed as shown in fig connected to one reader interface Operating parameters

6 Temperature C° 100-115 C° 7 ∆T in prop reading ±2 8 Curing time 30 min

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Check Sheet

Stage Parameter Date Month-year Op. Range day day

(1) Spray Clean

Pressure Temperature 75-90 C°

(2) Dip Clean

Temperature 70-95 C° R.M 4.6-6.6 ml Additions

(3) Water Rinse

Conductivity < 400µs R.M ml 0.46-0.66 ml

(4) Pickling Hcl

R.M ml Iron value K 70 g/l

(5) Water Rinse

Conductivity < 400µS

(6) Neutralization

Temperature 70-95 C° R.M ml 4.6-6.6 ml Additions

(7) Water Rinse

R.M 0.46-0.66 ml Conductivity < 400µs

(8) D.I Rinse

Conductivity < 50µs

(9) ACC866 Coating

ORP - 1

350-400 mV

ORP - 2 ORP - 3 101 - 1

125-300 µA

101 - 2 101 - 3 Starter Titr. < 36ml % Solids 5.0-7.0 % Bath Cond.µs 2500-3500 Temperature 20-22 C° Repl. Addition Stabilization

(10) Water Rinse

Conductivity < 400µs

(11) R.R 2150

Func. Cond. mmhos

1,000-3,000 mmoh

Additions (12)

Curing Temperature 100-115 C°

Total Production in 1m²

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References

-Autophoretic® International training manual (Henkel ACC)

-Autophoretic® Design Manual (Henkel )

-Progal D 346 TF technical data sheet

-Autophoretic® 866 technical data sheet

-Autophoretic® R.R 2150 technical data sheet

Documents

Khaled El Deeb Aquence 866 Process_Manual