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This is a tool-box to help you chose your next generation of pretreatment system. The goal is to give you input on different systems performance, some key elements regarding line design and goods and much more.

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  1. This is a tool-box to help you chose your next generation of pretreatment system. The goal is to give you input on different systems performance, some key elements regarding line design and goods and much more. • This tool-box was generated within the project ENABLE, Environmentally Acceptable Pretreatment System for Painting Multi Metals, funded by the European Union, within FP7–SME-2010-1. • By using the buttons in the lower right, you can navigate around. The other way is to simply read this document one page at the time. You can always scroll up or down using the arrows on your keyboard or the scroll wheel on your mouse. • Now, go to the next page for an introduction and how to use the tool-box. Welcome ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  2. How to Use it X/X How to use ENABLE Tool-box This tells you where you are and if there are several pages in this chapter. To go to the next page, simply scroll down. By clicking this arrow, you will return to the welcome page. Here you will find the project homepage, www.enablepretreatments.com With these boxes you can navigate around and learn more about every aspect of new pretreatments. This takes you to the seventh framework homepage ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  3. Introduction – the different parts of the Tool-box Line design addresses the different aspects of each pretreatment line. This includes information about incoming goods, degreasing, rinsing, process control, waste etc. See this chapter for more information about how to build and control your process. Line design Corrosion protection The performance of different types of new pretreatments (NPT) are studied regarding their corrosion protection. In Economics you find example of savings, from a company that have chosen to replace their zinc phosphate process with a new pretreatment. Furthermore, a model to calculate the cost in your plant is introduced. Economics This chapter is based on a study of a Swedish company introducing new pretreatment as a replacement of zinc phosphate. Including a Life Cycle Analysis (LCA) and a few tips direct from production, you can find some good information on environmental gains when changing pretreatment process. LCA-analysis Q & A Questions and answers tries to answer frequently asked questions regarding new pretreatments. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  4. Line design 1/2 Line design Process control Incoming goods Goods for painting Conversion coating Degreasing Rinse (s) A good degreasing is crucial to get a good end result out of your pretreatment. Click on the green square to read more about how to chose and maintain a good degreasing. The water rinses are a big part of the pretreatment plant. Click on the blue square above to get ideas on how to design your rinses and water flow. The conversion coating is the chemical process that promotes adhesion between goods and paint and provides corrosion protection. Waste Depending on your incoming goods, you will chose from different parameter settings with your conversion coating, and you can expect varying results. Click on the arrow to learn more. Waste and pollution from the plant can be considerably reduced using new pretreatments compared to Zinc phosphating. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  5. Line design 2/2 Line design • The number of baths in a traditional zinc phosphate line are usually more than enough when introducing a New Pretreatment system. A zinc phosphate line can have 7-9 baths depending on if sealing/passivation is necessary and depending on the number of rinses required. • A new pretreatment line will require at least 5 baths: • Degreasing • Rinse (tap water) • Rinse (deionised water) • Conversion coating – New Pretreatment • Rinse (deionised water) • The required number of baths will depend on the incoming goods and the oils, fats and dirt that must be removed. Two degreasing baths are recommended when very dirty goods is surface treated. Remember, the number of degreasing baths will have influence on the energy consumption. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  6. Line design Incoming goods 1/4 Incoming goods Incoming goods is the goods that your pretreatment plant needs to be able to handle. There are several ways to classify the goods, depending on its characteristics, and one crucial parameter is the construction material. A few examples of material that are usually coated are: Iron, Steel, Stainless steel, Cast Iron, Aluminum, Magnesium, Hot dip galvanized steel (HDG) and Electro galvanized steel. We will now look at an overview regarding the three most common construction materials, rather than to give you complete information on how each material and their different alloys behaves. Main focus are on three construction material mainly in sheet metal form. Worldwide production (1998) of crude steel, which constitutes 95% by volume of the total output of metals, was 760 million tons and nearly half of the output was in the form of sheet and strip. In tonnage, aluminum is second in volume to steel, and primary aluminum production is estimated to be around 17 million tons. Over 85% of fabricated aluminum products are rolled sheet and foil. • Cold rolled steel (CRS) • Galvanized steel (HDG) • Aluminum (Al) ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  7. Line design Incoming goods 2/4 Cold rolled steel (CRS) About the material Probably more than 90% of all metal production is hot rolled; cold rolling is performed on 30% of carbon steel, 60% of stainless steel, and 20% of copper alloys: overall, about 30% of the world metal production. Before cold rolling, which usually is at room temperature, the metal has almost always undergone a hot-rolling stage. Some properties or defects are inherited from the hot rolling stage and must be accounted for in the design of the cold rolling schedule (e.g., pickling to eliminate oxides prior to steel cold rolling). The necessary properties (geometric tolerances, surface finish, mechanical resistance) must be imparted at the cold rolling stage. Cold rolling, as any forming process, cannot be isolated from the previous and next processing stages. Suitable characteristics must be achieved in the cold rolled coil, along with sufficient ductility for further processing. Pre-treatment of CRS Cold rolled steel is the most difficult substrate to handle for the New pretreatment systems. The results obtained in accelerated corrosion tests are often inferior to zinc phosphate. Some oils on CRS can be difficult to remove before the conversion coating step. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  8. Line design Incoming goods 3/4 Galvanized steel (HDG) About the material The “hot dip galvanizing” process consists of immersing clean, oxide‐free iron or steel into molten zinc, in order to form a zinc coating which is metallurgically bonded to the iron or steel’s surface. Thus, the zinc coating protects the iron and steel surfaces against corrosion. The zinc coating on galvanized steel will react with the atmosphere over time to form zinc compounds on its surface. These form a protective, chemically inert, layer that inhibits further reaction with the metal beneath. In general, galvanizing consists of four steps: surface preparation, prefluxing, galvanizing and finishing. The preparation steps consist of cleaning and pickling operations that free the surface of dirt, grease, rust and scale. The preflux step serves to dissolve any oxide that may have been formed on the iron or steel surface after pickling and prevents further rust from forming. Clean, oxide‐free work is galvanized by immersion into molten zinc, which is commonly about 435–455 °C. Galvanizing is a diffusion process, where the reaction between the molten zinc and the steel or iron will proceed quickly at first, but will do slow as the alloy layer grows and becomes thicker. Zinc coating thickness is in the range 20- 100µm. Electrogalvanization is a very common method to create thin (~ 5- 15 µm) zinc protecting coatings on steel. The exterior skin of a car body is electrogalvanized. Pre-treatment of HDG The pretreatment of electrogalvanized steel or hot dip galvanized steel often give very similar results. The corrosion protecting performance of NPT systems on HDG is good and often on the same level as zinc phosphate. ENABLE LCA-analysis Line design Corrosionprotection Economics Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  9. Line design Incoming goods 4/4 Aluminum (Al) About the material There are numerous different types of aluminum in sheet metal form, but the main characteristic that will affect the ability to get a good result from pre-treating and coating is aluminum’s ability to form a very stable oxide on the surface. However, during all thermomechanical processing of aluminium, such as a hot/cold rolling or extrusion, a surface active layer will be formed. This layer has a deformed microstructure and must be removed before surface treatment in order to avoid filiform corrosion and paint delamination. Aluminium sheet metal used in the automotive industry is often “acidically pre-etched” or “deoxidised” which means that this surface active layer is removed. Extruded aluminium profiles also need this kind of treatment to get an optimised surface treatment. If acid deoxidising is impossible to perform in the surface treatment line, the alkaline degreasing should be studied carefully in order to chose a product that gives good results. Pre-treatment of Al New pretreament system give excellent results on aluminium and are very suitable for this substrate since there is almost no formation of sludge. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  10. Line design Degreasing 1/4 Degreasing A good degreasing is crucial for the end result of the pretreatment. Depending on substrate material, type of contamination, type of process (dip, spray, ultrasonic…) there are different aspects to consider. Cleanliness is not a definite concept, the demands is instead depending on costumer demands and the environment in which the product will be used. The time between cleaning and pretreatment is short to prevent rust or other oxides to form on the surface. For the pre-treatment process it is crucial that dirt, oil, particles and other contaminations are removed before pretreatment. Contaminations depend on substrate material, but processes such as metal cutting or sheet metal forming also generates dirt that need to be removed before pretreatment. By studying what types of contamination that remain on the surface it is possible to identify the biggest problems in the process. Surface topography and structure can also affect the amount of dirt. A rough surface may bind a larger amount of contaminations than a smooth one and a high roughness binds the dirt harder to the surface. A metal surface is not homogenous but structures on molecular level will remain from earlier processes affecting this. The result of the cleaning can be estimated by the following methods: • ”water-break-free” – the object that has been degreased should have an unbroken film of water over the complete surface for at least 30 seconds after the last rinse before chemical pretreatment/conversion coating • wiping with a white cloth after all rinses should not give any colored residues • laboratory analysis by evaporation of remaining carbon (from oils etc) should give a value < 0, 20mg/dm2 • Mechanical • Acid • Alkaline Learnmoreaboutcleaning in the Q&A section ENABLE Line design Corrosionprotection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  11. Line design Degreasing 2/4 Mechanical degreasing If the component has oxides, scales or rust a way to remove these is by mechanical degreasing. Examples of mechanical degreasing are blasting, grinding or tumbling. By using mechanical degreasing, the surface gets higher roughness, which is also beneficial regarding adhesion of the pretreatment and the paint. Before any mechanical cleaning method the surface should always be degreased using an alkaline cleaning. This is to remove oil, fat and salts to avoid them to bind harder on the substrate. This is important to remember since it is often overseen. ENABLE Line design Corrosion protection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  12. Line design Degreasing 3/4 Acid degreasing • Acid degreasing or pickling can remove oxides, scales or rust. • Since acid degreasing usually performs poorly when cleaning oil, grease or fat, it is usually not used as the only degreasing step. The use of a acid degreasing does however have some benefits over mechanical degreasing, mainly when it comes to complex objects when it is hard to reach all areas but also regarding process control. For these reasons, the acid degreasing is often used as a dipping process. ENABLE Line design Corrosionprotection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  13. Line design Degreasing 4/4 Alkaline degreasing Oil, fat and salts are effectively removed by alkaline degreasing and the bath liquid can be sprayed on the surfaces or objects can be dipped in the baths. The cleaning can be difficult if the goods have been exposed to increased temperature or if it has been stored for a long time (several months). The oil that normally is applied as rust protection can oxidize and form high molecular weight products. Any particles remaining from the mechanical cleaning will be removed during the spray operation or during dipping in the alkaline degreasing bath. ENABLE Line design Corrosionprotection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  14. Line design Rinse 1/4 Rinse(s) The number of required rinse steps depend on the pretreatment/conversion coating step. Some conversion coating require a very low conductivity in the last rinse before the conversion coating bath. This means that the rinses must ensure the removal of all degreasing chemistry. The first rinse is normally tap water since it more effectively dissolves encapsulatde dirt. A second and third rinse with distilled water often follow the first rinse. The last rinse before the conversion coating (New pretreatment bath) must according to the suppliers have a conductivity of max. 200 - 400 μS. The rinseafter the pretreatmentbathshouldalsohave a lowconductivityoften < 30 - 50 μS. Electrocoatingpaintsuppliersusuallyhave a requirement on the rinsebefore the ED-bathbutexperience has shown that the conductivity in the last rinse must be lowalsowhenpowderpaint is used as primer coating. ENABLE Line design Corrosionprotection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  15. Line design Coating Conversion coating The New Pretreatment systems are generally based on the precipitation of zirconium oxide on the metal surface. The precipitation can be compared to zinc phosphating which means that phosphate crystals are precipitated and adhesion is created by establishing a larger surface area. The coating thickness is a big difference between the phosphate coatings and those of new systems. A phosphate coating is often about 1 µm thick (1/1000 of a millimeter) and the crystals are needle shaped which helps in creating a mechanical interlocking of the paint when it is cured. A zinc phoshate coating is shown to the left below. The coatings of new systems are 10-100 times thinner and the precipitations are like small nodules or bumps (to the right below). The mechanical interlocking of the paint is not expected to be as high as for zinc phosphate but the results from adhesion tests often give excellent results. The new pretreatment systems sometimes contain silanes beside the zirconium component. These molecules can react with each other and create a net work on the surface. The silanes can also have reactive groups that are supposed to improve the bonding to the paint. Note! The photoshave different magnification. Look at scale bar at bottom of image. ENABLE Line design Corrosionprotection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  16. Line design Process control 1/6 Process Control Process control of new pre-treatment systems are generally easier compared to zinc phosphate processes when it comes to controlling bath parameters in production. This is mainly because there are fewer parameters that need to be controlled with fewer active steps. However, to control the result on pre-treated objects, there are several new measurement techniques that needs to be considered and used. The next pages gives you an overview of the different techniques needed to measure and control the pretreatment baths. The conclusion of this chapter Process Control can be found here. Learn more about process control in the Q&A section ENABLE Line design Corrosionprotection LCA-analysis Q & A Economics Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  17. Line design Process control 2/6 Process Control – Bath parameters • Measuring device/instruments • measurement of free and total alkali: burette, acid and indicator solution • pH meter • Conductivity meter • Measurement of Zr, Cu and Si content: analytical kit (salt to colour bath sampl) and spectrometer • Measurement of flouride ions: ion selective electrode ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  18. Line design Process control Process Control 3/6 A computer-based process supervision system can be installed to run a line with New pretreatment system to obtain high quality and control of the process. The system supervises several parameters and automatically dosages chemicals for each step required. The following parameters are measured each 5 minutes: • pH, temperature and conductivity in alkaline degreaser, • conductivity and temperature in rinse 1, 3 (DI-rinse before conversion step) and 4 (DI-rinse directly after conversion step) • pH, conductivity and temperature in the pretreatment bath Other parameters that are manually measured but logged in the control system are alkalinity in the degreasing step and in the concentration of F-, Zr and Cu in the pretreatment bath. The programs that are available are usually supplied by the producer of the pretreatment chemistry. Supervision system and program can be installed to a cost of about 30.000€ Pretreatment suppliers generally states that their processes are stable and do not need a closer follow-up than twice per day for any parameter. Today’s use of the computerised systems such can be evolved, for instance by adding another measuring technique that allows the user to measure other potentially crucial parameters such as F-. It is however unclear at this point if this is necessary. Other advantages can be found with the use of automatic dosage of chemicals, with more constant concentrations and lower total consumption. Today’s way to do this is either to constantly add chemicals at a low rate as long as the production runs (e.g. the conveyor is moving) or to set a high/low level of pH. The rate of dosage needs to be changed if, for instance, very large or very small goods are in production. OEM-companies or companies who coat very long series of the same product have the possibility to measure exactly how much chemistry that is used on each product and can therefore set a very exact dosage. For a job coater or SME this is more complex. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  19. Line design Process control 4/6 Process Control – coating control ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  20. Line design Process control 5/6 Process control - XRF X-rayflourescence (XRF) XRF is a hand held instrument that allows analysis in production. The analysis is done on pre-treated goods and the reading in % or ppm can be translated to coating weight by reference samples analyzed by for example inductive coupled plasma (ICP). The range for coating weight varies depending on the substrate and supplier. Depending on pre treatment system, it is most common to look at the zirconium signal to determine the coating weight. The measurement method is standardized according to ASTM_D7639, Standard Test Method for Determination of Zirconium Treatment Weight or Thickness on Metal Substrates by X-Ray Fluorescence. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  21. Line design Process control SEMand FE-SEM A scanning electron microscope (SEM) is a type of electron microscope that produces images of a sample by scanning over it with a high energy focused beam of electrons. The electrons interact with electrons in the sample, producing secondary electrons, back-scattered electrons, and characteristic X-rays that can be detected and that contain information about the sample's surface topography and composition. The electron beam is generally scanned in a raster scan pattern, and the beam's position is combined with the detected signal to produce an image. The electron beam can focused to a spot approximately 1 nanometer in diameter, and microscopes are able to resolve details ranging from 1–20 nm in size. Conventional SEM requires samples to be imaged under vacuum but methods have been developed that allow imaging biological samples. Field Emission Scanning Electron Microscopy (FE-SEM): A field-emission cathode in the electron gun of a scanning electron microscope provides narrower probing beams at low as well as high electron energy, resulting in both improved spatial resolution and minimized sample charging and damage. Higher magnifications with better image quality are possible ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  22. Line design Process control 6/6 Process control - conclusions Statement: XRF is an easy and simple technique to control the pretreatment result. Comment: For everyday use with similar material and conditions, this is true. But, as with all measurements it is important to learn the instrument and the technique. Furthermore, using coating weight as the only control parameter is tricky for many reasons. Statement: The New Pretreatment processes are easy to control and have a wide processing window Comment: Analyses of the process variables at a job shop running a New Pretreatment process showed that the process was very stable and the coating weight did not vary very much when the process was run within the given parameter ranges. This specific job shop had a computer based line control system installed. Statement: Coating weight is the only parameter needed to guarantee a good quality of the pretreatment Comment: There is no proven correlation between the coating weight and the corrosion protecting performance. Tests have shown that a very low coating weight (< 5 mg/m2 ) can result in inferior corrosion protection. The results obtained point in the direction that a rather wide range in value of coating weight can be accepted. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  23. Line design Waste Waste The sludge formation in a zinc phosphate line is dependent on the substrates. Cold rolled steel usually produces 3-5 g sludge /m2 and at least the double amount would be produced when treating aluminium. New pretreatment systems produce about 1000 times less sludge; i.e ~5 mg/ m2. A bath with New Pretreatment is typically changed once a year and should be treated in a waste water treatment plant. The substances in the bath are precipitated with milk of lime and easily filtrated. A certain small company running one of the new pretreatment systems change their bath once a year and the sludge residues on the bath walls or bottom are removed by rinsing with water. In the LCA section you can learn more about the environmental effects on changing process Learn more about waste in the Q&A section ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  24. Corrosion protection Corrosionprotection The corrosion protection of a surface treatment system is often measured by an accelerated test method in a test chamber that holds or cycles certain temperature(s) and relative humidity. Deposition of salt spray on the test panels is often part of the testing process. The different accelerated cyclic tests can be related to field test, where field can be exposure on bus or trail, or outdoor exposure for example in a marine environment. A close and proven correlation between test results from chamber and field is highly desirable. ACT1 is a Volvo standard test in which panels are exposed for 6 weeks in a chamber having a temperature range of 35-45C a humidity range of 50-97% R.H and salt spray rain: 1 w% NaCl, twice a week. The evaluation is done by measuring the corrosion spreading across a defined scribe. This test method has a proven correlation to field test performed on surface treatment systems based on zinc phosphate. ISO 12944 is a common standard used by general industry, not applicable for automobiles. The accelerated test used is Neutral Salt Spray which is performed in a chamber where the panels are exposed to a temperature of 35 C and a continuous spray of rain with 5 w% NaCl. The panels are usually tested at intervals of 250h and the corrosion spreading over scribe is visually determined. The test is very aggresive and usually gives more corrosion on galvanized steel than on plain steel. This is not in agreement with corrosion results obtained at outdoor exposure. Simulated corrosion atmospheric breakdown (SCAB) is an outdoor exposure test with 1w% salt spraying manually of panels mounted on a rack with a certain angle to the normal plane and directed toward the sun. The shortest exposure time is usually 6 months but 1 year is the normal. SCAB is one of the tests also used in ISO 12944. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  25. Corrosionprotection Corrosionprotection The results above show the corrosion spreading from scribe when cold rolled steel panels were exposed in the accelerated corrosion chamber test called ACT1 and their comparison to field test for one year. The paint systems were either polyester powder alone as one paint layer, or electrodeposited primer (ED) with polyester powder paint as top coat. “ZnPh” is short for zinc phosphate and “New 1” and “New 2” are pretreatment chemistries from different suppliers. Volvo’s requirement for passed systems is corrosion spreading ≤ 8mm. One layer polyester powder did not pass the requirement independent of the pretreatment, which was surprisingly bad for ZnPh. The results improved for the zinc phosphated panels when ED + powder was applied. None of the new systems pass the requirements for accelerated corrosion test but show promising results after one year field test with one paint layer. The ED+ powder paint gave less good results in field test. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  26. Corrosionprotection Corrosionprotection The results to the right show the corrosion spreading on galvanized panels . Volvo´s requirement for passed systems is corrosion spreading ≤ 5mm. Several new systems pass the requirement. The field results are also promising but the fact that ED+powder gives more corrosion spreading than one paint layer shows the need for more research. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  27. Corrosionprotection Corrosionprotection The diagram above shows the results from evaluations of two NPT systems compared to zinc phosphate (ZnPh) on hot dipped galvanized steel (HDG), cold rolled steel (CRS) and hot rolled steel (HRS). Evaluations were performed with field test (panels mounted on bus), accelerated chamber test (ACT) and simulated corrosion atmospheric breakdown (SCAB). The paint system is a 4 layer full system used on automotive bodies. Comparing the different evaluation methods, it can be concluded that the performance of NPT systems are rather good on HDG and HRS but there is a need for improvement on CRS. ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  28. Economics Economics One of the selling arguments for changing pre-treatment process are the economical benefits, with reduction of manual labor and heating for instance. However, this is much dependent on line design, type of production, substrates et cetera. The following section show the savings done at a Swedish SME company, powder coating about 105 000 m2 / year. Concluding the section is a easy template to calculate the costs and savings at your own plant. After the economics session, you will also find the environmental benefits gained at this company, calculated using LCA-analysis. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  29. Economics Economics – costs for rebuilding • 4 days • ~150 000 SEK • Included: • New equipment and rebuilding (new pipes, drainage, dosage pumps), 36% • Chemicals for cleaning and destruction of chemicals, 58% • Own work (cleaning), 6% • Not included: • Loss of production ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  30. Economics Economics • Less costs for chemicals • 49% reduction for chemicalsonly • Less costs for maintenace • ~83% reduction for maintenance • Less cost for heating of baths • 33% reduction for heating of baths • Less cost for sludge • ~83% reduction for sludge • Total reduction of cost • 47% reduction for chemicals, maintenace, heating and sludge ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  31. Economics Economics - example Template for calculation of cost, example SME-company ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  32. Economics Template ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  33. LCA-analysis LCA-analysis Life cycle analysis and comparisons of a production plant This LCA (life cycle analysis) was performed to provide an example between the zinc-phosphate process and a new, zirconium-based process. The LCA where performed only 2 weeks after the company switched pretreatment system and it is their consumption of chemicals as well as their actual costs that serves as input to this example. Background LCA-data ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  34. LCA-analysis Studiedpretreatment process • 105 000 m2/year • 2 m high, 1 m wide • Spray pretreatment • 60% aluminium zinc, 30% aluminium, 10% black sheet metal ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  35. LCA-analysis Outline ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  36. LCA-analysis Comments • Differences for the degreasing step is mainly because the new system has two more rinses connected to the degreasing. Also chemicals for the degreasing has been changed due to a switch of supplier. • Comments below the graphs indicates what affects the values most for the two systems. • The LCA was performed by using the “EPD– system” – the Environmental Product Declaration and The USEtoxTM model whichis an environmental model for characterization of human and ecotoxic impacts in Life Cycle Impact Assessment and for comparative assessment and ranking of chemicals according to their inherent hazard characteristics. ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  37. LCA-analysis System boundaries Product Energy Airborne emissions Chemicals raw material Company Production Chemical manufacturing Waste Deposit Water ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  38. LCA-analysis Conclusions • Energy usage and therefore also GWP is reduced due to less heating demand. • Acidification and photochemical smog is reduced due to change of surface treatment chemicals. • Eutrophication is reduced due to less sludge. • Toxicity is reduced due to change of surface treatment chemicals. • Around 50% less water usage • Almost 100% less sludge • Almost 50% total reduction of costs ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  39. LCA-analysis Comparison of zincphosphating and new pretreatment system ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  40. LCA-analysis Energy usage – 27% reduction Heat and electricity for both systems ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  41. LCA-analysis Global warming potential (GWP) – 35% reduction Zinc phosphating: Electricity usage, heating and sludge New pretreatment: Electricity usage and heating ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  42. LCA-analysis Acidification – 47% reduction Zinc phosphating: Electricity usage, heating and zinc phosphating chemicals New pretreatment: Electricity usage and heating ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  43. LCA-analysis Eutrophication – 90% reduction Zinc phosphating: Sludge and zinc phosphating chemicals New pretreatment: Electricity usage and heating ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  44. LCA-analysis Photochemical smog – 52% reduction Zinc phosphating: Electricity usage, heating and zinc phosphating chemicals New pretreatment: Electricity usage and degreasing chemicals ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  45. LCA-analysis Ozonedepletion – 11% reduction Zinc phosphating: Electricity usage and degreasing chemicals New pretreatment: Electricity usage and degreasing chemicals ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  46. LCA-analysis Ecotox – 86% reduction Zinc phosphating: Electricity usage, degreasing chemicals, zinc phosphating chemicals and sludge New pretretment: Electricity usage and degreasing chemicals ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  47. LCA-analysis Humantoxcarcinogenic – 62% reduction Zinc phosphating: Electricity usage, degreasing chemicals, zinc phosphating chemicals and sludge New pretreatment: Electricity usage and degreasing chemicals ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  48. LCA-analysis Humantoxnon-carcinogenic – 94% red. Zinc phosphating: Zinc phosphating chemicals New pretreatment: Electricity usage ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  49. LCA-analysis Water usage and sludge • 59% less water usage with the new pretreatment system compared to zincphosphating • Less water usage for cleaning of nozzles • Less evaporation of water • Almost 100% less sludge ENABLE Line design Corrosion protection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

  50. Q & A Q&A The Questions and Answers section are divided into the following sections: • Cleaning process • Process parameters for coating step • Robustness • Adaption to different paints • How to follow up your process • Water and chemical consumption (incl. waste) ENABLE Line design Corrosionprotection Economics LCA-analysis Q & A Environmental Acceptable Pretreatment Systemsfor Painting Multi Metals - No 262473

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