Kokan Permata Gading. Jl.

Boulevard Bukit Gading Raya Blok D-3

Phone: 021-4897358 / Fax: 021-4720058
Email: [email protected]

IMMERSION PHOSPHATING LINE PROCESS

Date: November 02, 2001
PROCESS DEGREASING WATER PICKLING WATER SURFACE ZINC PHOSPHATING WATER NEUTRALIZER
RINSE RINSE CONDITIONING RINSE
Product Metaclean 1500 PAM Descaler PAM Metalene ZN Metaphos 442 R/M DI Passivator
WATER
Process Dipping Dipping Dipping Dipping Dipping Dipping Dipping Dipping
Temp. C 50 - 60 R.T R.T R.T 40 - 55 R.T R.T
Dip time (min) 5-10 1 10-30 1 1 5-10 2 1
Volume (Lt) 1000 1000 1000 1000 1000 1000 1000 1000
Concentration (%) 4–6 20-50 0.1 – 0.2 6-8 0.1-0.5
Make-Up New Solution (kg) 30 - 50 - 200-500 1- 5 Metaphos 442= 50 – 60 Kg - 1-5
Accelerator 12= 2 – 3 Kg
Soda Ash = 3 – 5 Kg
Analysis / Pointage Free Alkali = 8-15 pts Overflow PH 2 – 3 Overflow PH 9,5 – 10,5 Total Acid : 25 - 32 Overflow PH >10
Free Acid : 0.3-1.0
Toner gas : 3-5
Increase 1 pts 2 kg / m3 - 0.15 kg/m3 Metaphos 442= 2.5 kg/m3 - -
Accelerator 12= 0.3 kg/m3
Analysis methode Free Alkali Free Acid Total Acid - -

10 ml samples 10 ml samples 10 ml contoh

 + 5 tetes PP  + 5 tetes BPB  + 5 tetes PP
Titrate with HCl 0.1N Titrate with NaOH 0.1 N Titrate with NaOH 0.1 N
  
Pink color to clear Yellow to bluish color Clear to pink color
 METACLEAN 1500
(Alkaline Immersion/Spray Cleaner)
1. INTRODUCTION
METACLEAN 1500 is a medium to strong alkaline chemical, powder cleaner which primarily used in spray application. The product can be used for general purpose cleaning of
steel, galvanized, zinc alloy, or aluminized steel surfaces. METACLEAN 1500 prepare the metal surface to receive uniform and dense phosphate coating in combination with
METAPHOS 442 Phosphating processes. METACLEAN 1500 is especially well suited for the removal of heavy oils.

2. OPERATING SUMMARY
Chemical Bath Preparation per 1000 liters
METACLEAN 1500 20 to 30 Kg (Spray)
30 to 50 Kg (Dipping)
Operation and Control
Free Alkalinity 8 to 15 points
Time 3 to 5 minutes
Temperature 40  5 C

3. MATERIALS
1. METACLEAN 1500
2. Testing Reagent

4. TESTING AND CONTROL

Free Alkalinity:
Pipette 10 ml sample into Erlenmeyer glass and add 3-5 drops of PP (phenolphthalein). Titrate slowly with HCl 0.1 N until a color change from pink to clear. The ml of titrating
solution used is the Free Alkalinity value in points.
Free Alkalinity range: 8 – 15 points (ml)
To increase value 1 point (ml): add 2.0 kg of METACLEAN 1500 per 1000 liters of bath

5. AFTER CLEANING
Water Rinsing
One rinse stage after the METACLEAN 1500 cleaning process should be sufficient, although two rinses can be used to minimize carry over to the following phosphating process.

6. PRECAUTIONARY INFORMATION
METACLEAN 1500 is a medium to strong alkaline powder. When handling, wear a face shield and PVC or rubber gloves. In case of skin contact, wash immediately with large
quantities of water.

7. STORAGE
 Do not require special protection
 Do not store near acidic materials
 In dry conditions to avoid moisture contact from the atmosphere
 DESCALER H901
Acidic immersion for Rust Removing

DESCALER H901 is an acidic material supplied in liquid form. It is used as a cleaner for the removal of soil, rust and light heat scale from iron and steel

PROCESS
Concentration : 20 -50%

Temperature : R.T – 60 0C

Contact time : as required

Free acid : 8 – 45 point

TESTING AND CONTROL

Pipette a 1 ml sample into a 150 ml beaker glass. Add ± 25 ml of water and drops of methylorange. Titrate with NAOH 0.1 N to change the color from red to yellow. The ml of
NAOH 0.1 N required gives the Free Acid in points.
To increase 1 point titration, add 18 kgs of DESCALER H901 per 1000 liters solution.

AFTER TREATMENT
After cleaning, the parts are thoroughly rinsed with water. The rinsed should be overflowed continously at a rate which will keep it clean and free from scum and
contamination.

STORAGE
No special storage requirement are needed for DESCALER H901
 METALENE ZN
(Conversion Coating Conditioner)

1. INTRODUCTION
METALENE ZN is a powdered, water soluble product, especially formulated to prepare iron, steel, zinc, and zinc alloy surfaces for subsequent phosphate coating applications.
These surfaces may be treated individually or in mixed production by spray processing of the conditioning solution.

The METALENE ZN titanium containing conditioning pretreatment promotes the formation of a dense, fine grained phosphate coating, which offer superior paint adhesion and
durability in corrosive environment.

2. OPERATING SUMMARY
Chemical Bath Preparation per 1000 liters
METALENE ZN 2 to 5 kg

Operation and Control

PH 8.5 to 9.5
Time 0.5 to 1 minutes
Temperature R.T

3. THE PROCESS
A. Cleaning (METACLEAN 1500)
B. Water Rinsing
C. Surface Conditioning (METALENE ZN)

4. MATERIALS
1. METALENE ZN
2. Testing Reagents

5. TESTING AND CONTROL

The conditioning bath pH should be maintained between 8.5 and 9.5. For pH in excess of 9.5, a partial dumping of the conditioning bath should be made and fresh METALENE
ZN added to bring the titanium levels back to normal operating conditions. For pH below 8.5, soda ash may be added for adjustment.

6. PRECAUTIONARY INFORMATION
METALENE ZN is a mildly alkaline powder . when handling, wear a face shield and PVC or rubber gloves. In case of skin contact, wash immediately with large quantities of
water.

7.STORAGE
 Do not require special protection
 Do not store near acidic materials
 In dry conditions to avoid moisture contact from the atmosphere
 METAPHOS 442
(Dipping Zinc Phosphate)

1. INTRODUCTION
METAPHOS 442 is formulated for Dipping application to steel, galvanized steel, electro-galvanized steel, and zinc-alloy coated steel. The metals can be treated individually or in
mixed production.

The METAPHOS 442 process converts the metal surface to a nonmetallic, polycrystalline coating containing iron, and zinc phosphates. This coating provides high alkaline
resistance and is a preferred paint base for the subsequent application to gives equally good performance with all types of paint and powder coating. In addition to offering superior
paint adhesion and durability, the METAPHOS 442 coating also provides:
A. A clean, grease free surface
B. A non conducting bond between base metal and paint
C. A chemically inert surface which prevents reaction between the metal surface and the paint ingredients.

2. OPERATING SUMMARY
Chemical Bath Preparation per 1000 liters

METAPHOS 2014 40 to 50 kg
Accelerator 12 1 to 2 kg
Soda Ash 3 to 5 kg
Operation and Control

Total Acid 25 to 32 points

Free Acid 0.5 to 1.5 points
Accelerator level 3 to 5 points
Time 1.5 to 3 minutes
Temperature 40 to 55 C

3. THE PROCESS
The complete process for the METAPHOS 442 treatment normally consists of the following steps:
A. Cleaning with METACLEAN 1500 cleaner
B. Water rinsing
C. Surface conditioning with METALENE ZN
D. Treatment with the METAPHOS 442 processing solution
E. Water rinsing
F. D.I. water rinsing
G. Drying
4. MATERIALS
A. METACLEAN 1500 (Cleaner)
B. METALENE ZN (Conditioning rinse agent)
C. METAPHOS 442 (Treatment)
D. Accelerator 12
E. Soda Ash
F. Testing Reagents and Apparatus

5. SURFACE PREPARATION
Cleaning
All metal to be treated with the processing solution must be free from grease, oil, solvents, and other foreign matter before the treatment. A complete line of METACLEAN 1500
cleaners is available.
Water Rinsing
After cleaning, the metal must be thoroughly rinsed with water. The rinse should be overflowed continuously at rate which will keep it clean and free from scum and
contamination.
Surface Conditioning
A METALENE ZN Conditioning rinse is required in the process to obtain the proper crystal structure.

6. TREATING WITH THE METAPHOS 442 SOLUTION

The properly cleaned and conditioned metal is immersion with the METAPHOS 442 solution for 5 to 10 minutes at R.T - 55 C.

7. TESTING AND CONTROL

Total Acid
Pipette a 10 ml samples into a flask and add a few drops of PP. Titrate slowly with 0.1 N NaOH to the development of a permanent, faint pink color. The ml of titrating solution
used is the total acid value in points.
Total acid range: 25 to 32 points (ml.)
To increase value 1 points Total acid: add 3 kg of METAPHOS 442 per 1000 liters of bath.

Free Acid
Pipette a 10 ml samples into a flask and add a few drops of BCG. Titrate slowly with 0.1 N NaOH until the yellow color change to bluish green. The ml of titrating solution used is
the free acid value in points.
Free acid range: 0.5 to 1.0 points (ml.)

Accelerator 12 level (accelerator)

Fill Saccharometer tube with processing solution approximately 75 ml. Add  2 gram sulfuric acid into the saccharometer tube. Place the tube upright on a table top and remove
the stopper after three minutes (minimum), record the volume of gas entrapped in the closed end of the tube.
ACCELERATOR 12 levels: 3 to 5 points
To increase value of 1 points Accelerator level: add 0.3 kg of Accelerator 12 per 1000 liters of bath.
8. AFTER TREATMENT
Water rinsing
After METAPHOS 442 treatment, the metal should be thoroughly sprayed with cold water. The rinse should be overflowed at a rate sufficient to prevent excessive contamination
from the processing solution.

D.I. Water rinsing

The treated metal should be thoroughly sprayed with D.I. water. Use of D.I. water is essential to prevent contamination of the solution in the paint tank

9. PRECAUTIONARY INFORMATION
These are an acidic liquid; when handling, wear a face shield and PVC or rubber gloves. In case of skin contact, wash immediately with large quantities of water.
.
10. STORAGE
 Does not require special protection
 Does not store near alkaline materials
 PASSIVATOR / NEUTRALIZER

(Additive for Descaling Process)

APPLICATION
Neutralizer is a liquid product, it is used as an additive for descaling solution to adjust the acid. (Decreasing the acid)

COMPOSITION
Alkaline Anorganic

APPEARANCE
Colourless clear liquid

DENSITY
Approx. 1.10 g/ml at 27 degree celsius

PH VALUE
12,5 – 13,2 ( 10 g/L solution )

CONCENTRATION
50 kilograms per 1000 Litres bath solution (20 – 22% referred to the concentration of acid / Descaler H-901 in the solution)

PRODUCT USE
The required amounts of Neutralizer have to be added to the Descaling tank continuously to maintain free acid that is suitable with the standard range.