Gb2013 wim brandsema_euromáquina

FluxcleaningFluxcleaningbyby

IndufinishIndufinish

FluxcleaningFluxcleaningbyby

IndufinishIndufinish

Wim BrandsemaWim Brandsema Managing Director, Owner of

Indufinish 25 years of experience HDG Board member branch

organization

Wim BrandsemaWim Brandsema Managing Director, Owner of

Indufinish 25 years of experience HDG Board member branch

organization

We are an innovative full service-oriented manufacturer in the surface treatment industry, with a unique combination of market knowledge 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.

We are an innovative full service-oriented manufacturer in the surface treatment industry, with a unique combination of market knowledge 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.

Short story of companyShort story of company

Our company in Emmen, The Netherlands

Our company in Emmen, The Netherlands

Grounded in 1991 Owned by Wim Brandsema & Han Kleijn 40 full time employees Company surface 7.500 m² R&D budget 2-3% of annual turn-over Installations throughout Europe.

Grounded in 1991 Owned by Wim Brandsema & Han Kleijn 40 full time employees Company surface 7.500 m² R&D budget 2-3% of annual turn-over Installations throughout Europe.

FactsFacts

Powered by Dutch technologyPowered by Dutch technology

Powered by Dutch technologyPowered by Dutch technology

Intelligence, Dynamic, Driven Passionate about their company and

products Development power 40 ambitious people to improve

constantly

Intelligence, Dynamic, Driven Passionate about their company and

products Development power 40 ambitious people to improve

constantly

ISO 9001 DVS, Deutsche Verein für

Schweißtecnik TÜV, Anerkennung Fachbetrieb Continuous training of employees

ISO 9001 DVS, Deutsche Verein für

Schweißtecnik TÜV, Anerkennung Fachbetrieb Continuous training of employees

QualityQuality

Linkedin Twitter You Tube

Linkedin Twitter You Tube

Social mediaSocial media

Galvanizing Powder Coating Anodizing Plating E-coat

Galvanizing Powder Coating Anodizing Plating E-coat

PortfolioPortfolio

GalvanizingGalvanizing

pre treatmentpre treatment

GalvanizingGalvanizing

pre treatmentpre treatment

Pre-treatment plantsPre-treatment plants

Pre-treatment plantsPre-treatment plants

LiningsLinings

SpinningSpinning

Fluxcleaning Fluxcleaning 1.01.0

Fluxcleaning Fluxcleaning 1.01.0

Getting the Iron out Compact unit Easy to maintain & service Transportable Online servicing

Getting the Iron out Compact unit Easy to maintain & service Transportable Online servicing

GoalsGoals

The unitThe unit

Protoype 6 months trial Still up & running Learning curve

Protoype 6 months trial Still up & running Learning curve

ResultResult

Standard chemistry No overdosing H2O2 No sludge in your tank Fe on constant level

Standard chemistry No overdosing H2O2 No sludge in your tank Fe on constant level

FactsFacts

Fluxcleaning Fluxcleaning 2.02.0

Fluxcleaning Fluxcleaning 2.02.0

Process controlProcess control&&

Quality improvement Quality improvement of galvanized steelof galvanized steel

Process controlProcess control&&

Quality improvement Quality improvement of galvanized steelof galvanized steel

Temperature Concentration and Ratio pH Fe content Surface tension

Temperature Concentration and Ratio pH Fe content Surface tension

Flux parametersFlux parameters

Important but not influenced by flux treatmentMinor drop during proces in external unitHeater can be installed in unit

Drying is very important!Reduces splatter

Important but not influenced by flux treatmentMinor drop during proces in external unitHeater can be installed in unit

Drying is very important!Reduces splatter

Flux parameters temperatureFlux parameters temperature

Concentration in between 200-550 g/l total saltAlthough lower concentrations are mentioned

Ratio

Mono, double, triple, quadra salts

Influenced by flux treatmentNH4OH pH correction will influence ratio and densityCorrection with ZnCl2 is necessaryPossible through ZnCl2 solution or stripping acid!

Concentration in between 200-550 g/l total saltAlthough lower concentrations are mentioned

Ratio

Mono, double, triple, quadra salts

Influenced by flux treatmentNH4OH pH correction will influence ratio and densityCorrection with ZnCl2 is necessaryPossible through ZnCl2 solution or stripping acid!

Flux parameters concentrationFlux parameters concentration

The “least” discussed parameterWhat is your pH? 4,5

Why pH 4,5?Because we’ve done so for agesLess agressive/active flux less Fe built up

What are the benefits of pH 2,3?More active fluxWill “polish” the surfaceFe building is not an issue with a flux treatmentBetter circumstances in the flux treatmentDry filter cake, faster reaction, no Zn oxidation

The “least” discussed parameterWhat is your pH? 4,5

Why pH 4,5?Because we’ve done so for agesLess agressive/active flux less Fe built up

What are the benefits of pH 2,3?More active fluxWill “polish” the surfaceFe building is not an issue with a flux treatmentBetter circumstances in the flux treatmentDry filter cake, faster reaction, no Zn oxidation

Flux parameters pHFlux parameters pH

Drag in of Fe gives higher dross and ash production

Iron content < 5 g/l is recommendableHard to achieve without flux treatment

Main reason to start with flux treatment!Concentrations < 1 g/l are achievableAmount of rinses between pickle and flux can be 1 or even none

Oxidation with hydrogen peroxide is most common

Drag in of Fe gives higher dross and ash production

Iron content < 5 g/l is recommendableHard to achieve without flux treatment

Main reason to start with flux treatment!Concentrations < 1 g/l are achievableAmount of rinses between pickle and flux can be 1 or even none

Oxidation with hydrogen peroxide is most common

Fe contentFe content

Important for an equally fluxed surface Modern wetting agents are stable

towards H2O2 Automated dosing of wetting agent in

small amounts is recommendable and can be performed in the flux treatment

Important for an equally fluxed surface Modern wetting agents are stable

towards H2O2 Automated dosing of wetting agent in

small amounts is recommendable and can be performed in the flux treatment

Surface tensionSurface tension

1. Case 1, proto type Dutch general galvanizer 7 metres

2. Case 2, crash barriers, extremely high Fe content German crash barrier galvanizer 13 metres

3. Case 3, advantages low pH German general galvanizer 15 metres

1. Case 1, proto type Dutch general galvanizer 7 metres

2. Case 2, crash barriers, extremely high Fe content German crash barrier galvanizer 13 metres

3. Case 3, advantages low pH German general galvanizer 15 metres

Quality improvementQuality improvement

Prototype Fluxcleaner Dutch general galvanizer 15.000 tons/year capacity 30 m3 flux

pH at start 3,9 Fe content 19 g/l Colour at start coffee brown Start up at October 27th 2007, no cure no pay Started with iron removal at 1 g/l program Stable situation from february 2008

different programs (removal rate) changed pump

Prototype Fluxcleaner Dutch general galvanizer 15.000 tons/year capacity 30 m3 flux

pH at start 3,9 Fe content 19 g/l Colour at start coffee brown Start up at October 27th 2007, no cure no pay Started with iron removal at 1 g/l program Stable situation from february 2008

different programs (removal rate) changed pump

Quality improvement, case 1Quality improvement, case 1

Status April 2008 pH 2-3 Color coffee brown Iron content < 5 g/l Filter press is emptied once a week Customer purchased unit

Savings 30 m3 new flux Disposal of 30 m3 old flux Disposal sludge from flux tank Overall impression of better quality

Status April 2008 pH 2-3 Color coffee brown Iron content < 5 g/l Filter press is emptied once a week Customer purchased unit

Savings 30 m3 new flux Disposal of 30 m3 old flux Disposal sludge from flux tank Overall impression of better quality

Quality improvement, case 1Quality improvement, case 1

Extremely high Fe content German crash barrier galvanizer 25.000 tons/year capacity 48 m3 flux

pH at start < 0,5 Fe content 78 g/l Color at start pitch black Start up February 2009

Corrected pH to > 1 Started iron removal at 5 g/l program Filter press is emptied multiple times a week

Extremely high Fe content German crash barrier galvanizer 25.000 tons/year capacity 48 m3 flux

pH at start < 0,5 Fe content 78 g/l Color at start pitch black Start up February 2009

Corrected pH to > 1 Started iron removal at 5 g/l program Filter press is emptied multiple times a week

Quality improvement, case 2Quality improvement, case 2

Status June 2009 pH 2,3 Fe content < 1 g/l Color coffee brown

Savings 48 m3 of new flux Disposal of 48 m3 heavily contaminated flux Disposal of sludge from flux tank Lower dross production (from 0,35% to 0,24%) Lower ash production (from 0,54% to 0,48%)

Status June 2009 pH 2,3 Fe content < 1 g/l Color coffee brown

Savings 48 m3 of new flux Disposal of 48 m3 heavily contaminated flux Disposal of sludge from flux tank Lower dross production (from 0,35% to 0,24%) Lower ash production (from 0,54% to 0,48%)

Quality improvement, case 2Quality improvement, case 2

Advantages low pH German general galvanizer 35.000 tons/year capacity 92 m3 flux

pH at start 4,5 Fe content 1,3 g/l Color coffee brown Test to see if the expected advantages of

pH 2,3 are found in praxis Test for 7 months using identical, numbered products

Advantages low pH German general galvanizer 35.000 tons/year capacity 92 m3 flux

pH at start 4,5 Fe content 1,3 g/l Color coffee brown Test to see if the expected advantages of

pH 2,3 are found in praxis Test for 7 months using identical, numbered products

Quality improvement, case 3Quality improvement, case 3

Test followed the following steps;Filtration at pH 4,5Iron removal at pH 4,5Lowering pH to 2,3 combined

with iron removal5 months of testing to ensure quality improvement is stable

ConclusionsDistinguished quality improvement after lowering pH (over X-mas)

Less pickle and roughness Less ashes, different type of ashes

Test followed the following steps;Filtration at pH 4,5Iron removal at pH 4,5Lowering pH to 2,3 combined

with iron removal5 months of testing to ensure quality improvement is stable

ConclusionsDistinguished quality improvement after lowering pH (over X-mas)

Less pickle and roughness Less ashes, different type of ashes

Quality improvement, case 3Quality improvement, case 3

As iron was already low specific attention wasgiven to dross production.

A higher dross production related to lower pH was not found.

Higher dross production was identified and originating from change of products

Conclusion in a, by the galvanizer written, report was that a lower pH gives a considerable quality improvement but can’t be achieved

without a Fluxcleaner

As iron was already low specific attention wasgiven to dross production.

A higher dross production related to lower pH was not found.

Higher dross production was identified and originating from change of products

Conclusion in a, by the galvanizer written, report was that a lower pH gives a considerable quality improvement but can’t be achieved

without a Fluxcleaner

Quality improvement, case 3Quality improvement, case 3

Status June 2013pH 2,3Fe content < 0,5 g/lColour coffee brownCustomer purchased the unit

Savings Slightly cheaper then sludge removal from the tank

The improved quality meant less after work, the savings on this labour were not calculated but estimated to be at least one FTE!

Status June 2013pH 2,3Fe content < 0,5 g/lColour coffee brownCustomer purchased the unit

Savings Slightly cheaper then sludge removal from the tank

The improved quality meant less after work, the savings on this labour were not calculated but estimated to be at least one FTE!

Quality improvement, case 3Quality improvement, case 3

Indufinish propositionIndufinish proposition

www.fluxcleaning.com

Compact Lowest chemistry consumption Usage of basic chemistry only Corrosion resistance, only plastic Will clean up existing flux with high iron content Best ROI Fully automated Easy to maintain Short delivery times 35 units in the European market Knowhow and experience with the unit since

2006 

Compact Lowest chemistry consumption Usage of basic chemistry only Corrosion resistance, only plastic Will clean up existing flux with high iron content Best ROI Fully automated Easy to maintain Short delivery times 35 units in the European market Knowhow and experience with the unit since

2006 

Indufinish propositionIndufinish proposition

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Thank you for

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