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Transfer of production technology of environmental protection type yellow tobacco diacid mirror polishing additive for aluminum alloy

Ⅰ.Introduction of technical achievements and products

Project Background Technology: In the traditional polishing technology, when the surface of aluminum alloy is acidic chemical polishing, the commonly used polishing agent is triacid polishing agent prepared by three acids including phosphoric acid (H3PO4), sulfuric acid (H2SO4) and nitric acid (HNO3). Polishes the three acid with nitric acid as a corrosion inhibitor, when polishing, nitric acid reaction with aluminum and nitric acid is a strong oxidizer, but also the effect of acid, especially under the condition of the heating, reduction of nitric acid, which will produce large amounts of NO2 rust-worn gears flaking, air pollution, harm to human body, and also has serious corrosion for plant and equipment, The chemical equation of nitric acid and aluminum is as follows: Al+6HNO3=Al (NO3) 3+3NO2↑+3H2O

Triacid polishing agent in the aluminum alloy polishing, its high operating temperature, the polishing operation brings some difficulties. In order to eliminate chemical polishing process of pollutants to the environment pollution and the damage to human body, has carried on the improvement to the traditional chemical polishing, we developed the countless rust-worn gears flaking two acid chemical polishing bright additive, nitrate in three acid instead of traditional polishing process, into the two sulfur acid is polishing additives and can use of aluminum, The polishing process will not produce harmful gas, the polishing effect is comparable to the traditional triacid polishing process, even beyond the triacid polishing process, and its polishing production temperature requirements are lower than the triacid polishing temperature, energy consumption is lower than the triacid polishing process, energy saving and environmental protection. Smokeless mirror polishing technology is the upgrading technology of ordinary triacid and electrolytic polishing, and is the development direction of chemical polishing technology for aluminum alloy profiles and alloy parts. Smokeless mirror polishing has the characteristics of no yellow smoke, no flow mark, low cost, low consumption, low equipment investment, high brightness, high stability, high efficiency, high yield and so on, which breaks through the bottleneck and defect of traditional polishing technology.

Ⅱ.Technical specifications, characteristics and application of biacid smokeless polishing additive

Product features and technical indicators and use methods

1, based on a two sulfate acid phosphate polishing system development, the type of multicomponent compound liquid polishing agent, selection of a variety of special additives scientific distribution, traditional polishing process does not produce nitrogen oxides three acid polishing rust-worn gears flaking, and other gas pollutants, smokeless without odour, also won't produce poisonous gas, the composition of environmental friendly, Thus eliminate the polishing damage to human body and environment, solve the problem of triacid polishing smoke, can save a lot of environmental treatment costs. It is an environment-friendly and efficient new aluminum alloy diacid polishing additive, which clears the main technical obstacles for the wide application of chemical polishing.

2, brightness stability: Inhibitors as additive have enough amount of smoke, rust-worn gears flaking decomposition was completely suppressed, strong oxidizer decomposition slower, than three acid tank is stable and need frequent adjustment groove, different batch production of polishing materials, brightness stability, polishing the surface of a product after gloss over 700 degrees, uniform luster, mirror effect is good, the polishing quality are comparable to those obtained and three acid polishing process; So different batches of aluminum alloy brightness difference than triacid polishing is much smaller;

3, brightness increase: under the condition of adjusting different phosphorus-sulfuric acid ratio and additive content, different polishing effect, adaptability. The brightness of chemical polishing is not only related to the concentration of phosphoric acid, sulfuric acid and temperature, but also related to the water content of the polishing fluid. The higher the water content, the lower the brightness, smokeless mirror polishing solution in the production process, after a long time of high temperature concentration, the water content is less than 5%, so the brightness of mirror polishing material is significantly improved;

4, long time drip without flow mark: special corrosion inhibitor can effectively control the flow mark, sand whitening and other common problems in the process of chemical polishing. Considering that the chemical polishing reaction is too violent, aluminum alloy after leaving the bath liquid, the drip time can not exceed 20s, a large amount of polishing liquid is brought into the wash tank, resulting in the cost of polishing material is too expensive. There is enough corrosion inhibitor added in the smokeless mirror polishing solution to protect the aluminum alloy after leaving the tank for a long time without flow marks and over corrosion phenomenon, and it can be dripped in the air at any time without material flowers and no flow marks. It overcomes the defect of rapid transfer of triacid polishing, reduces acid loss and low consumption, and completely solves the problem of polishing flow mark. Smokeless mirror polishing saves more than 70% of polishing fluid. Compared with electrolytic polishing consumption reduced by 60%-70%;

5, automatic ash removal: aluminum alloy impure or polishing liquid aging, aluminum after triacid polishing, the surface often has a layer of black ash, the general method is difficult to remove, seriously affect the quality of polishing material. Smokeless mirror polishing tank, add ash removal ingredients, can automatically remove polishing ash;

6, high yield: due to the smokeless mirror polishing groove to solve the color difference, flow marks, flower material, polishing ash and other problems, the yield is greatly improved. Thus reduce the cost, improve the production efficiency, smokeless mirror polishing process almost no defects, high product yield;

7, tank liquid stability: smokeless mirror polishing tank almost no groove, can work steadily for a long time. It paves the way for large-scale industrialization and automatic production of chemically polished aluminum. The tank liquid maintenance of the two acid yellow smoke free polishing liquid is relatively simple :(1) only when the tank liquid level drops, according to the proportion of the tank appropriate add phosphoric acid, sulfuric acid, polishing additives; (2) There is no need to analyze the tank liquid often, only need to analyze the contents of phosphoric acid and sulfuric acid in the tank liquid every other week or in case of problems, and adjust them to the parameter range;

8, zero nitric acid addition, the chemical throwing process is smokeless and tasteless, completely environmental protection, help the factory clean production, polishing operation temperature requirements are low, less energy consumption, energy conservation and environmental protection;

9, special formula, washing tank mixed acid can be 100% reflux utilization (using acid recovery equipment), greatly reduce the cost of polishing and wastewater treatment. No need to re-slot, can be adjusted on the basis of three acid tank, save the cost of slotting.

Process technical index:

Acid polishes 20 ~ 30 g/L

Phosphoric acid (H3PO4) 60 ~ 70% (W/W)

Sulfuric acid (H2SO4) 30 ~ 40% (W/W)

Density (25℃) : 1.86-1.92

Mass ratio of phosphoric acid to sulfuric acid: 1.3-1.5:1

Aluminum ion ≦ 30 g/L

Polishing temperature 90 ~ 100 ℃

The polishing time is 0.5 ~ 4 min

Before slotting, carefully check whether the welding of the stainless steel tank is intact, whether the heating and cooling circulation pipe leaks, and whether the ventilation and exhaust device can work normally.

After the inspection, the phosphoric acid, sulfuric acid in proportion (mass ratio 1.5: 1 case into the tank, can only be poured into 3/4 of the total volume of the tank, start heating, tank liquid temperature reaches 100℃, stop heating, start the exhaust device, add 3% to 6% of the total acid mass additives stir evenly, and then add 30kg/m3 aluminum waste into the tank to dissolve aluminum (try to press the waste aluminum to the bottom of the tank, the effect is better).

High temperature and smoke will be generated in the process of aluminum dissolving, please pay attention to safety protection measures. Input waste aluminum can not be added in one time, according to a small number of times. After the aluminum is dissolved, the temperature can be produced when it drops to 100℃.

(Liquid/solid type two products)

Packing, storage and shelf life

25kg plastic drum or iron drum packaging; Keep away from light and alkali, put gently, seal in dry and cool place to prevent leakage. Store at room temperature for 1 year.

Tank liquid maintenance and management

1. When the polishing liquid is just slotted, the activity is large, the polishing speed is fast, and the temperature is reduced as far as possible. With the increase of aluminum ions, the polishing speed slows down.

2, there is only loss in the production process, we recommend to drain each hanging workpiece and then enter the washing tank. The product can be recycled, the use of acid recovery equipment to recover acid without additional additives. Equipped with waste liquid recovery will greatly reduce production costs.

3. When the liquid level is lowered, the mass ratio of phosphoric acid to sulfuric acid is 1.5-2: 1. The additive is added in the proportion of 3%-6% of the total acid. Adding other chemical components will destroy the original polishing fluid ratio, resulting in quality problems and even tank scrapped.

4, the workpiece due to spatial shape, surface geometry, holes and gaps and other factors can not be completely drained and caused by tank liquid loss is often difficult to avoid, reasonable binding material and fixture design can greatly reduce production costs.

5, do not pay attention to waterproof cover. If it is not used after a long time shutdown, the tank liquid shall be heated to 150℃ and kept for more than 6 hours for cooking water.

Ⅲ.Application field, market prospect and industrial production conditions of biacid smokeless polishing additive project

Scope of application: Diacid polishing additive is mainly used for polishing ordinary aluminum profiles, mechanical sandblasting, mechanical drawing, mechanical polishing and other decorative aluminum alloy parts, the polished aluminum has high gloss and mirror effect.

In recent years, high decorative aluminum alloy materials are widely used in construction, daily hardware, equipment and other fields and the market demand is increasing. High decorative aluminum and aluminum alloy parts before anodic oxidation, electrolytic coloring, chemical dyeing usually need to finish the material before polishing.

The commonly used surface finishing treatment methods of aluminum parts mainly include mechanical polishing, electrolytic polishing and chemical polishing. Chemical polishing method is not limited by the shape of the workpiece and does not need power equipment, so chemical polishing is the most widely used.

With the implementation of national environmental protection laws and regulations and the strengthening of people's awareness of environmental protection, as a key technology in the surface treatment of highly decorative aluminum parts, the demand for smoke-free chemical polishing process and products is very strong in recent years.

Main production equipment and site: the threshold of the production field is relatively low, as long as there is a capital foundation, you can enter the line, the investment can be large or small, as low as several thousand yuan to buy a equipment can produce.

Diacid polishing additive production equipment: the main equipment is stainless steel dry mixing and mixing machine (1000L capacity machine price is about 10,000, small batch production can also be manually mixed with small tools);

Production site: production workshop 50-80 square meters, warehouse 70-100 square meters, power supply 380 volts, total power 10-18 kw.

One person can operate the whole set of equipment, and two people can run the factory.

Production workers: one shift needs 1-2 people, can produce more than 1~2 tons of diacid polishing additive per day, workers' education level is not limited;

Ⅳ.Analysis of technical economic benefit and environmental protection evaluation of biacid smokeless polishing additive industrialization

Expected economic benefits of the project:

The production cost of acid polishing additive products is 15000-18000 yuan/ton (grade is not the same as the cost is different), the price of each ton on the market is 40,000-60000 yuan, and the high one is even 60,000-80000 yuan /T. The net profit of each ton of products is calculated between 22000-25000 yuan at the lowest sales price. Monthly production of 10 tons, then the annual net profit in 2.2 to 2.5 million yuan, if the marketing channel smooth, the actual output is far more than this, according to the current market situation, if the sales are good, the profit is considerable.

The raw materials used in production are non-toxic common chemical raw materials, no waste water, waste gas, waste residue discharge in the production process, the production process will not cause environmental pollution.

Ⅴ.Methods of technology transfer and cooperation

Transferable product technology:

Aluminum alloy environmental protection high brightness no yellow tobacco diacid polishing additive production technology.

Way of cooperation: one-time technology transfer, providing a full set of technical formula, production process, equipment list, raw material manufacturers, construction specifications, etc. Can study in my company, on-site training, learn so far. Engineers can also be sent to provide on-site technical services to guide the production of qualified products.

Detailed project feasibility analysis report on request.

Product technology for large-scale production of mature technology, technology transfer fee call to discuss.

No yellow nicotinic acid polishing agent

Diacid polishing effect drawing