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Ion Exchange Purification of Trivalent Zinc Passivating Solutions. Presented to The National Environmental Partnership Summit 2007 New Orleans, LA May 8, 2007 Michael P. McMonagle President, Superior Plating, Inc. Special Thanks. Cindy McComas Karl DeWahl Steve Kocha . Zinc Plating.

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ion exchange purification of trivalent zinc passivating solutions

Ion Exchange Purification of Trivalent Zinc Passivating Solutions

Presented to

The National Environmental Partnership Summit 2007

New Orleans, LA

May 8, 2007

Michael P. McMonagle

President, Superior Plating, Inc.

special thanks
Special Thanks
  • Cindy McComas
  • Karl DeWahl
  • Steve Kocha
zinc plating4
Zinc Plating
  • Most commonly used
  • Lowest priced
  • Offers Anodic Corrosion Protection to Steel Parts
zinc plating5
Zinc Plating
  • Conversion Coatings (passivates)
      • Retards White Rust Formation of Zinc
      • Choices are:
          • Clear
          • Yellow
          • Black
          • Olive Drab
zinc plating6
Zinc Plating

4 Hours Salt Spray Exposure

With Passivate Without Passivate

zinc plating7
Zinc Plating
  • Conversion Coatings
      • Hexavalent Chromates were standard for years
      • Trivalent Passivates now available for Clear
      • Yellow and Black can be produced with dyes and top coats
zinc plating8
Zinc Plating
  • Conversion Coatings

Most commonly finished are Yellow and Clear

Hexavalent yellow gives more protection than Hex Clear or Inexpensive Tri’s

zinc plating9
Zinc Plating
  • Conversion Coatings
      • New Trivalent Conversion Coatings are available with corrosion protection greater than Hex. Yellows
      • 120+ Hours VS 96 Hours (ASTM B117 Neutral Salt Spray)
zinc plating10
Zinc Plating
  • Conversion Coatings
      • Advantages of Trivalent Conversion Coatings:
          • Excellent Corrosion Protection
          • No Cr +6
          • Safer for Environment, Employees
          • Complies with EU Directives (WEEE/RoHS, ELV)
          • Helps meet OSHA Cr PEL
          • Uniform “Blue Bright”
zinc plating11
Zinc Plating
  • Conversion Coatings
      • Disadvantages of Trivalent Conversion Coatings
          • Does not provide inhibition to uncoated areas
          • Not Self-healing
          • Less tolerant to Zn and Fe*
          • Expensive make-up and operations (approx 20X)*

* reasons for purification process

zinc plating12
Zinc Plating
  • Effects of Contamination:
      • From Zn – source is the deposit itself
      • Above 2000 mg/l
          • Reduced corrosion protection
          • White, cloudy appearance
      • From Fe – source is uncoated area of parts
      • Above 100 mg/l
          • Reduced corrosion protection
          • Dull, yellowish appearance
ion exchange purification
Ion Exchange Purification
  • ATOTECH Tricotect System
ion exchange purification14
Ion Exchange Purification
  • The ATOTECH Tricotect unit is a fully automated ion exchange system.
  • Uses a selective cation IX-resin.
  • Unit is leased to users of ATOTECH trivalent passivating solutions.
ion exchange purification15
Ion Exchange Purification
  • Operations at Superior Plating, Inc.
      • 11 months experience
      • Connected by manifold system to three different tanks
      • Process tank volumes range from 440 to 2500 gallons.
      • On-line purification cycle ranges from 4 to 6 hours.
ion exchange purification16
Ion Exchange Purification
  • Operations at Superior Plating, Inc.
      • Consistently maintains Zn below 2000 mg/l (1500 to 1800 mg/l normal range)
      • Consistently maintains Fe below 100 mg/l (60 to 90 mg/l normal range)
ion exchange purification17
Ion Exchange Purification
  • Operations at Superior Plating, Inc.
      • Economic Analysis
          • Annual Cost Factors Include:

make up costs maintenance costs

treatment costs utility costs

labor costs reagent chemical costs

equipment lease cost

ion exchange purification18
Ion Exchange Purification
  • Operations at Superior Plating, Inc.
  • Processing without Purification

Bath #1 Bath #2 Bath #3

Vol. (gals) 440 750 2500

Make ups 24 18 14

Costs($) 14400 18000 30900

ion exchange purification19
Ion Exchange Purification
  • Operations at Superior Plating, Inc.
  • With Purification

Bath #1 Bath#2 Bath#3

Vol. (gals) 440 750 2500

Make ups* 1(?) 1(?) 1(?)

Costs ($) 6200 9100 7500

Tricotect($) 3400 3500 6900

Totals ($) 9600 12600 14400

* need to monitor Cu and Pb but could be 18 to 24 months bath life

ion exchange purification20
Ion Exchange Purification
  • Summary of Benefits:
      • Consistent Product Appearance
      • Consistent Corrosion Protection
      • $26,700 Annual Savings (approx. 42%)
      • 660 Pounds of Chromium not used AND not discharged to the environment.