E-Coat Seminar. 2008

A.

Neutralization ( )Electro-deposition Reaction Mechanism Electro Deposition Section Parameter ED Trends of Future

6. Trouble Shooting

1. Neutralization ( )

2. Electro-deposition Reaction Mechanism , , H+, OH- . , . ( +) . . OH- . H+ OH- H2O . . . () () (Electrolysis) (Electrophoresis) (Electro deposition) (Electro endosmosis)

(Cathode)- Electrolysis of water( ) 4 HO + 4 e- 2 H + 4 OH- Film deposition( )

4 RNH+ + 4 OH- 4 RN + 4 HO- p H : 12 ~ 14 (Anode)- Electrolysis of water( ) 2 HO 4 H+ + O + 4 e- 4 CH3COO- + 4 H+ 4 CH3COOH- p H : 1 ~ 3 (Electrochemical Reaction)

3. Electro Deposition Section ( ) . (Electro deposition, E-Coat, ELPO) Bath . , . . UF (Ultra Filtration Rinse Section)

. UF . Spray immersion . UF #1 UF #2 UF #3 95% (Deionized Water Rinse) (Cure)

UF () . , .

4. Parameter

UF Module / / 1 / UF 70% ~ 80% Module .Electrode(Anode) 50% 1 / 2 Anolyte Flow .- Anode ( SUS 316 L ) Membrane . / P - Bath 28 ~ 34Ripple 5% - Max. Filter 1 / Cartridge / Bag Filter Bag : 2~3 pH Module : 1/2Ion Change :2- R/O Module / Ion Resin

UF System (Ultra Filtration) : . Bath UF Module UF (Permeate) UF Permeate UF Rinse ( ) , , . Bath , UF Permeate Bath fresh . 1/min UF Permeate : 1.3L /min

UF Module Filter - : Bag Filter Cartridge Filter UF Module . UF Permeate Flux() - Bath Carry Over - Bath p H ( pH Flow ) - Membrane . - (Filter Clog )/ . Permeate Back Pressure - Parameter (NV,)

4. Parameter

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Foulant Membrane Membrane Support

UF Module Type - Spiral Wound Type - Hollow Fiber Type- Multi Tubular Type - Plate Type UF Module Spiral Wound Type . UF Module . . UF Module 2.50.5 Kg.f/( P 2.0 Kg.f/ ) 100 L/Min , : 35 .

Membrane PVDF (Polyvinylidene Fluoride) . Molecular Weight Cut Off (MWCO) (NV,)4. Parameter

SpiralWoundMulti Tubular Hollow Fiber

Electrode (Anode : )

(+) . Box Cell Tubular Cell 1 4 ~ 6 . (-) Fresh Bath Electrode System Membrane Anode(SUS 316L) . Membrane , Anode . Electrode .

Anode , Anolyte() .

Anode 1 8L/min Membrane Surface Resistance : Max. 25000. 4. Parameter

(Heat Exchange) : (30 2)

Pump . Pump Bath . Bath 35 . , Line . 34 . IN Put - OUT Put (P )0.5 ~ 1.0 Kg.f/ . (Rectifier)

: / 0V ~ 350V : Continues Type : (21 Amp.min/ / min) : UP-Down Program hoist Type : 75 A / m2 : Ramp Time : 1sec ~ 60 sec : Ripple : Max. 5%4. Parameter .

(Deionized Water System)

Line Raw Material (Water). 90% (Water) . Material . () Mineral pH . 100 . - (Conductivity : /), ( Resistivity : .) p H ( ) . - p H 5.0 ~ 6.5 , - 10 / , ( 0.1 . ) 1 / ( 1 . ) .

4. Parameter

, R/O (Reverse Osmosis : ) EDI . 4. Parameter

Filtration - Cartridge Filter : , (2.0 Kg.f/ )

- Bag Filter : , 1.0 Kg.f/ (Oil Magnetic Filter).

,SEED Cartridge Filter Bag Filter . Conveyor System

(Continuous) Type Conveyor Speed . Line Space . .(P & F Conveyor type)

Up-Down Type (Programmable hoist) - .- PARAMETER .- Line . ( : min 45 sec) 4. Parameter

ED Zone Grounding System ( Electro coat 2000 / Electrocoat for advanced users )

, Bath Bath FRP Coating . .

.

(wt %)15 ~ 20 - , ( ) 1 /1 . p H 5.9 ~ 6.3 - . - p H . p H (25%: ADJ-002) . p H p H .(/) 1000 ~ 1800 - , UF Drain . 30 2 - . 36 34 .

(%) : : BATH LEVEL : : : UF RUPTURE VOLTAGE ( )THROW POWER ROUGH FILMPHOSPHATE SENSITIVITY UF (UF ) SYSTEM BATH

P/B Ratio PASTE BINDER Rough , DIRT ,UF THROW POWER CRATER THROW POWER PASTE BINDER BINDER PASTE

% BINDER % UF Rough ( )RUPTURE VOLTAGE THROW POWER Rough THROW POWER UF ( ) System UF

pH PASTE Leak DIRT FILTER CLOGT/POWER UF , , Rough FILM GAS PINHOLE TANK SYSTEM

Improvement of Economic Advantages ( ) - Excellent Film Uniformity and Control ( ) - Low Applied Cost ( ) : Reduce Film density / Heat weight loss : Low Temperature Cure - Low Maintenance Cost ( )

Improvement of Environmental Advantages ( )

- VOC(Volatile Organic Compounds)& HAPs(Hazardous Air Pollutants) Free Formulations - Lower BOD/COD in Waste Streams5. ED Trends of Future

5. ED Trends of FutureGen. 4pigment = 33 binder= 100Gen. 5 pigment = 17 binder = 100Gen.6 pigment = 12 binder = 100Future pigment = 4 binder = 100120 mg/h50 mg/h30 mg/h1 mg/hSedimentation VelocityReduced Pigment

- Lower Dry Film Density- Improved Usage- Lower Applied Cost

Low P/B RatioPowercron 640Powercron 648Powercron 643Powercron 6000CXPowercron 659ElectroClear 2700

6.Introduction of New ED Products

PropertyPowercron 659Electroclear 2700Resin TypeEpoxyAcrylicCR 659 - CP 506CR 955 Solid (%)18 ~ 2211~ 13P/B ratio0.02 0.010.02 0.01p H5.0 ~ 604.5 ~ 6.0Conductivity2100 ~ 2900400 ~ 500Bath Temperature30 230 2Coat Volt / Time225 V / 120 sec60 V ~ 100 V / 60 secBake schedule121 20 Minutes (Metal Temperature)160 20 Minutes (140 ~190 )

6.Introduction of New ED Products

PropertyPowercron 659Electro Clear 2700ColorBlackClearFilm Thickness0.4 - 1.2 Mils0.4 - 1.2 MilsGloss - 60 Degree55 75%Full GlossPencil Hardness2H Minimum2H MinimumCrosshatch Adhesion100%100%Salt spray500 Hours Minimum500 Hours MinimumHumidity500 Hours Minimum500 Hours MinimumWater Soak250 Hours Minimum-UV Durability-750 Hours MinimumThrow power11 13 inches-

B.

1. 2.

~ . , .

, .

(Hot Water Rinse) (Degreasing) (Rinse) (Activation) (Phosphates) (Rinse/Pure Water)

~ , , . ( , ) .1.(PRETREATMENT)

(- : - : Blaster ) ~ . . Line Alkali . , . (Saponification) + , , , . . CH2-OOC-R - CH-OOC-R - CH2-OOC-R (fat) + 3NaOH (or KOH) heated CH2-OH -CH-OH - CH2-OH (glycerol) + 3 R-CO2-Na (soap)

~ . , Alkali . .

. Ca,Mg ( ) . Scale ( ) , .

1000cc CaCO3 1mg 1ppm .

40 ppm 120 ~180ppm 40 ~ 80 ppm 180 ~ 300ppm 80 ~ 120 ppm 300ppm

~ . Etching . Etching , . (Ti- Colloid) Etching

~ Phosphophyllite [Zn2Me(PO2)4] Hopeite [Zn3(PO2)4] Hopeite Phosphophyllite Zn Mn, Ni Tri cationic . Tri cationic P/P+H Ratio (Phosphophyllite / Hopeite) , , . 2Fe + 2H3PO4 Fe(H2PO4)2 1 + H2 Fe(H2PO4)2 + [O]/(NaNO2) FePO4 (Sludge) + H3PO4 + H20 Zn + 2H3PO4 Zn(H2PO4)2 + H2 3Zn(H2PO4)2+ 4H2O Zn3(PO4)2.4H2O Hopeite+ 4H3PO4 Fe(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Fe(PO4)2.4H2O Phosphophyllite + 4H3PO4 Ni(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Ni(PO4)2.4H2O Phosphonickelite + 4H3PO4Mn(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Mn(PO4)2.4H2O Phosphomangollite + 4H3PO4

.

.

.

. 160 ~ 170 . : 1.5g ~ 3g/ ( 8% )

BeforeAfter CRS GA SEM of Zinc Phosphates

SEM of Zinc PhosphatesBeforeAfter MG

2.

() . . . : - : CHECK. : CHECK .( ) - . - - - Sludge . Sludge . . Sludge Sludge Sludge .( UF Module ) - p H / p H : 5.0 ~ 7.0 ,- : Max 25/ .

The Solubility of Zinc Phosphates Phosphophyllite[Zn2Me(PO2)4] Hopeite[Zn3(PO2)4] . Phosphophyllite[Zn2Me(PO2)4] Hopeite [Zn3(PO2)4] . (Immersiong Type) Phosphophyllite[Zn2Me(PO2)4] .

. , .

pH

(dm2) = (kg) (mm) x 2 x 100

pHpHZn10.0Al10.0Sn11.0Cu11.5Fe13.0

Fe7.876Al2.7Zn7.13Mg1.74Mn7.3Bi9.8Sn7.28Pt21.45

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