ZINCA H.S. BRIGHT ACID ZINC PROCESS

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1 TECHNICAL DATA SHEET ZINCA H.S. BRIGHT ACID ZINC PROCESS Zinca H.S. Bright Acid Zinc is a production proven process developed primarily for high speed zinc plating of wires, strips and tubes in continuous process plating plant. The process bath is a highly concentrated electrolyte based on sulphate and the deposit produced is uniform, fine crystalline and mat. The process with two addition agents namely Zinca H.S.Additive No.1 and Zinca H.S.Additive No.2, the deposit becomes smooth and uniform semi-bright. The addition agents are exceptionally stable, resistant to high temperature and thus designed to run with extremely high current density and high temperatures in order to achieve highest possible rate of deposition. Though the process is developed primarily for plating wire, strips and tubes, this can also be used for galvanizing of drums and frames. The zinc deposits produced with Zinca H.S.process are bright and highly ductile. Zinca H.S. Additive No.2 is a main brightner which gives excellent results in combination with the carrier brightner Zinca H.S.Additive No.1. The deposit obtained by the process is so ductile, the plated tube can be deformed, tempered and coated with synthetic resin coating, without peeling or cracking of the zinc plate. To improve the corrosion resistance, the galvanised deposits can be readily passivated with blue, yellow or olive by using Ginthox Q 550, Zincafix Yellow 953 or Zincafix Oilve 952 respectively. FEATURES BENEFITS Zinca H.S. Acid Zinc is a acidic Low initial costs. Almost no treatment is zinc process based on zinc sulphate required on waste water. Low consumption. Zinca H.S.Acid Zinc process can produce acceptable deposits with a wide range of current densities and temperatures. Bright, Soft, fine grained deposits at A/dm 2 and temperatures of C. Zinca H.S. Additive No. 1 and No. 2 are highly stable and do not decompose No decomposition products during working of the bath and idle periods. Even after longer idle periods, larger additions are not required. Addition Agents are clear liquids and two components additive. The electrolyte is very clear, does not become cloudy at higher temperature. Promotes the corrosion of anodes and the same additives are used for make up and maintenance of the bath.

2 BATH MAKE-UP : Optimum Range Zinca H.S. Salt 500 g/l g/l Zinca H.S. Conducting Salt 30 g/l g/l Zinca H.S. Additive No ml/l ml/l Zinca H.S. Additive No ml/l ml/l In case the bath has to be operated at very high current density (upto 100 A/dm 2 ) 800 g/l Zinca H.S. Acid Zinc Salt is required to be added along with 50 g/l conducting salt. OPERATING CONDITIONS : Temperature 60 C C ph Value Cathode Current Density 30 A/dm A/dm 2 Voltage (Varies depending upon the Volts inter electrode distance) Filtration Continuous Agitation Cathode rod movement and/or air SOLUTION PREPARATION : Prior to making up a Zinca H.S. Acid Zinc Solution, the plating tank must be cleaned and rinsed thoroughly. In addition the tank should be leached for a minimum of 24 hrs. To make up the operating solution proceed as follows and add components in the order given : 1. Fill the clean plating tank with clean water (Preferably deionized to almost two-thirds of the operating level and heat the water to C 2. Add the calculated quantity of Zinca H.S. Conducting Salt and stir until dissolved 3. Then add the required amount of Zinca H.S. Salt and dissolve well with stirring. Continue stirring until all the salts are dissolved completely. 4. Check the ph and adjust it to by adding dilute Sulphuric Acid (C.P.) to lower the ph or potassium hydroxide to raise the ph. 5. Pack the filter unit with zinc dust and carbon and run the filter for 8 hours and then clean the filter unit. 6. Add the measured quantities of Zinca H.S. Additive No.1 and Zinca H.S. Additive No. 2 with stirring. 7. Add sufficient water to bring the solution to final operating volume. 8. Recheck the ph and adjust as above if necessary. The plating bath is now ready for production use. REPLENISHMENT Periodic analysis for zinc metal, chloride and boric acid should be performed as outlined under CONTROL. Make required additions using Zinca H.S. Acid Zinc Salt and Conducting Salt.

3 The additive agent consumption is depending upon the degree of brightness needed, drag out of plating solution, temperature and area plated. Zinca H.S. Additive no. 1 and Zinca H.S. No.2 are consumed during working and based on actual production usage, Zinca H.S. Additive No.1 and No.2 are to be added at the rate of ml for one thousand amphere hours. In continuous process plant for plating wires, and tubes, two or three Zinc plating tanks are employed to get the required thickness rate and normally the Zinca H.S. Additive No.1 are only added on the first two tanks and in the final tank, Zinca H.S. Additive No.1 and No.2 are both added to get the desired degree of brightness with good ductility. FILTRATION The solution require continuous filtration to remove iron sludge contamination from the plating bath. The filter unit should have adequate capacity to have solution turn over 6-10 times and this will facilitate good electrolyte circulation and the solution movement is very important to get acceptable deposit without burning at higher current densities. All the filter parts that come in contact with the plating solution should be non-metallic. ANODES Zinc anodes should be pure (99.99%) and should meet the standard specifications special high grade. Anodes should be kept clean to maintain good contact between the anode and the busbar. Anode area should be sufficient to keep the anode current density as low as possible. It is desirable to use anode bags and polympropylene bags are suitable. Anode bags should be cleaned periodically. Cover busbars with plastisol coating or plastisol tape except at points of anode hook contact to minimize corrosion and possible contamination. TANKS Plating tanks of steel lined with PVC or PVC reinforced fibre glass tanks are recommended to contain the acid zinc solution. The tank should be leached for 24 hrs. with 5-10% Sulphuric acid solution and should be properly cleaned before making the solution. For steam heating, coils made from Teflon or titanium isolated from the direct current circuit are employed and in case of electrical heating, Quartz or Teflon immersion heaters are normally used. CONTROL The bath should be analysed periodically so as to keep the chemical balance within the optimum range and additions of Zinca H.S. Acid Zinc Salt and Conducting Salt are regularly added to restore the solution balance. The solution should be maintained within the folliwing range. Zinc metal : g/l Chloride as Cl : 4-8 g/l Boric Acid : g/l

4 ph : Consumption per : 100 ml Zinca H.S. Additive No Ampere hrs. 100 ml Zinca H.S. Additive No.2 ANALYSIS FOR ZINC METAL Apparatus Needed - 2 ml Pipette 25 ml Graduated cylinder 50 ml Burette 250 ml Erlenmeyer flask ERIOCHROME BLACK T indicator mix - mix 0.1 of Eriochrome Black T, Tetrasodium salt with 100 gms of AR grade sodium chloride. CHLORAL HYDRATE - Laboratory Grade LIQUOR AMMONIA - Laboratory Grade AMMONIUM CHLORIDE - Laboratory Grade 0.1 M EDTA solution add sufficient deionized or distilled water to 40.0 gms of EDTA disodium dihydrate salt and 6 gms of sodium hydroxide to make 1 litre of solution. Procedure : 1. Pipette a 2 ml sample of the plating bath into a 250 ml Erlenmeyer flask. Add 50 mls water. 2. Add 2 gms of Ammonium Chloride and 5-10 ml of Ammonium Hydroxide 3. Add a pinch of Erichrome Black T indicator and add 1-2 gm of Chloral Hydrate. 4. Titrate immediately with 0.1 M EDTA solution to a peacock blue end point. ml of 0.1 M EDTA titrated x = g/l of Zinc Metal ANALYSIS FOR TOTAL CHLORIDE Apparatus Needed - 1 ml pipette 25 ml graduated cylinder 50 ml burette 250 ml Erlenmeyer Flask Buffer solution - dissolve 90 gms of anhydrous sodium acetate in 500 ml of distilled water. Add 15 ml of AR grade, concentrated acetic acid and dilute to 1 litre with water. Chromate solution - dissolve 20 gms of either Potassium Chromate or Sodium Chromate in 1 litre distilled water. 0.1 N Silver Nitrate Solution (AgNo 3 ) 17.0 gms of Silver Nitrate add sufficient deionized water to make 1 litre of solution. Store in brown glass bottle.

5 Procedure : 1. Pipette 1 ml sample of the Zinca H.S. Bright Acid Zinc process operating solution into a 250 ml Erlenmeyer flask. Add 50 ml distilled or deionized water. 2. Add 25 ml of buffer solution. 3. Add 5 ml of Chromate solution to give the solution a yellow colour. 4. Titrate with 0.1 N Silver Nitrate solution until permanent reddish brown coloration forms on the white silver chloride precipitate. ml of 0.1 N AgNo 3 Solution titrated x 3.5 = g/l chloride as Cl ANALYSIS FOR BORIC ACID Apparatus Needed - 2 ml pipette 50 ml burette 100 ml beaker glass stirring rod 0.1 N Sodium Hydroxide (NaOH) - To 4.0 gms of AR grade sodium hydroxide add sufficient deionized or distilled water to make 1 litre of solution. Standardize against a sulphuric acid of a known normality. Mannitol AR Grade Bromocresol purple indicator solution - dissolve 0.1 gms of Bromocresol purple solid dye in 18 ml of 0.01 N Sodium hydroxide and dilute to 250 ml with deionized or distilled water. Procedure : 1. Pipette a 2 ml sample of the Zinca H.S. Bright Acid Zinc process solution into a 100 ml beaker 2. Add sufficient Mannitol to form a thick slury 3. Add several drops of Bromocresol purple indicator solution and titrate with stirring with 0.1 N Sodium hydroxide solution onto a purple end point. ml of 0.1 N NaOH Solution titrated x 3.08 = g/l boric acid WASTE TREATMENT The Zinca H.S. Acid Zinc solution contains Zinc metal and chlorides and is acidic in nature. It should be neutralized to a ph 7.5 to 8.0 prior to disposal into sewage system. Consult your GROWEL representative for specific waste treatment procedures. Issued on Supersedes all eralier

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