AMBIENT BASED CHEMICALS

Henkel and other pretreatment suppliers to the automotive industry are developing new
pretreatment systems to replace the traditional Wationic zinc phosphate process, which has been
the industry norm for more than 60 years

Basic Chemistry
Fluorozirconic acid reacts with the metal substrate to form a zirconium oxide layer. This
zirconium oxide layer is approximately 20-50 nm thick. This is much thinner than a zinc
phosphate layer, which is 2-10pm (2,000-10,000 nm), and there is much less material in the
zirconium oxide layer (2b200 mglm2 coating weight) versus 3,000-4,000 mg/rnz for zinc
phosphate. The coating weight and thickness depends on the exact coating conditions (e.g.
concentration, temperature, time). However, the largest factor controlling coating weight is the
substrate, with increasing coating weights on aluminum < cold-rolled steel c galvanized steel.
The atomic force micrograph below shows the coatings nodular structure (1 pm x 1 pm).
Coatings offer the adhesion and corrosion protection on painted metal surfaces
Coatings are a reactive, rinsable pretreatment that can be used on steel, zinc, and aluminum
surfaces.
Since painting accounts for a large share of energy consumed at an automobile plant,
using a new energy efficient technology will provide substantial energy savings. TecTalis is one
such green and efficient alternative to zinc phosphate. It is a multi-metal pre-treatment, which
provides better corrosion resistance and paint adhesion. These coatings are composed of nano-
ceramics free of nickel, phosphate, VOC and CO2 equivalent emissions resulting in minimal
environmental impact. TecTalis can also be applied in already existing lines, with slight
modifications. This pretreatment coating is applied at ambient temperature, reducing utilities and
natural resource requirements, resulting in energy saving. Thus, the pretreatment footprint can be
reduced significantly in a brown
field as well as in a green field project.
new greenfield plant can be designed with a smaller footprint that uses less water and less energy than a traditional
zinc phosphate line. This has both environmental and economic value a5 outlined in the next section.
POTENTIAL SAVINGS:
1. Energy Savings
• Reduction in the number of heated stages
2. Water Savings
• Reduction in number of stages, reduced water requirements
3. Man Power – Labor and Maintenance costs
• Reduction in sludge generation
• Reduction of waste disposal costs
• Less Clean-outs of the system
4. Reduction in Floor Space
• Reduction in number of stages

 No heat required – cuts energy costs!

 Significantly reduce inner-stage rusting - improve adhesion &
reduce reject rates!
 Less reaction with metal surface - generate very little sludge!
 Shorter treatment time – increase production throughput!
 No post treatment required – decrease chemical handling & costs!
 No hazardous waste disposal – reduce labor / chemical costs
CASE STUDY:
A typical two wheeler plant in India which has transformed from phosphate to
TecTalis coating has seen the following savings:

PARAMETER PHOSPHATING TEC TALIS REMARK

Bath Temperature 50 deg ºC Ambient temperature Energy efficient Process

Electrical Energy
61 kWh/hr 29.50 kWh/hr Saving-Rs.1.015 million
Consumption
Saving-Rs.1.160 million
LPG Consumption 327 kg/day 245 kg/day Total Saving-Rs.2.175
million
Phosphating Sludge- Iron Oxide Sludge-0.1
2.5-2.8 gm/m2 gm/m2 of MS Elimination of Hazardous
Hazardous sludge phosphating and Chrome
  < 5 kg/Month
sludge
190-200 kg/month  
Heavy metals – Zinc,
Load of heavy metals on
Nickel and Free of Heavy metals Eco friendly (Green) Process
ETP
Manganese