Emulsion cleaning is a process for removing from metal parts, a wide variety of soil including drawing Lubricants, Pressing compounds, oil, greases, cutting fluids, polishing and buffing residues, temporary rust preventives by Dip/ Spray. It is ideal for use in all types of mechanized power spray plants for cleaning both ferrous and non-ferrous metal surfaces.
Emulsion cleaning is used when repaid superficial cleaning is required and where some protection of a light residual film of oil is desirable or is not objectionable . It is usually less costly than solvent cleaning, because relatively small concentration of solvents and high concentration of water are used.
Emulsion cleaning is safe to use on virtually any metal if used within the specified alkalinity. When used on ferrous and ferrous alloy components, emulsion cleaner does not deactivate the steel surface and thus helps in getting a smooth, compact phosphate coating which is ideal for paint bonding and excellent corrosion resistance. This is particularly evident in the case of Zinc and Manganese phosphate coating.
Emulsion cleaners are practically free from any hazard either from fire or toxic fumes, if the operating temperatures are within the maximum recommended. The hazards of toxicity and irritation to the skin resulting from the contact with FRANK SOL cleaners are also negligible.
FRANK SOLideally fulfils all the requirements of good emulsion degreasing either by spray or dip.
NOTE :Where heavy and stubborn contamination is involved a prior solvent cleaning or treatment with Frank move by manual wiping or Immersion is advisable for quick degreasing and prolonging the life of the FRANK SOL bath.
PAPAMETERS ( for GUIDANCE ONLY)
a) BATH MAKE -UP : ( 1000 Litres)
b) FRANK SOL : 50 Litres
c) FRANK ADDITIVE – X :10 kgs
a) TEMPERATURE : 65 TO 70°
b) DIP TIME : 5 to 10 Minutes
(c ) FREE ALKALI : 2.4 to 4.8 ml ( Required when fine / coarse phosphate coating is desired)
( optional ) (d) TOTAL ALKALI : 6 to 13 ml.
(essential)
1. Fill the tank with water approximately to the operating level and heat it up to the operating temperature.
2. Dissolve FRANK ADDITIVE – X in a small quantity of water and add to the tank with continuous agitation. This can be repeated till all the quantities to be added are exhausted.
3. Add FRANK SOL in increments of about 1/10 of the total amount with constant agitation.
The agitation in the tank can be conveniently done by ingesting compressed air at the bottom of the tank.
The concentrations and operating bath constants mentioned here are for normal applications. FRANK may suggest a deviation, if required.
In full production, the FRANK SOL bath should be tested regularly and adjusted if necessary, to maintain it with in the working limits.
10 ml Pipette
250 ml Conical flask
25 ml Burette
0.1 N Hydrochloric Acid
Phenolphthalein Indicator
Bromo Cresol Green Indicator.
1.Pipette a 10 ml bath sample into a clean conical flask.
2.Add 4 to 6 drops Phenolphthalein Indicator.
3.Titrate with 0.1 N HCL to the disappearance of pink colour; record the amount of acid used – this is the Free Alkali reading.
4.Using the same sample add 4 to 6 drops Bromo Cresol Green Indicator solution ( 1gm.Bromo Cresol Green in 1 litre of 50% denatured alcohol.)
5. Continue titration with 0.1 N HCL until the colour changed from blue-green to yellow. The total milliliters of acid used indicates the Total Alkali present.
1.Pipette a 10 ml bath sample into a clean conical flask.
2.Add 4 to 6 drops Bromo Cresol Green Indicator ( 1 gm.Bromo - Cresol Green in 1 Litre of 50% denatured alcohol).
3.Titrate with 0.1 N HCL until the colour changed from blue – green to yellow. The total milliliter of Acid used indicates the total Alkali present.
A bath containing 5% v/v Frank Sol and 1% w/v Frank additive X will give a total alkali strength of 6.0 millilitres ( points) minimum, when determined a per the above method. i.e. when 1000 litre bath made with the addition of 50 litres of FRANK SOL ( 5% v/v) and 10 kgs Frank additive X ( 1% w/v) will give a strength of 6.0 millilitres ( points) minimum, when determined as above.
To raise the alkali content, dissolve FRANK ADDITIVE - X in a portion of the water ( preferably De-mineralised or de-Ionised water) and then add to the tank. To raise 1 Millilitre strength of total alkali In a 1000 litre bath, which is containing 5% v/v of Frank sol and 1% w/v Frank Additive- X, add 1.7 kg of frank Additive-X and 8.5 litres of Frank Sol.
In general and in most cases, the bath strength is kept constant by adding 5 litres of Frank Sol for every addition of 1 kg of Frank additive- X is added.
Generally higher content of Frank Additive- X will lead to coarser Phosphate coating. If required and desired can be made finer by reducing the alkali content by adding 0.600 litres of Phosphoric Acid per 1000 litres of bath solution at a time. This will reduce the total alkali content by one milliliter.
Best results are obtained when the total alkali content is maintained around 9.0 ± 1.0 millilitre through out.
Each day, run in cold water and allow slight over-flow to remove any oil scum from the bath surface.
After emulsion cleaning the work must be thoroughly rinsed. The rinse water tank must have a continuously over flowing arrangement to keep contamination level low.
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