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Kemphos - 821 (Wire Drawing Chemical)
(Wire Drawing Chemical)
Product Description
Kemphos - 821 is a heavy zinc phosphate
compound, which produces excellent Zinc/Iron phosphate coating on Iron
and steel supplementary finishes. This product needs accelerator
addition in the bath periodically. The conversion coating produced
with Kemphos-821, when used in conjunction with suitable lubricant,
reduce friction under low medium and high forming on steel, cold
shaping drawing of wire and tubes etc. Lubricants and drawing
compounds become firmly anchored to the phosphate coating for
improved drawing.
Production Specifications
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a
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Colour
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Light green liquid.
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b
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Chemical Composition
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Blend of Zinc and Nickel metal
phosphates, Nitrates and additives.
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c
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Odour
Zinc Content
Phosphate Content
Nitrate Content
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Slightly Pungent
9-10 gm/liter in 5% solution
22-25 gm/liter in 5% solution as Po4
8-10 gm/liter in 5% solution of as No. 3
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d
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Foaming Tendency
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Nil
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e
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Reliability
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Good
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f
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Handling
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Avoid skin contact
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g
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Solubility
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Good
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h
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pH
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Acidic Range
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i
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Toxicity
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Nil
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J
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Flash Point
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Nil
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K
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Pollution Hazard
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Moderate
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Product
Operating Data
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Concentration
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50% by v/v
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Temperature
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60-70°c
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Time
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10-15 min
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T.A.
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37-40 ml (5% solution)
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F.A.
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6.5 7 ml (5% solution)
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Acid Ratio
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5.5 6.0
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Accelerator
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2.0 3.5 ml
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Product
Operating Procedure
Pickling
Pickling should be carried out either in sulphuric or Hydrochloric
Acid, in combination with suitable acid Inhibitors in sufficient
strength to remove rust and scale present on the work.
Rinsing
The stage rinsing should be followed after the pickling process, first
rinse with cold water and finally rinse with jet pressure. The rinsing
tank should be cleaned regularly.
Phosphating
Fill the tank 2/3 with clean water and add recommended amounts of
kemphos-821. Fill the tank to the operating level with water and mix
thoroughly and for total acid and if necessary add enough kemphos821 to bring total acid to operating level and mix thoroughly.
Add 3035 gm of kemphos-002 accelerator in the bath by dissolved
in cold water. After phosphating with Kemphos-821, the work should be
rinsed with continuous flowing water and subsequently once again
rinsed in hot neutralizing solution. The neutralizing solution is
made up with 0.1 kg of soda ash per 100 litres of bath.
Operating Recommendation
Proper rinsing is very much essential after pickling in mineral acids,
in order to remove the acid residues from the surface of the work.
Any carry over of the acid to the phosphating tank will lead to
excessive sludge formation leading to deterioration of phosphate coating and
high chemical cost.
Product
Application Equipment
Kemphos-821 tank should be fabricated with 3 to 4 mm thick M.S.
Plates with continuous convection current heating system.
Testing
and Control Procedure
The Kemphos-821 is controlled by simple titration for total acids.
Ferrous Iron concentration of Kemphos-002 (Accelerator) by titration
method.
Total Acidity
Pipe out 10 ml. bath solution into a beaker. Add 5-10 drops of
indicator Phenolphathalein. Fill the burette to the zero mark. And
titrate with N/10 sodium Hydroxide solution. Stir the solution until
pink colour appears. Note volume of N/10 Sodium Hydroxide solution
used.
Free Acidity
Pipette out 10 ml. of bath solution into a beaker. Add 510 drops
of Methyle Orange Indicator. Fill the burette to the zero mark and
titrate with N/10 Sodium hydroxide Solution. Stir the solution until
pink colour appears. Note volume of N/10 sodium Hydroxide solution
used.
Accelerator
Titration
Pipette out 10 ml. of bath solution into flask. Add 5 ml of
concentration H2SO4 and mix, Titrate against N/10 Kmno4 solution a
pink colour which will persist for few seconds. Note the number of ml
of N/10 KmnO4 added in the solution. Normal limits of Kemphos-002
(Accelerator) titration is 2-6 ml. Lower limit is preferable, Prior
to titration. Starch lodide test should be positive. Approximately 30
ml of 25% Kemphos-002 (Accelerator) solution in water should be added
to increase the Kemphos-002 (Accelerator) pointage by 1 ml.
Determination
of Iron Contents
Pipette out 10 ml of bath solution in 150 ml. conical flask. Add
2ml. of 50% and titrate with N/10 KmnO4 (3.16gm/litrs)
solution to a pink end point persisiting for 15 seconds. Multiply the
titration reading with 0.056 to get percentage of ferrous Iron in the
bath.
A fresh bath when aged with steel wool or steel scrap as described
earlier should give ferrous Iron concentration of about ferrous 0.5%
for a normal loading in the bath, the ferrous Iron concentration
will stay with 0.05% o 4%.
Chemical
Replenishment
Add 135 ml. Of Kemphos-821 per 100 ltrs. Bath for each point
lacking. The bath should be kept with in 1 ml of the specified
titration values.
During the processing sludge is formed and the same is accumulated in
the bottom of the tank. It should be removed at regular intervals.
Sludge removal is carried out by decanting the clear solution is
restored to its operating level by adding water and chemical in the
recommended proportion as used in the original bath.
Safety Measures
Kemphos-821 is an acidic liquid material, and while handling proper
care should be taken. Protect eye, skin by means of goggles, aprons,
gloves etc. If it comes in contact with skin and eyes wash thoroughly
with a flush of water and get medical advice.
General
Information
Corrosion Resistance: Excellent
Lubrication During Wire Drawing: Excellent.
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