彩涂基板的化学清洗方式

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彩涂板的化学清洗可以用浸洗和喷洗两种方式，旧工艺中脱脂清洗段一般用浸泡、润湿以及将一部分设为皂化等称为浸洗的方式来洗涤基板上的污物，浸泡是一种比较传统的清洗方式，这种清洗工艺需要的浸泡段和冲洗段的槽体占地面积非常大，清洗时间长，仅适用于早期的或一些速度较低的彩涂机组，现在的大中型彩涂机组已经基本上不使用这种清洗工艺。现在的清洗段不论是碱液清洗还是水清洗已大部分采用水力喷射的方式。

采用水力喷射清洗的方式是溶液通过排列整齐的V形喷嘴以一定的压力直接喷射到基板上，污垢受到冲击和冲刷，水力喷射的基本原理是:将增压的水通过喷嘴的快速释放形成高速度的水射流，它像水箭一样冲击需清洗的钢带表面，当水箭的冲击能超过了粘附在钢带表面的污物的极限强度时，污物就会被分解并清除。要想达到不同的清理效果，可以调节水流的压力，也可以保证在一定的水流压力下，增加水流的流量。喷射水流必须对垢层或沉积物有足够的撞击力使其粉碎，一旦垢层被滲透，流体呈楔子插入垢层和金属表面间，使垢层脱落而露出清洗的表面。结垢多呈层状或多孔状，容易碎裂，因为喷射水流的撞击可以击中一个孔，在表面以下的形成一个内压而使上部垢层裂开。在喷射操作过程中，冲碎的颗粒夹杂在喷射流中帮助冲击更多的颗粒。

喷洗工艺大大提高了清洗效果。另外，还可以缩短清洗时间，设备布置可以更加紧凑，此法特别适用于高速机组的生产。

据资料介绍，为了降低清洗设备的成本和提高清洗效率，瑞士 Griesser股份公司与德国研究机构 Nanocraft合作，已经将全球第一台 Openair等离子体预处理设备应用于卷材涂层工艺。这台常压等离子体处理设备替代了以往所使用的长达12m的清洗线，使彩涂板生产将不再受到化学清洗液和工艺废水的困扰。不仅使成本大为降低，而且也对环境保护作出的巨大贡献。

表面侵蚀、轧制油残余物污染以及迄今为止所使用的不仅污染环境，而且耗能极大的湿化学法清洗工艺，均为铝材加工的常见问题。现在终于研发出一种能够完全消除上述问题的新工艺。这种技术能够在化学处理膜涂层之前，对铝卷材进行超级精细的净化处理，可完全替代污染环境的湿化学法清洗工艺。

在初期工艺试验过程中，一直将传统的化学预清洗方法作为参照。通过对等离子体工艺参数的优化(等离子体聚焦，强度/能量沉积)，已经证明新的工艺技术明显优于传统的方式。试验结果表明 Openair常压等离子体清洗工艺不仅能够进行工业化应用，而且还具有更高的效率，它在所有科目上的试验结果均明显优于化学处理法。

从首次萌发采用在线等离子体清洗这样一种工艺设想，直至最终进行调试运行，这种新技术经历了大约五年的研发时间。采用 Openair等离子体处理工艺之后，整条卷材涂装线的速度比原有设备高出了四倍。德国的 Vits Systems Gmbh公司负责研发这种新设备的冷却与烘干技术，由瑞士的 Werner Mathis AG公司负责成套设备工程，包括卷材输送装置以及应用研发。

The chemical cleaning of color coated sheet can be done by soaking and spraying. In the old process, the degreasing cleaning section is usually washed by soaking, wetting and saponification. Soaking is a more traditional cleaning method. The soaking section and the trough of the washing section are needed in this cleaning process. It covers a large area and takes a long time to clean. It is only suitable for the early or some low-speed color painting units. Nowadays, the large and medium-sized color painting units have basically not used this cleaning process. Nowadays, most of the cleaning sections, whether in alkali or water cleaning, have adopted hydraulic spraying.

The method of hydraulic jet cleaning is that the solution is directly sprayed onto the substrate by a V-shaped nozzle arranged in a regular way at a certain pressure, and the fouling is impacted and scoured. The basic principle of hydraulic jet is to form a high-speed water jet through the rapid release of pressurized water from the nozzle, which impacts the surface of the steel strip to be cleaned like a water arrow. When the impact energy of the water arrow exceeds the ultimate strength of the dirt adhering to the surface of the steel strip, the dirt will be decomposed and removed. In order to achieve different cleaning effects, the pressure of water flow can be adjusted, and the flow of water can be increased under a certain flow pressure. Jet water must have enough impact force on scales or sediments to crush. Once the scales are penetrated, the fluid is wedged between the scales and the metal surface to make the scales peel off and expose the cleaned surface. Scaling is mostly layered or porous, which is easy to break up, because the impact of jet water can hit a hole, forming an internal pressure below the surface and cracking the upper scale layer. During the injection operation, the impulsive particles are mixed in the jet stream to help impact more particles.

Spray washing process greatly improves the cleaning effect. In addition, the cleaning time can be shortened and the equipment layout can be more compact. This method is especially suitable for the production of high-speed units.

According to information, in order to reduce the cost of cleaning equipment and improve cleaning efficiency, Griesser Switzerland, in cooperation with Nanocraft, a German research institute, has applied the world's first Openair plasma pretreatment equipment to coil coating process. This atmospheric pressure plasma treatment equipment replaces the 12 m long cleaning line used in the past, so that the production of color coated plate will not be troubled by chemical cleaning liquid and process wastewater. It not only greatly reduces the cost, but also makes a great contribution to environmental protection.

Surface erosion, contamination of rolling oil residues and wet chemical cleaning processes used so far not only pollute the environment, but also consume a lot of energy are common problems in aluminium processing. Now a new technology has been developed that can completely eliminate the above problems. This technology can purify the aluminium coil superfine before the chemical treatment of the film coating. It can completely replace the wet chemical cleaning process which pollutes the environment.

In the initial process test, the traditional chemical pre-cleaning method has been used as a reference. By optimizing plasma process parameters (plasma focusing, intensity/energy deposition), it has been proved that the new technology is superior to the traditional one. The experimental results show that Openair atmospheric pressure plasma cleaning process can not only be used in industry, but also has higher efficiency. The experimental results on all subjects are obviously better than chemical treatment.

This new technology has been developed for about five years, from the first time to the final commissioning of the process concept of on-line plasma cleaning. After using Openair plasma treatment process, the speed of the whole coil coating line is four times higher than that of the original equipment. The German company Vits Systems Gmbh is responsible for developing the cooling and drying technology of the new equipment. The Swiss company Werner Mathis AG is responsible for the complete equipment engineering, including coil conveyor and application research and development.