Zero emission method for metal surface treatment

Abstract

The present application relates to a kind of metal surface treatment zero emission method, including environmental cleaning agent, environmental film-forming protective agent, cleaning equipment and baking equipment, the process cancels traditional water washing step, through the atomization spraying of environmental cleaning agent and film-forming protective agent, realizes the recycling of cleaning fluid, effectively avoids the generation and discharge of a large amount of waste water, thereby substantially reduces the consumption of water resources, meets the requirements of modern environmental regulations.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of metal surface treatment zero emission method. BACKGROUND

[0002] In the field of metal manufacturing and processing, metal surface treatment technology has been the key link to improve product performance, corrosion resistance and appearance quality. Traditional metal surface treatment process mainly relies on chemical cleaning and water washing, which flushes away the impurities such as oil stains, scale and dust on the metal surface by using a large amount of water resources, and adopts rust prevention treatment and coating process to form a protective film. However, with the continuous expansion of industrial production scale and the increasing strictness of environmental protection requirements, the existing technology has the following main problems and deficiencies:

[0003] In the traditional metal surface treatment process, the water washing step occupies an important position, and the consumption of a large amount of cleaning water not only significantly increases the production cost, but also causes great dependence and waste of freshwater resources. Especially in large-scale production environment, the high consumption of water resources has become an important factor restricting production efficiency and economic benefit of enterprises.

[0004] The wastewater generated by water washing process often contains high concentrations of oil stains, chemical cleaning agents and other pollutants, which will cause serious pollution to the surrounding water, soil and ecological environment if not fully treated before discharge. In recent years, environmental protection regulations in various countries have become increasingly strict, and enterprises not only face increasingly strict environmental protection inspection, but also may bear high sewage treatment cost and fine risk due to non-compliance of wastewater discharge, thereby adversely affecting the enterprise image and market competitiveness.

[0005] In continuous operation, the oil stains, dust and other pollutants attached to the metal surface continuously enter the cleaning liquid, causing the liquid pollution speed to accelerate, and the cleaning effect to gradually decline. In the traditional process, the cleaning liquid needs to be frequently replaced to ensure the cleaning quality, which not only increases the material consumption, but also reduces the continuous operation efficiency of the production line.

[0006] Due to the high degree of pollution of the cleaning liquid, the traditional process cannot ensure that the metal surface reaches the ideal cleaning state in the cleaning process, thereby affecting the adhesion, rust prevention and corrosion resistance of the subsequent film forming or coating process. Products may have uneven coating, insufficient weather resistance and other problems in actual application, which is difficult to meet the high-standard and fine market demand. SUMMARY

[0007] The purpose of the present application is to provide a metal surface treatment zero emission method that efficiently cleans oil stains on metal surface, forms a protective film and recycles cleaning liquid, thereby effectively solving the problems of water resource waste, wastewater discharge and treatment liquid pollution in traditional technology.

[0008] The purpose of the present application is achieved in that:

[0009] A metal surface treatment zero-emission method, comprising an environmentally friendly cleaning agent, an environmentally friendly film-forming protective agent, a cleaning device and a baking device, the environmentally friendly cleaning agent comprising a surfactant, a chelating agent, an inhibitor and deionized water, the surfactant accounting for 30%, the chelating agent accounting for 15%, the inhibitor accounting for 5%, and the deionized water accounting for 50%;

[0010] The environmentally friendly film-forming protective agent comprises silicone resin, anti-rust additive, solvent and curing agent, the silicone resin accounting for 10%, the anti-rust additive accounting for 5%, the solvent accounting for 80%, and the curing agent accounting for 5%;

[0011] The cleaning device comprises a first spraying device, an ultrasonic demulsification and oil removal machine, a precision filter and a second spraying device, the first spraying device comprising a liquid storage tank and a first nozzle, the first nozzle being in communication with the liquid storage tank, and the second spraying device comprising a liquid storage tank and a second nozzle, the second nozzle being in communication with the liquid storage tank;

[0012] Metal surface treatment zero-emission operation steps,

[0013] Step one: pour 10% of the environmentally friendly cleaning agent into the liquid storage tank of the first spraying device, adjust the pressure and flow rate of the first spraying device, and spray the cleaning agent in the form of uniform mist to the metal surface through the first nozzle, and spray and clean for 3 to 5 minutes to remove oil stains, particles and impurities on the metal surface of the workpiece;

[0014] Step two: the oil stain particles and the environmentally friendly cleaning agent in step one form a mixed solution which flows into the cleaning tank of the ultrasonic demulsification and oil removal machine;

[0015] Step three: place the workpiece into the cleaning tank of the ultrasonic demulsification and oil removal machine, and add the environmentally friendly cleaning agent into the cleaning tank, the ultrasonic demulsification and oil removal machine uses high-frequency vibration waves to make the oil stain particles fall off from the metal surface of the workpiece and disperse in the environmentally friendly cleaning agent to form a mixed solution, and then the ultrasonic demulsification and oil removal machine uses high-frequency vibration waves to disperse the oil stain particles in the mixed solution;

[0016] Step four: the mixed solution in step three flows into the precision filter, the precision filter separates the mixed solution into hazardous waste and environmentally friendly cleaning agent through multiple layers of filter medium, the environmentally friendly cleaning agent is recycled and circulated to the cleaning tank of the ultrasonic demulsification and oil removal machine, and the hazardous waste is handed over to a third-party professional institution for recycling and treatment;

[0017] Step five: pour the environmentally friendly film-forming protective agent into the liquid storage tank of the second spraying device, take out the workpiece, and spray the metal surface of the workpiece through the second nozzle of the second spraying device until a protective film with a thickness of 0.2-2 μm is formed on the metal surface;

[0018] Step six: Put the workpiece into the baking equipment, dry the metal surface at 120 DEG C for 15 min, and solidify the protective film.

[0019] The process cancels the traditional water washing step, realizes the recycling of the cleaning liquid through the atomized spraying of the environment-friendly cleaning agent and the film-forming protective agent, effectively avoids the generation and discharge of a large amount of wastewater, thereby greatly reduces the consumption of water resources, and meets the requirements of modern environmental protection regulations.

[0020] The high-frequency vibration of the ultrasonic demulsification oil removal machine can quickly detach and scatter the oil stain particles on the metal surface, and the precise filter machine can effectively separate the oil stains and impurities in the mixed liquid, so that the stability and excellence of the cleaning effect are ensured. At the same time, the environment-friendly film-forming protective agent forms a uniform and dense protective film on the metal surface, which not only significantly improves the rust and corrosion resistance of the metal product, but also provides a good adhesion basis for subsequent coating.

[0021] Since the cleaning liquid is recycled through efficient ultrasonic demulsification and precise filtration technology, the frequent replacement of the cleaning liquid and the consumption of chemical reagents are reduced, thereby reducing the production cost. In addition, avoiding wastewater discharge also reduces the investment and potential legal risks of enterprises in environmental governance, and improves the market competitiveness of enterprises.

[0022] The purposes of the present application can also be solved by the following technical measures:

[0023] Further, the surfactant is a biodegradable non-ionic surfactant;

[0024] The chelating agent is ethylenediaminetetraacetic acid which can chelate with impurity ions on the metal surface to remove the impurity ions from the metal surface;

[0025] The corrosion inhibitor is a black metal corrosion inhibitor and a silane coupling agent which can form a protective film on the metal surface to prevent the metal from being corroded during the cleaning process.

[0026] The use of biodegradable non-ionic surfactants helps to reduce the generation of persistent organic pollutants during the cleaning process, meets the green environmental protection requirements, and has less negative impact on the ecological environment.

[0027] Ethylenediaminetetraacetic acid (EDTA) as a chelating agent can effectively chelate with impurity ions on the metal surface, quickly remove pollutants adhered to the metal surface, improve the cleaning effect, and ensure higher cleanliness of the metal surface.

[0028] By using the corrosion inhibitor combined with ferrous metal corrosion inhibitor and silane coupling agent, a dense protective film can be formed on the metal surface during cleaning process, effectively preventing corrosion of metal and cleaning liquid from long-term contact, prolonging the service life of metal products, and providing a good substrate for subsequent protection process (such as painting).

[0029] The reasonable collocation of the three functional components makes the whole cleaning process not only efficient in stain removal, but also corrosion protection, further ensuring the product quality and performance after metal surface treatment, achieving the comprehensive effect of environmental protection, cleaning and high efficiency.

[0030] Further, the organic silicon resin is an organic silicon resin with good film-forming performance and weather resistance that can form a tough protective film on the metal surface;

[0031] The anti-rust additive is a silane coupling agent with excellent anti-rust performance;

[0032] The solvent is an environmentally friendly alcohol solvent and pure water that can dissolve organic silicon resin and other additives;

[0033] The curing agent is an isocyanate that can react with organic silicon resin to quickly cure the protective film.

[0034] The use of organic silicon resin with good film-forming performance and weather resistance forms a tough protective film on the metal surface, effectively isolating air, moisture and corrosive media, and improving the corrosion resistance and service life of the metal.

[0035] The protective film has high weather resistance and can remain stable in harsh environments (such as high temperature, high humidity or acid-base environment), and is not prone to cracking or peeling, improving the long-term stability of the coating.

[0036] The use of silane coupling agent as anti-rust additive can further enhance the adhesion of protective film to metal substrate due to its excellent metal bonding ability, while providing anti-rust performance to prevent metal oxidation and rusting, improving the protection effect.

[0037] The use of environmentally friendly alcohol solvent and pure water as solvent avoids the pollution problem of volatile organic compounds (VOCs) in traditional solvent-based coatings, reduces the impact on the environment, and reduces health hazards during production and use, meeting environmental regulations.

[0038] The use of isocyanate as curing agent can cross-link with organic silicon resin to quickly cure the protective film, improve the construction efficiency, reduce the workpiece processing time, and contribute to large-scale industrial application.

[0039] The formula realizes the balance of film-forming property, weather resistance, rust resistance, environmental protection and rapid curing, provides an efficient, environmentally friendly and long-lasting metal surface protection solution, and can be widely used in metal protection fields of machinery, automobiles, ships and other industries.

[0040] Further, the ultrasonic demulsification and oil removal machine comprises an ultrasonic generator, a transducer, a cleaning tank and a control system.

[0041] The ultrasonic generator generates a high-frequency electrical signal, which is transmitted to the transducer through a cable. The transducer converts the high-frequency electrical signal into a high-frequency mechanical vibration wave, which is transmitted into the cleaning liquid in the cleaning tank. When the high-frequency mechanical vibration wave acts on the oil stain particles, the oil stain particles resonate, thereby destroying their adhesion to the metal surface, allowing them to fall off the metal surface and disperse in the cleaning liquid.

[0042] The high-frequency mechanical vibration wave generated by the ultrasonic generator causes the oil stain particles to resonate, thereby destroying their adhesion to the metal surface, making it easier for the oil stain to fall off the metal surface and improving cleaning efficiency.

[0043] Compared with traditional chemical cleaning or mechanical wiping methods, ultrasonic cleaning can penetrate complex structures or small pores, achieving uniform and thorough decontamination and improving the overall cleanliness of the workpiece.

[0044] Since ultrasonic waves can effectively disperse oil stain particles, making them more likely to fall off the metal surface and suspend in the cleaning liquid, the dependence on strong alkali, strong acid and other chemical cleaning agents is reduced, and the risk of waste liquid discharge and environmental pollution is reduced.

[0045] The cleaning liquid can be recycled, further reducing cleaning costs and waste liquid treatment pressure, and achieving a more environmentally friendly metal surface treatment solution.

[0046] Traditional mechanical cleaning may cause scratches or wear on the metal surface, while ultrasonic cleaning uses non-contact high-frequency vibration waves to act on the oil stain, avoiding physical friction and reducing damage to the workpiece surface, ensuring the integrity of the metal surface.

[0047] The control system precisely adjusts the ultrasonic frequency, amplitude and cleaning time, achieving intelligent cleaning, which helps to improve production efficiency and meet the needs of large-scale industrial production.

[0048] The ultrasonic demulsification and oil removal machine is suitable for various metal materials (such as steel, aluminum, copper, etc.) and various types of oil stains (such as machine oil, lubricating grease, cutting fluid residue, etc.), and is suitable for metal surface cleaning processes in automobile manufacturing, precision electronics, aerospace and other fields.

[0049] Further, the ultrasonic demulsification oil removal machine also includes a frequency adjustment module. The frequency of the ultrasonic demulsification oil removal machine is 20-40 kHz, the power is 500-1000 W, and the working time is 10-15 min. The frequency adjustment module can automatically optimize the working frequency of the ultrasonic wave according to the type and pollution degree of the oil stains on the metal surface.

[0050] The adjustable ultrasonic frequency of 20-40 kHz can be automatically optimized according to the type of oil stains (such as light oil, heavy oil, lubricating grease, etc.). For example:

[0051] Low frequency (20-25 kHz): suitable for removing thick and strongly adhered oil stains, such as lubricating grease on heavy machinery and coking oil stains.

[0052] High frequency (30-40 kHz): suitable for removing fine or easily dispersed oil stains, such as machining residual cutting fluid or light oil film on precision electronic components.

[0053] By accurately matching the cleaning requirements, the cleaning time is reduced, and the decontamination efficiency is improved.

[0054] The frequency adjustment module can automatically adjust the power (500-1000 W) according to the pollution degree, avoiding excessive cleaning or ineffective energy consumption, thereby reducing energy consumption.

[0055] By intelligently regulating the ultrasonic output, the continuous high-load operation of the equipment is reduced, the service life of the equipment is prolonged, and the maintenance cost is reduced.

[0056] Excessive ultrasonic frequency may cause minor damage to some precision metal workpieces, while low frequency may not clean thoroughly. Through the frequency adjustment module, the best balance between cleaning effect and material protection can be achieved to ensure the integrity of the metal surface.

[0057] With automatic optimization and adjustment function, manual intervention is reduced, and the intelligent level of the cleaning process is improved, which is suitable for large-scale industrial production.

[0058] The optimal working time range of 10-15 min is set to ensure uniform and stable cleaning, improve production rhythm control ability, and improve overall production efficiency.

[0059] It is suitable for metal surface cleaning requirements in multiple industries such as aerospace, automobile manufacturing, precision electronics, medical devices, and machining, and can be applied to different materials (such as stainless steel, aluminum alloy, copper, etc.) and different types of oil stain treatment, realizing one machine for multiple purposes, improving the universality and economic value of the equipment.

[0060] Further, the precision filter includes a filter tank and a filter medium capable of effectively intercepting oil and solid impurities, the filter tank is provided with the liquid inlet, the liquid outlet and the waste outlet, the filter medium is arranged in the filter tank, and the liquid inlet is provided with a liquid inlet valve for controlling the flow rate of the cleaning liquid to be 20-100 L / min.

[0061] The mixed solution of step three enters the filter tank through the liquid inlet, and then the clean environmental cleaning agent is discharged to the cleaning tank of the ultrasonic demulsification and oil removal machine through the filter medium, and the hazardous waste is discharged to the waste outlet.

[0062] Through the high-efficiency filter medium, oil and solid impurities can be effectively intercepted, and the cleaning ability of the cleaning agent after filtration can be ensured.

[0063] The filtered environmental cleaning agent is returned to the cleaning tank of the ultrasonic demulsification and oil removal machine from the liquid outlet, realizing the recycling of the cleaning agent, reducing the consumption of the cleaning agent, thereby reducing the production cost of the enterprise, and reducing the frequency of supplementing new cleaning agent.

[0064] The liquid inlet valve with adjustable flow rate of 20-100 L / min can accurately control the flow rate according to different cleaning needs, and optimize the filtering effect:

[0065] Low flow rate (20-50 L / min): suitable for deep filtration of high-viscosity oil and fine impurities, and improves the decontamination precision.

[0066] High flow rate (50-100 L / min): suitable for high flow rate cleaning needs, and ensures high efficiency of industrial production.

[0067] The filtered cleaning agent has high cleanliness, which ensures that it still has excellent decontamination ability when recycled, and improves the cleaning quality of the metal surface.

[0068] During the filtration process, the oil and solid impurities in the cleaning liquid are intercepted and collected, and finally discharged from the waste outlet, which ensures that the hazardous waste is collected and treated, and avoids secondary pollution caused by mixing with the recycled cleaning agent.

[0069] By transferring the hazardous waste to a third-party professional institution for recycling, the impact of industrial production on the environment is reduced, which meets the requirements of environmental protection regulations and improves the green manufacturing level of the enterprise.

[0070] The filter tank design avoids failure or damage of the filter medium due to high pressure or high speed flow, and improves the stability and service life of the filtration system.

[0071] By reasonably designing the fluid distribution structure of the liquid inlet, the liquid outlet and the waste outlet, the cleaning liquid can uniformly pass through the filter medium, preventing local blockage or reduction of filtration efficiency.

[0072] The filter medium can be replaced or upgraded according to application requirements, suitable for separation of different types of oil pollution particles and solid impurities, widely used in metal surface cleaning processes in automobile manufacturing, mechanical processing, aerospace, electronic manufacturing and other industries.

[0073] The inlet flow rate can be adjusted to meet the cleaning needs of different scales and different pollution levels, improving the adaptability and economic value of the equipment.

[0074] Further, after step four is completed, the concentration of the environmentally friendly cleaning agent discharged from the precision filter is checked. If the concentration of the environmentally friendly cleaning agent is less than 50%, the circulation to the cleaning tank of the ultrasonic demulsification oil removal machine is stopped, and the environmentally friendly cleaning agent in the cleaning tank of the ultrasonic demulsification oil removal machine is discharged. Then, the environmentally friendly cleaning agent is refilled.

[0075] Through the concentration monitoring mechanism, when the concentration of the cleaning agent is less than 50%, the system automatically stops its circulation to prevent the cleaning ability from decreasing and to ensure that the oil, particles and impurities on the workpiece surface can be fully removed, thereby improving the cleaning quality.

[0076] Refilling the environmentally friendly cleaning agent can ensure that high-efficiency cleaning agents are always used during the metal surface treatment process, avoiding the problems of secondary pollution or incomplete cleaning caused by low-efficiency cleaning agents.

[0077] When the concentration of the cleaning agent is too low, continued use will cause oil and impurities to accumulate, increasing the burden on the filtration equipment and accelerating the clogging or wear of the filter medium.

[0078] Timely replacement of low-concentration cleaning agents can reduce the load on the ultrasonic demulsification oil removal machine and the precision filter, prolong their service life, and reduce equipment maintenance costs.

[0079] Low-concentration cleaning agents often require longer time and higher ultrasonic power to achieve the same cleaning effect, thereby increasing energy consumption.

[0080] Through the concentration detection and cleaning agent replacement mechanism, the equipment can always operate in the best working state, improving energy efficiency and reducing unnecessary energy consumption.

[0081] Low-concentration cleaning agents may contain a large amount of dispersed oil particles. If they continue to be circulated, they may cause internal pollution of the cleaning equipment to worsen, and even make the waste liquid difficult to handle.

[0082] Timely replacement of cleaning agents can ensure the separation efficiency of the precision filter, reduce the accumulation of harmful substances, reduce the amount of hazardous waste emissions, meet environmental regulations, and improve the green production level of enterprises.

[0083] The scheme can be combined with an automatic monitoring and control system to realize real-time detection and automatic replacement of the cleaning agent concentration, reduce manual intervention, improve the automation level of the production line, reduce manual operation errors, and improve production efficiency.

[0084] Further, an online sensor and a central control system are further included, the cleaning device and the baking device are respectively electrically connected with the central control system, the online sensor monitors the concentration of the environmental-friendly cleaning agent and transmits the detection data to the central control system, and the central control system sends a replacement signal when the concentration of the environmental-friendly cleaning agent is lower than a preset threshold value.

[0085] By adopting the online sensor and the central control system, the concentration of the environmental-friendly cleaning agent is monitored in real time, and a replacement signal is automatically sent when the concentration is lower than a preset threshold value, so that the whole cleaning process is more stable and intelligent, facilitating large-scale continuous production, and further improving production efficiency and product consistency.

[0086] Real-time monitoring of the cleaning agent concentration is realized to ensure stable cleaning effect

[0087] Through the online sensor, the system can continuously monitor the concentration of the cleaning liquid, avoiding the uncertainty and delay of manual detection and improving the accuracy of data.

[0088] The system automatically judges the state of the cleaning agent and immediately sends a replacement signal when the concentration is lower than a set threshold value, preventing the cleaning quality from being affected due to the failure of the cleaning agent and ensuring that the workpiece surface always maintains high cleanliness.

[0089] Traditional cleaning agent replacement relies on manual monitoring and experience-based judgment, which may lead to judgment lag or untimely replacement.

[0090] Through the automatic management of the central control system, human errors can be reduced, the intelligent level of the production process can be improved, and the cleaning process can be more efficient and stable.

[0091] The timing of cleaning agent replacement is accurately controlled to avoid waste of cleaning agent due to early replacement and to prevent a decrease in cleaning capacity due to late replacement, effectively prolonging the service life of the cleaning agent.

[0092] Optimizing resource allocation can reduce unnecessary cleaning agent replenishment and waste liquid discharge, reduce production costs, and improve economic benefits.

[0093] Long-term use of inefficient cleaning agents may cause oil accumulation inside the equipment, increasing the burden on the ultrasonic demulsification oil removal machine and the precision filter, and affecting their normal operation.

[0094] Through intelligent concentration management, it can be ensured that the cleaning equipment is always in the best working state, reducing problems such as equipment jamming and overload operation, thereby prolonging the service life of the equipment and reducing maintenance costs.

[0095] The central control system can record the concentration trend of the cleaning agent, providing data support for production optimization, troubleshooting, and quality management.

[0096] Combined with the concept of intelligent manufacturing, remote monitoring and maintenance can be achieved, enhancing the digital management level of enterprises and the fine control of production processes.

[0097] By precisely controlling the replacement of cleaning agents, excessive use and frequent disposal are avoided, reducing hazardous waste emissions from the source, meeting environmental regulations, and improving the green production capacity of enterprises.

[0098] The online monitoring system ensures the optimal timing of cleaning agent recycling, reducing environmental pollution and promoting sustainable development.

[0099] Furthermore, the environmentally friendly film-forming protective agent also contains one or more corrosion inhibitors to further improve the corrosion resistance of the metal surface. The corrosion inhibitors are selected from silanes, phosphates, or tannin compounds.

[0100] Traditional silicone resin protective films can provide basic protection, but in harsh environments with high humidity and high salt fog, there is still some risk of corrosion.

[0101] This solution actively inhibits corrosion reactions on the metal surface by adding additional corrosion inhibitors, providing more durable protection in acidic, alkaline, and salty environments, and extending the service life of the metal.

[0102] Silane corrosion inhibitors: can chemically bond with the metal surface, forming a dense silicon-oxygen network structure that enhances the water resistance and corrosion resistance of the coating.

[0103] Phosphate corrosion inhibitors: can form an insoluble phosphate protective layer on the metal surface, reducing the erosion of oxygen and corrosive media, and are widely used in the protection of easily corroded metals such as steel.

[0104] Tannin compounds: undergo chelation reactions with metal ions, forming a stable metal-tannin complex layer that prevents the intrusion of corrosive media, suitable for non-ferrous metal protection.

[0105] By combining different types of corrosion inhibitors, a synergistic protective effect can be achieved, further optimizing the overall protective performance of the film-forming protective agent.

[0106] Traditional rust inhibitors may affect the film-forming quality while improving corrosion resistance, leading to a decrease in the adhesion of the protective layer.

[0107] By optimizing the types and proportions of corrosion inhibitors, good compatibility with silicone resin is ensured, which will not affect the uniformity and adhesion of the protective layer, ensuring the long-term stability of the coating.

[0108] This solution is suitable for metal protection in humid, high-salt mist, acidic or alkaline environments, and can be widely used in shipbuilding, automotive, construction, mechanical equipment, aerospace and other fields.

[0109] It is particularly suitable for steel, aluminum alloy, stainless steel and other metal materials, enhancing their durability in complex environments and reducing maintenance costs.

[0110] The selected silane, phosphate and tannin compounds are all environmentally friendly corrosion inhibitors, which are more environmentally friendly than traditional heavy metal inhibitors (such as chromate, nitrite, etc.), non-toxic or low toxicity, and reduce environmental pollution.

[0111] It can be combined with water-based environmentally friendly solvents to avoid volatile organic compound (VOC) emissions, meet modern green manufacturing requirements, and help enterprises achieve sustainable development.

[0112] Further, the water contact angle of the protective film is greater than 90°.

[0113] A water contact angle greater than 90° indicates that the surface is hydrophobic, making it difficult for water droplets to spread on the surface and form a spherical shape that rolls off, reducing the residence time of moisture on the metal surface.

[0114] This effectively reduces moisture penetration, reduces the risk of metal exposure to corrosive media such as humidity, acid rain, salt mist, and improves overall corrosion resistance.

[0115] The hydrophobic surface reduces the likelihood of dirt and water-soluble contaminants (such as dust, silt, salt, etc.) adhering to it.

[0116] When water droplets roll on the surface, they can carry away adhering dirt, forming a self-cleaning function similar to the lotus effect, keeping the metal surface clean and reducing the cost of manual maintenance.

[0117] Traditional protective films may age and peel due to moisture intrusion when exposed to humidity, high temperatures and UV light for long periods.

[0118] Hydrophobic protective films can reduce moisture absorption, effectively delaying oxidation, aging and degradation, and maintain long-term stability in harsh environments, extending the service life of metal surface treatment.

[0119] It is suitable for metal equipment in marine environments, humid areas and high-salt mist areas (such as ships, bridges, vehicles, aerospace vehicles, etc.), enhancing their corrosion resistance.

[0120] It can be used for outdoor facilities, building facades, metal roofs, etc., reducing water stain pollution and improving aesthetics and durability.

[0121] It is suitable for electronic devices, precision instruments, etc., preventing water vapor condensation, reducing the risk of circuit short circuits, and improving safety.

[0122] By optimizing the material formula (such as adding a specific hydrophobic agent or adjusting the chemical structure of the silicone resin), high-efficiency hydrophobic effect can be achieved without using fluorides, meeting the requirements of environmental protection and sustainable development.

[0123] The beneficial effects of the present application are as follows:

[0124] In the present application, the efficient recovery and reuse of cleaning liquid are achieved through the recycling of environmentally friendly cleaning agents, ultrasonic demulsification oil removal machines, and precision filters, avoiding direct discharge of waste liquid, thereby reducing environmental pollution and meeting the requirements of green manufacturing. In addition, hazardous waste is effectively separated and handed over to professional agencies for treatment, ensuring compliance with environmental regulations and sustainable development requirements.

[0125] In the present application, the ultrasonic demulsification oil removal technology is used to destroy the adhesion of oil particles through high-frequency vibration waves, making them fall off from the metal surface, significantly improving the cleaning efficiency and quality. At the same time, the frequency adjustment module can automatically optimize the ultrasonic frequency according to the type and degree of oil pollution, improving the decontamination effect while reducing energy consumption, making the entire cleaning process more efficient and stable.

[0126] In the present application, in terms of metal surface protection, a dense protective film is formed on the metal surface by the environmentally friendly film-forming protective agent, enhancing the oxidation resistance and corrosion resistance. The water contact angle of the protective film is greater than 90°, with excellent hydrophobicity and self-cleaning ability, effectively preventing water and pollutants from adhering, improving the long-term service life of metal parts, and reducing maintenance costs.

[0127] In the present application, intelligent monitoring and automatic control are realized, with online sensors monitoring the concentration of environmentally friendly cleaning agents in real time and transmitting data to the central control system, automatically issuing a replacement signal when the concentration is below the preset threshold, ensuring the effectiveness of the cleaning liquid. At the same time, the precision filter can automatically detect the concentration of environmentally friendly cleaning agents, and stop circulating and replacing when it is below 50%, ensuring the stability of cleaning quality.

[0128] In the present application, the method has high process adaptability and is suitable for cleaning and protecting various metal materials. Biodegradable non-ionic surfactants are used to improve the compatibility of different metal materials and avoid environmental pollution. In addition, the flow of the spraying equipment can be adjusted, suitable for workpieces of different shapes and sizes, making it widely applicable in aerospace, automobile manufacturing, precision instruments, electronic equipment, and other industries, meeting the high-standard metal surface treatment requirements. BRIEF DESCRIPTION OF DRAWINGS

[0129] Figure 1 Flowchart of the metal surface treatment zero-emission method. DETAILED DESCRIPTION

[0130] The application will be further described below in conjunction with the accompanying drawings and embodiments:

[0131] Embodiments, in conjunction with Figure 1 As shown in the embodiment, a metal surface treatment zero-emission method comprises an environmentally friendly cleaning agent, an environmentally friendly film-forming protective agent, a cleaning device and a baking device, the environmentally friendly cleaning agent comprises a surfactant, a chelating agent, an inhibitor and deionized water, the surfactant accounts for 30%, the chelating agent accounts for 15%, the inhibitor accounts for 5%, and the deionized water accounts for 50%;

[0132] The environmentally friendly film-forming protective agent comprises silicone resin, anti-rust additive, solvent and curing agent, the silicone resin accounts for 10%, the anti-rust additive accounts for 5%, the solvent accounts for 80%, and the curing agent accounts for 5%;

[0133] The cleaning device comprises a first spraying device, an ultrasonic demulsification and oil removal machine, a precision filter and a second spraying device, the first spraying device comprises a liquid storage tank and a first nozzle, the first nozzle is in communication with the liquid storage tank, and the second spraying device comprises a liquid storage tank and a second nozzle, the second nozzle is in communication with the liquid storage tank;

[0134] Metal surface treatment zero-emission operation steps,

[0135] Step one: pour 10% of the environmentally friendly cleaning agent into the liquid storage tank of the first spraying device, adjust the pressure and flow of the first spraying device, and spray the cleaning agent in the form of uniform mist to the metal surface through the first nozzle, and spray and clean for 3 to 5 minutes to remove oil stains, particles and impurities on the metal surface of the workpiece;

[0136] Step two: the oil stain particles and the environmentally friendly cleaning agent in step one form a mixed solution and flow into the cleaning tank of the ultrasonic demulsification and oil removal machine;

[0137] Step three: place the workpiece in the cleaning tank of the ultrasonic demulsification and oil removal machine, add the environmentally friendly cleaning agent to the cleaning tank, and use high-frequency vibration waves to make the oil stain particles fall off from the metal surface of the workpiece and disperse in the environmentally friendly cleaning agent to form a mixed solution, and then use high-frequency vibration waves to disperse the oil stain particles in the mixed solution;

[0138] Step four: the mixed solution in step three flows into the precision filter, the precision filter separates the mixed solution into hazardous waste and environmentally friendly cleaning agent through multiple layers of filter medium, the environmentally friendly cleaning agent is recycled and circulated to the cleaning tank of the ultrasonic demulsification and oil removal machine, and the hazardous waste is handed over to a third-party professional agency for recycling treatment;

[0139] Step five: pour the environmental protection film-forming protective agent into the liquid tank of the second spraying device, take out the workpiece, and spray the metal surface of the workpiece through the second nozzle of the second spraying device until a protective film with a thickness of 0.2-2 μm is formed on the metal surface;

[0140] Step six: place the workpiece into the baking device, dry the metal surface at 120℃ for 15 min, and allow the protective film to solidify.

[0141] Further, the surfactant is a biodegradable non-ionic surfactant;

[0142] The chelating agent is ethylenediaminetetraacetic acid that can chelate with impurity ions on the metal surface to remove the impurity ions from the metal surface.

[0143] The corrosion inhibitor is a black metal corrosion inhibitor and a silane coupling agent that can form a protective film on the metal surface to prevent corrosion of the metal during cleaning.

[0144] Further, the silicone resin is a silicone resin with good film-forming properties and weather resistance that can form a tough protective film on the metal surface;

[0145] The rust-preventing additive is a silane coupling agent with excellent rust-preventing properties;

[0146] The solvent is an environmentally friendly alcohol solvent and pure water that can dissolve the silicone resin and other additives;

[0147] The curing agent is isocyanate that can react with the silicone resin to rapidly solidify the protective film.

[0148] Further, the ultrasonic demulsification and oil removal machine comprises an ultrasonic generator, a transducer, a cleaning tank, and a control system;

[0149] The ultrasonic generator generates a high-frequency electric signal, which is transmitted to the transducer through a cable. The transducer converts the high-frequency electric signal into a high-frequency mechanical vibration wave, which is transmitted into the cleaning liquid in the cleaning tank. When the high-frequency mechanical vibration wave acts on the oil stain particles, the oil stain particles resonate, thereby destroying their adhesion to the metal surface, allowing them to fall off the metal surface and disperse in the cleaning liquid.

[0150] Further, the ultrasonic demulsification and oil removal machine further comprises a frequency adjustment module. The frequency of the ultrasonic demulsification and oil removal machine is 20-40 kHz, the power is 500-1000 W, and the working time is 10-15 min. The frequency adjustment module can automatically optimize the working frequency of the ultrasonic wave according to the type and pollution degree of the oil stains on the metal surface.

[0151] Further, the precision filter comprises a filter tank and a filter medium capable of effectively intercepting oil particles and solid impurities, the filter tank is provided with the liquid inlet, the liquid outlet and the waste outlet, the filter medium is arranged in the filter tank, and the liquid inlet is provided with a liquid inlet valve for controlling the flow rate of the cleaning liquid to be 20-100 L / min.

[0152] The mixed solution of step three enters the filter tank through the liquid inlet, is filtered through the filter medium, and then the clean environmental cleaning agent is discharged to the cleaning tank of the ultrasonic demulsification and oil removal machine through the liquid outlet for recycling, and the hazardous waste is discharged through the waste outlet.

[0153] Further, after step four is completed, the concentration of the environmental cleaning agent discharged by the precision filter is checked, when the concentration of the environmental cleaning agent is lower than 50%, the recycling to the cleaning tank of the ultrasonic demulsification and oil removal machine is stopped, the environmental cleaning agent in the cleaning tank of the ultrasonic demulsification and oil removal machine is discharged, and then the environmental cleaning agent is refilled.

[0154] Further, it further comprises an online sensor and a central control system, the cleaning device and the baking device are respectively electrically connected with the central control system, the online sensor monitors the concentration of the environmental cleaning agent and transmits the detection data to the central control system, and the central control system sends a replacement signal when the concentration of the environmental cleaning agent is lower than a preset threshold according to the detection data.

[0155] Further, the environmental film-forming protective agent further contains one or more corrosion inhibitors for further improving the corrosion resistance of the metal surface, and the corrosion inhibitor is selected from silane, phosphate or tannin compound.

[0156] Further, the water contact angle of the protective film is greater than 90°.

Claims

1. A metal surface treatment zero-emission method, comprising an environmentally friendly cleaning agent, an environmentally friendly film-forming protective agent, a cleaning device and a baking device, characterized in that: the environmentally friendly cleaning agent comprises a surfactant, a chelating agent, an inhibitor and deionized water, the surfactant accounts for 30%, the chelating agent accounts for 15%, the inhibitor accounts for 5%, and the deionized water accounts for 50%; the environmentally friendly film-forming protective agent is composed of silicone resin, anti-rust additive, solvent and curing agent, the silicone resin accounts for 10%, the anti-rust additive accounts for 5%, the solvent accounts for 80%, and the curing agent accounts for 5%; the cleaning device comprises a first spraying device, an ultrasonic demulsification and oil removal machine, a precision filter and a second spraying device, the first spraying device comprises a liquid storage tank and a first nozzle, the first nozzle is in communication with the liquid storage tank, and the second spraying device comprises a liquid storage tank and a second nozzle, the second nozzle is in communication with the liquid storage tank; the metal surface treatment zero-emission operation steps are as follows: step 1: pour 10% of the environmentally friendly cleaning agent into the liquid storage tank of the first spraying device, adjust the pressure and flow of the first spraying device, and spray the cleaning agent in the form of uniform mist to the metal surface through the first nozzle, and spray and clean for 3-5 min to remove the oil stains and impurities on the metal surface of the workpiece; step 2: the oil stains and the environmentally friendly cleaning agent in step 1 form a mixed solution which flows into the cleaning tank of the ultrasonic demulsification and oil removal machine; step 3: place the workpiece in the cleaning tank of the ultrasonic demulsification and oil removal machine, and add the environmentally friendly cleaning agent into the cleaning tank, the ultrasonic demulsification and oil removal machine uses high-frequency vibration waves to make the oil stains fall off from the metal surface of the workpiece and disperse in the environmentally friendly cleaning agent to form a mixed solution, and then the ultrasonic demulsification and oil removal machine uses high-frequency vibration waves to disperse the oil stains in the mixed solution; step 4: the mixed solution in step 3 flows into the precision filter, the precision filter separates the mixed solution into hazardous waste and environmentally friendly cleaning agent through multiple layers of filter medium, the environmentally friendly cleaning agent is recycled to the cleaning tank of the ultrasonic demulsification and oil removal machine, and the hazardous waste is handed over to a third-party professional agency for recycling treatment; step 5: pour the environmentally friendly film-forming protective agent into the liquid storage tank of the second spraying device, take out the workpiece, and atomize and spray the metal surface of the workpiece through the second nozzle of the second spraying device until a protective film with a thickness of 0.2-2 μm is formed on the metal surface; step 6: place the workpiece in the baking device, dry the metal surface at 120℃ for 15 min, and allow the protective film to solidify; the surfactant is a biodegradable non-ionic surfactant; the chelating agent is ethylenediaminetetraacetic acid which can react with impurity ions on the metal surface to remove the impurity ions from the metal surface; the inhibitor is a black metal inhibitor and a silane coupling agent which can form a protective film on the metal surface to prevent the metal from being corroded during the cleaning process; the silicone resin is a silicone resin with good film-forming performance and weather resistance which can form a tough protective film on the metal surface; and the anti-rust additive is a silane coupling agent with excellent anti-rust performance. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The solvent is an environmentally friendly alcohol solvent and pure water capable of dissolving silicone resin and other additives; The curing agent is isocyanate capable of reacting with silicone resin to rapidly cure the protective film; The environmentally friendly film-forming protective agent further contains one or more corrosion inhibitors selected from silane, phosphate or tannin compounds to further improve the corrosion resistance of the metal surface.

2. The metal surface treatment zero emission method according to claim 1, wherein: The ultrasonic demulsification and oil removal machine comprises an ultrasonic generator, a transducer, a cleaning tank and a control system. The ultrasonic generator generates a high-frequency electric signal, which is transmitted to the transducer through a cable, and the transducer converts the high-frequency electric signal into a high-frequency mechanical vibration wave, which is transmitted into the cleaning liquid in the cleaning tank. When the high-frequency mechanical vibration wave acts on the oil stain particles, the oil stain particles resonate, thereby destroying their adhesion to the metal surface, allowing them to fall off the metal surface and disperse in the cleaning liquid.

3. The metal surface treatment zero emission method according to claim 2, wherein: The ultrasonic demulsification and oil removal machine further comprises a frequency adjustment module, the frequency of the ultrasonic demulsification and oil removal machine is 20-40 kHz, the power is 500-1000 W, and the working time is 10-15 min. The frequency adjustment module can automatically optimize the working frequency of the ultrasonic wave according to the type and pollution degree of the oil stain on the metal surface.

4. The metal surface treatment zero emission method according to claim 1, wherein: The precision filter comprises a filter tank and a filter medium capable of effectively intercepting oil stain particles and solid impurities. The filter tank is provided with the liquid inlet, the liquid outlet and the sewage outlet. The filter medium is arranged in the filter tank. The liquid inlet is provided with a liquid inlet valve for controlling the flow rate of the cleaning liquid at 20-100 L / min. The mixed solution of step three enters the filter tank through the liquid inlet, and then is filtered through the filter medium. The clean environmentally friendly cleaning agent is discharged to the cleaning tank of the ultrasonic demulsification and oil removal machine through the liquid outlet for recycling. The hazardous waste is discharged through the sewage outlet.

5. The metal surface treatment zero emission method according to claim 1, wherein: After step four is completed, the concentration of the environmentally friendly cleaning agent discharged from the precision filter is checked. When the concentration of the environmentally friendly cleaning agent is lower than 50%, the recycling to the cleaning tank of the ultrasonic demulsification and oil removal machine is stopped, and the environmentally friendly cleaning agent in the cleaning tank of the ultrasonic demulsification and oil removal machine is discharged. Then, the environmentally friendly cleaning agent is refilled.

6. The metal surface treatment zero emission method according to claim 1, wherein: The cleaning equipment and the baking equipment are respectively electrically connected with the central control system. The online sensor monitors the concentration of the environmentally friendly cleaning agent and transmits the detection data to the central control system. The central control system sends a replacement signal when the concentration of the environmentally friendly cleaning agent is lower than the preset threshold value.

7. The metal surface treatment zero emission method according to claim 1, wherein: The water contact angle of the protective film is greater than 90°.

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