Chemical Pre-Treatment Plant
Chemical treatment is another type of surface preparation and cleaning process like shot blasting. In chemical treatment the part to be powder coated or spray painted needs to be thoroughly cleaned for production process impurities, oils and or flash rust. Depending on the material and thickness of the product, various processes are followed in a chemical treatment plant.
Chemical treatment is also essential for products having material thickness of lower than 3 mm as shot blasting of such materials causes damage to the surface and can cause material cracks.
Chemical treatment is a mandatory process for CED and powder coating plants as both applications are chosen for high volume production lines and a continuous operation chemical treatment can be installed in line with both these plants to increase efficiency and production volume.
Process flow
Types
Chemical treatment is a very important process before powder coating or CED coating of the parts to ensure strong bonding of the paint and the job parts. Chemical Treatment plants are of below mentioned types based on applications and production required.
Dip Tank Chemical Pre-Treatment Plants
A dip tank pre-treatment plant is a facility or system designed for the pre-treatment of materials or products through a process involving immersion in a dip tank. The purpose of dip tank pre-treatment is to prepare surfaces for subsequent processes, such as painting, coating, plating, or other finishing applications.
Dip tank pre-treatment plays a vital role in enhancing the durability, corrosion resistance, and overall quality of products in various industries before they undergo further finishing processes.
Applications for ARIA Dip type pre-treatment plant:
Large parts which cannot be hung on an overhead automated conveyor usually use dip type pre-treatment plants, usually applications where in low production rate is required is best suited for dip type pre-treatment plants.
Industries for ARIA dip type pre-treatment plants:
Dip pre-treatment plants are usually used in industries such as automotive, heavy engineering, railway and wagons, aerospace, commercial vehicles, electronics and appliances, gear boxes and motor casings, pumps and cast products etc.
Spray Type Chemical Pre-Treatment Plants
A spray pre-treatment plant is a facility or system designed for the pre-treatment of materials or products using a spray application of chemical solutions. This type of pre-treatment is commonly used in applications where a consistent and controlled coating is necessary before subsequent processes like painting, coating, or finishing.
Spray pre-treatment is advantageous for covering large surface areas efficiently and achieving a uniform coating on complex shapes. It is often a critical step in enhancing the adhesion and durability of subsequent finishes applied to the materials or products.
Applications
Small light weight parts or long profiles which can easily be suspended on an overhead automated conveyor usually use Spray or tunnel type pre-treatment plants, usually applications where in high continuous production rate is required is best suited for Spray or tunnel type pre-treatment plants.
Industries
Dip pre-treatment plants are usually used in industries such as automotive, heavy engineering, railway and wagons, aerospace, commercial vehicles, electronics and appliances, gear boxes and motor casings, pumps and cast products etc.
Construction Materials
Tanks & chemical storage
Chemical pre-treatment plant tanks are typically constructed using materials that provide resistance to corrosion, chemical degradation, and other adverse effects of the chemicals used in the pre-treatment process.
The choice of material depends on the specific chemicals involved in the pre-treatment process, as well as the temperature and environmental conditions. It is essential to consider the compatibility of the tank material with the chemicals used to ensure the longevity and effectiveness of the pre-treatment system. Additionally, safety and regulatory considerations may influence the selection of materials for chemical pre-treatment dip tanks. We at ARIA always design our plants based on chemical compatibility charts and adhere to industry standards and regulations when designing and constructing such systems.
Common materials used for manufacturing chemical pre-treatment dip tanks include:
Polypropylene (PP):
Polypropylene is a thermoplastic polymer known for its excellent chemical resistance. It is commonly used in the construction of dip tanks for various chemical pre-treatment processes.
High-Density Polyethylene (HDPE):
HDPE is another thermoplastic that offers good chemical resistance and is often chosen for dip tanks. It is lightweight, durable, and resistant to corrosion.
Fiberglass Reinforced Plastic (FRP):
FRP is a composite material that combines the strength of fiberglass with the corrosion resistance of plastic. FRP dip tanks are suitable for handling corrosive chemicals in chemical pre-treatment applications.
Polyvinyl Chloride (PVC):
PVC is a thermoplastic known for its chemical resistance and versatility. It is suitable for certain chemical pre-treatment processes, especially those involving acids and bases.
Stainless Steel:
Stainless steel is a corrosion-resistant alloy that can be used in the construction of dip tanks for chemical pre-treatment. It is durable, easy to clean, and offers good resistance to a wide range of chemicals.
Galvanized Steel:
Galvanized steel is a cost-effective option for dip tank construction. It is coated with a layer of zinc to enhance corrosion resistance, making it suitable for certain chemical pre-treatment applications.
Pipes and mechanical components
Stainless steel is a usual material of recommendation for all piping in both dip type and spray type pre-treatment plants. Other mechanical equipment like filter presses, pumps, valves, strainers are also recommended to be of stainless-steel body to avoid untimely corrosion.
Tunnel wall panels:
Spray or tunnel type pre-treatment wall panels are recommended to have stainless steel 316 inner lining and M.S outer shell to keep the cost of the tunnel under budget. The stainless steel on the inside wall ensures longevity of the wall panels as they are continuously exposed to chemical and water spray as per the process requirement.
Mechanical Equipment
A chemical pre-treatment plant typically involves various mechanical equipment to facilitate the preparation and processing of raw materials before they undergo chemical reactions or other treatments. The specific equipment used can vary based on the type of pre-treatment and the nature of the chemicals involved. Here is some common mechanical equipment found in a chemical pre-treatment plant:
Conveyors:
These are used to transport raw materials, intermediates, or finished products between different stages of the pre-treatment process. Belt conveyors, screw conveyors, or pneumatic conveyors may be used depending on the material characteristics and plant layout.
Mixers and Agitators:
Mixing equipment is essential for blending different chemicals or ensuring homogeneity of a mixture. Mechanical mixers and agitators help in achieving the desired consistency and distribution of substances within a solution.
Reactors:
Depending on the pre-treatment process, reactors may be employed to facilitate chemical reactions. These can be batch reactors or continuous flow reactors, and they often have temperature and pressure control systems.
Pumps:
Pumps are used to transfer liquids from one part of the plant to another. Different types of pumps, such as centrifugal pumps or positive displacement pumps, may be employed based on the specific requirements of the pre-treatment process.
Filters:
Filtration equipment is used to separate solid particles from liquids or gases. This is crucial for ensuring the purity of the chemicals involved in the pre-treatment process.
Heat Exchangers:
These devices are used to control the temperature of chemical processes. Heat exchangers facilitate the transfer of heat between different process streams, helping to maintain optimal reaction conditions.
Storage Tanks:
Tanks are used for storing raw materials, intermediates, or final products. They come in various shapes and sizes and may be equipped with agitation or temperature control systems.
Dryers:
If the pre-treatment involves drying processes, industrial dryers such as rotary dryers or fluidized bed dryers may be used to remove moisture from solids.
Instrumentation and Control Systems:
Sensors, detectors, and control systems are integrated into the plant to monitor and regulate various parameters such as temperature, pressure, flow rates, and composition, ensuring the efficiency and safety of the pre-treatment process.
It’s important to note that the specific equipment used in a chemical pre-treatment plant can vary significantly based on the industry, the nature of the raw materials, and the desired outcome of the pre-treatment process. Safety measures and compliance with environmental regulations are also critical considerations in the design and operation of such plants.
Safety Devices
Safety is a paramount concern in chemical processing plants, including pre-treatment facilities, where various hazardous materials and processes are involved. The implementation of safety devices is crucial to prevent accidents, protect personnel, and safeguard the environment. Here are some common safety devices found in chemical pre-treatment plants:
Emergency Shutdown Systems (ESD):
These systems are designed to rapidly shut down the entire plant or specific sections in the event of an emergency. They can be activated manually or automatically in response to abnormal conditions, such as leaks, overpressure, or fire.
Pressure Relief Devices:
Pressure relief valves are installed on vessels and pipelines to release excess pressure and prevent equipment failure or explosions. These devices are critical for maintaining safe operating conditions.
Fire and Gas Detection Systems:
These systems use sensors to detect the presence of flammable gases or the onset of a fire. Once a threat is identified, alarms are triggered, and appropriate emergency responses can be initiated.
Emergency Ventilation Systems:
In the case of the release of hazardous gases or vapors, emergency ventilation systems help disperse and dilute the substances to prevent their accumulation in concentrations that could pose a threat to personnel or the environment.
Personal Protective Equipment (PPE):
Workers in a chemical pre-treatment plant should use appropriate PPE, such as gloves, goggles, masks, and protective clothing, to minimize the risk of exposure to harmful substances.
Eyewash and Emergency Shower Stations:
These stations are strategically located throughout the plant and provide immediate access to water for rinsing off chemicals in case of skin or eye contact. Quick response is crucial to minimize the impact of chemical exposure.
Explosion Suppression Systems:
In areas where the potential for combustible dust or gases exists, explosion suppression systems may be installed. These systems are designed to detect and suppress explosions before they can cause significant damage.
Leak Detection Systems:
Sensors and monitoring devices are employed to detect leaks of hazardous substances. Early detection allows for prompt intervention to stop the release and mitigate the consequences.
Process Interlocks:
Interlocking systems can automatically shut down specific equipment or processes if certain conditions are not met. For example, if a vessel reaches a critical temperature or pressure, the interlock system may trigger a shutdown to prevent equipment failure.
Safety Alarms and Communication Systems:
Audible and visual alarms are used to alert personnel to potential hazards or emergencies. Communication systems, including two-way radios, are essential for coordinating emergency responses.
Safety Signage and Labels:
Clearly marked signage indicating the location of emergency equipment, hazard areas, and escape routes helps personnel navigate the facility safely.
It’s important for a chemical pre-treatment plant to have a comprehensive safety plan, conduct regular safety drills, and comply with relevant safety standards and regulations to ensure a secure working environment. Additionally, ongoing training for personnel on safety procedures and the proper use of safety devices is critical for accident prevention and response.
Site Installations
ARIA Offers complete turnkey solutions for clients not having inhouse maintenance teams to undertake site installations.
Our Site technicians and engineers travel from South Africa or India depending on the location of installations.
All our technicians and engineers are highly skilled and experienced in undertaking Chemical Pre-treatment plants installation in as little as 4 days depending on the size of the Chemical Pre-treatment plants.
In case the client budget does not allow for site installation crew we offer a unique method of client providing local technicians and general helpers and ARIA will only send 1 engineer to guide the team to install and commission the Chemical Pre-treatment plants.
ARIA also offers detailed installation drawings and videos of tricks to install Chemical Pre-treatment plants for clients to independently install and commission the Chemical Pre-treatment plants.
The accommodation, food and travel arrangements for any of the above options must be borne by the client as a separate line item on the offer document.
Commissioning
ARIA Chemical Pre-treatment plants come with complete commissioning documentation required by your local insurance, Fire safety department, Council and regulatory standards of the region.
A Mechanical engineer signed COC will be issued once our in-house engineer commissions the Chemical Pre-treatment plants.
A master electrician signed COC will be issued once the electrical engineer has tested and found all compliant.
An Emissions certificate will be issued by our in-house team based on the filtration manufacturer third party testing certificate.
A wall panel fire rating certificate will be issued by ARIA in house team based on our fire tests performed in the past and test reports attached as proofs.
Fume proof light fittings certificates or Explosion proof light fittings certificate will be issued as per local mandatory requirements.
Apart from the above certificates the Chemical Pre-treatment plants come with a maintenance checklist and manual for operations and periodic preventative maintenance of your assets.
All the above documentation will be handed over to the client only after full and final payments are settled.
Warranty
All ARIA Manufactured Chemical Pre-treatment plants come with a 5-year warranty on construction and
materials used.
All third-party manufacturer products such as motors, pneumatic cylinders etc. come with third party warranty of 1 year.
All electrical components do not get any warranty and will have to be checked to be in working order before signing off on the plant handover certificate.
The only condition for 5 years warranty on ARIA Chemical Pre-treatment plants is to purchase all spares and consumables from ARIA, in case a third-party supplier is used for pirate spare parts the warranty stands void.
In case the client does not follow instructions in the manual for preventative maintenance the warranty is void.
In case there is damage to the Chemical Pre-treatment plants due to human error, act of God and physical damage due to non-changing of filters on time also the warranty will be void.
IASF Technologies India Pvt. Ltd.
ADDRESS: Gat 87/5, Malwadi, Talegaon Chakan Road, Talegaon Dhabade, Maval, Pune, Maharashtra, India 410506
PHONE: +91 8484 92 93 63
ALTERNATE: +91 82630 94819
EMAIL: INFO at ARIAIASF.COM