监测电磁化过程

位于萨尔茨堡奥地利，摩洛是一家领先的窗户和门件制造商。该公司成立于1947年，现已拥有约2300人的国际劳动力，在奥地利的三个地点和各种其他国际网站工作。

MACO’s window and door fittings are manufactured in sophisticated facilities in Austria and are marketed worldwide. A large number of in-house production includes numerous surface-finishing processes like anodizing (electrolytic oxidation of aluminum), electrogalvanizing, and chrome-free powder coating. In order to reduce environmental impact, MACO uses only modern technologies for wastewater treatment and processing operations.

电镀过程过程

理所当然的在我们的日常生活中,窗口和做or fittings are typically produced in huge quantities. Based on where they are utilized, window and door fittings should be able to fulfill different types of needs, and at the same time they should be able to endure adverse weather conditions. As a result, manufacturers usually add an additional coating to these fittings to realize these product properties. For instance, when steel components are covered with a thin zinc layer, they develop more resistance against corrosion.

在里面电动血管过程，使用电流施加锌层。使用配备有两个电极的锌电解质浴 - 阳极（正极）和待镀锌作为阴极（负极）的钢部件，施加电流。

溶解的锌也包括在浴中，并通过计量泵和导电盐引入浓缩物，通常也加入苛性钠（氢氧化钠/ NaOH）以促进导电性。在电流的影响下，溶解在浴中的锌（Zn²⁺) is reduced on the cathode and then gradually deposited on the steel component surface (Figure 1).

图1。Electrogalvanizing in an alkaline zinc bath.

在电凝血过程中，阴极上存在的锌离子收集电子，随后沉积在组件上作为元素锌：

Zn²⁺+ 2e^¯→Zn

在里面current scenario the anode does not contain zinc, but includes an inert material. During the galvanizing process, zinc ion concentration reduces in the zinc bath and zinc ions are added again as zinc concentrate. Zinc coating quality relies on the whole manufacturing process being executed properly. In this context, downstream and upstream process steps are equally significant as the galvanizing itself with respect to creating high-quality and durable coatings.

The steel components are cleaned and prepared for the coating process with the help of pickling baths and upstream degreasing. Since process work is performed with a cyanide-free and eco-friendly zinc bath, it must be ensured that the components to be coated are free of impurities, like surface scale and rust. Subsequent to coating, the zinc’s sensitive layer is further protected and sealed through passivation.

The numerous baths are:

• Acid degreasing bath (1)
• 冲洗浴（2 + 3）
• Acid pickling bath (4)
• Rinsing baths (5 + 6)
• 碱性锌浴（7）
• 冲洗浴（8 + 9）
• Passivating bath (10)
• 冲洗和清洁浴（11 + 12）

因此，电镀化方法包括四个活性浴和互补清洗和漂洗浴（图2）。为了实现优异的产品质量，重要的是确保众多浴的组成仍然在给定的范围内。即使与过程窗口的略微差异也可以显着降低质量并导致拒绝数量增加。

图2。电镀膜中的各种处理阶段的示意图。

Different coating methods can be utilized based on the size of the metal parts to be coated. A good current flow is required during the galvanizing process, so smaller parts are galvanized in a barrel while larger parts are allowed to travel via the baths in a rack.

这被称为桶和齿条镀锌。这里，必须对锌浴中的电流密度进行调节以适应特定条件。电镀是金属精加工中最常用的方法之一，也是最具成本效益的技术，可确保保持腐蚀的一致保护。

对新流程监测系统的需求

窗口和门配件的制造，然后是电缩探是一种时间密集的方法。

为了获得高度可靠的产品质量，应在指定限度内密切观察到该过程的每个步骤。早些时候，除了执行通常的流程职责外，浴缸分析是由负责该过程的人员进行的。然而，宝贵的时间丢失，因为分析不仅困难，而且在很大程度上也是手动进行的。

响应这种情况，最终制作了浴缸分析的自动化。尽管如此，理想的解决方案需要满足过程需求，并应在过程中以直接和快速的方式测量众多浴室参数，而不占用任何额外的时间。这个想法是旨在实现简单的操作。

Process Monitoring at a Glance

Metrohm开发了一种新的ProcessLab分析系统，以最合适的方式满足摩托的需求。该系统具有模块化设计，在这种情况下，为镀锌过程定制。因此，它旨在满足客户的需求，并有助于在过程线上快速轻松测量。设计用于摩洛浴缸分析的ProcessLab系统包括两个分析模块和TFT监视器，用于调节整个系统（图3）。

图3。ProcessLab is characterized by its ability to carry out analysis directly at the process line (atline analysis). At MACO the analysis system is located directly by the galvanizing baths.

All the user has to do is load the bath sample onto the system and begin the analysis, and the ProcessLab system will automatically perform all the additional steps. The system determines the amount of sample required, moves it to the measuring vessel, and introduces the auxiliary substances and reagents. Following this, the analyte concentration is determined by subjecting it either to photometric measurement in the analysis module on the right, or to titration in the analysis module on the left.

完全集成的光度计用于进行光度测量。评估和计算自动使用内置Tiamo™for ProcessLab软件进行。在该控制和测量软件的帮助下，所有分析结果都保存在中央数据库中，该数据库可以在稍后的时间访问。

Status signals can be easily forwarded using the input/output controller integrated within the ProcessLab system. For instance, if there is a potential system fault or if a value exceeds or falls below a limit, these data can be sent. The quantified bath concentrations can also be relayed to the control room as an analog signal of 4…20mA.

Based on these quantified values, all other process steps are started and automatically controlled. ProcessLab is used by MACO as an atline system to track the overall process. All parameters related to the processes in the active baths are rapidly and directly examined with just a single system, and more process chemicals can also be added if required.

Since seven parallel process lines are being operated at the Trieben site, Applikon’s ADI 2040 online analyzer was also installed because of the high frequency of analysis. Applikon is part of Metrohm AG, which has been manufacturing process analyzers for over 25 years. The ADI 2040 is used to monitor the NaOH and zinc content in the zinc baths and the same are automatically adjusted, while the ProcessLab system is used to observe the overall process within all the active baths.

At the Salzburg site there are fewer parallel lines being operated, and hence only the ProcessLab system is being used there to monitor the processes. This case shows how atline and online analyzers ideally complement each other, particularly if the solutions are delivered from the same supplier.

方法的详细描述

An automated analysis system is able to measure all the pertinent parameters of the electrogalvanizing procedure and tracks all of the active baths.

脱脂浴中的酸浓度

使用用pH电极（普硝基）和苛性钠的基本滴定来进行酸浓度的测定，并且基于所消耗的NaOH量可以测量酸浓度。

Acid Concentration in the Pickling Bath

在里面pickling bath, the acid concentration is established using titration with a pH electrode and NaOH. Using the ProcessLab system, the acid concentration is automatically determined from the consumed NaOH.

锌浴中的锌浓度

A complexometric titration is used to determine zinc concentration. When a Cu-EDTA buffer solution is added to a bath aliquot, the Cu²⁺ions that are discharged are titrated with an ion-selective copper electrode (Cu-ISE) and an EDTA solution. The zinc concentration in the zinc bath can be determined from the volume of EDTA consumed. Figure 4 illustrates a standard titration curve for the titrimetric Zn²⁺确定，作为众多滴定的一个例子。

图4。复杂Zn的典型滴定曲线²⁺决心。

NaOH Concentration in the Zinc Bath

碱性锌浴中的NaOH浓度通过用HCl和pH电极滴定来测量。锌浴中NaOH的浓度由消耗的HCl的量确定。

Bath Concentrate in the Passivating Bath

可以溶解浴浓缩物以实现钝化浴。由于浴中的添加剂存在，浴室具有固有的颜色，其用于钝化浴的光度跟踪。

废水中金属的测定

除了跟踪与过程相关的参数外，还应检查废水中的重金属。这有助于遵守严格的法定要求。由于ProcessLab系统的模块化设计，光度分析模块也可用于制造这些测量，并且还可以基于特定要求测量铁，铬，铜或锌等金属。使用测光法，磷酸盐自动测量1,5-二苯基咔唑，用2,2'-百喹啉，锌用锌的铜和具有5-砜的铁。

Conclusion

The ProcessLab system designed by Metrohm fulfills all the process demands of MACO, makes it easy and simple to perform routine atline analysis, and offers reproducible and reliable readings of all relevant bath parameters in the galvanizing process. The system can also be used to measure the concentrations of heavy metals in the wastewater. While choosing the system, an important factor is to opt for an automated system that removes pressure from the personnel responsible for the process, and provides them with additional time to track the actual process. MACO also selected the Process Lab system for its modular design as well as for the prospect of expanding it in the future.

Further literature

• Monograph: Practical Titration, 2005, 164 pages, Metrohm AG, Switzerland.
• T. W. Jelinek, Prozessbegleitende Analytik in der Galvanotechnik, 1999, 440 pages, Eugen G. Leuze Verlag, Saulgau.
• Mordechay Schlesinger, Modern Electroplating, Fourth Edition, 2000, 870 pages, John Wiley & Sons, New York.
• N. Kanani，电镀：基本原则，流程和实践，2005年，354页，elsevier，牛津，阿姆斯特丹。

这些信息已被源，从Metrohm AG提供的材料进行审核和调整。欧洲杯足球竞彩

For more information on this source, please visit Metrohm AG.