Abstract:
This invention is related to a method for recovery of aqueous wash in a phosphate chemical conversion of a shaped metal product involving carrying out chemical conversion and subsequent cleaning with water,  
     wherein said cleaning with water is performed in one or more stages and comprises  
     a step of withdrawing aqueous wash from a first cleaning stage and adjusting the pH of the wash with at least one acid selected from the group consisting of phosphoric acid, nitric acid, hydrofluoric acid, hydrosilicofluoric acid and fluoroboric acid,  
     a step of treating said pH-adjusted aqueous wash with a first reverse osmosis membrane to separate it into a first filtrate and a first concentrate, and  
     a step of neutralizing said first filtrate with an alkali and treating the alkali-neutralized filtrate with a second reverse osmosis membrane to separate it into a second filtrate and a second concentrate,  
     said first concentrate being recycled for said phosphate chemical conversion,  
     said second filtrate being recycled as aqueous wash for said aqueous cleaning, and said second concentrate being discarded from the system.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to a method for recovery of aqueous wash in a phosphate chemical conversion and an apparatus for metal surface treatment.  
         PRIOR ART  
         [0002]    The phosphate chemical conversion has been frequently used in the pretreatment of shaped metal products prior to coating. In this phosphate chemical conversion, the shaped metal product must be cleaned with water after the chemical conversion treatment. This cleaning involves multi-stage washing with water and in the final stage of cleaning, fresh aqueous wash is used. The overflow of this water is recycled serially to the preceding stages and a portion of the washes from the first stage is discharged from the system, whereby the contaminant concentration of water in each stage is controlled so as to maintain a steady chemical conversion treatment. The aqueous wash from the first stage contain metal ions such as zinc, nickel and manganese ions, as well as ingredients of the phosphate chemical conversion such as phosphate ions, nitrate ions, hydrofluoric acid, hydrosilicofluoric acid, fluoroboric acid, etc., which, if discharged as they are, cause pollution of river and other water. Therefore, it is common practice to pool these washes with other plant effluents and subject the pooled water to flocculation-sedimentation or biological treatment before disposal.  
           [0003]    Referring to the aqueous wash produced in suchaphosphate chemical conversion, various methods utilizing reverse osmosis membranes for recovery of useful components and for reducing the amount of effluents have been reported. In order to improve the rate of recovery of useful components by a reverse osmosis technique, it already belongs to the known technology to install two reverse osmosis membrane modules in series so that the concentrated water produced in the first module is further treated in the second module to give a concentrated water and a filtrate. However, when the aqueous wash to be treated contains substances which will form precipitates on the membrane-water interface, such as metal salts, chances for precipitation of such substances on the membrane surface of the second reverse osmosis module are high so that the membrane flux of the second reverse osmosis module drops gradually. The resultant disadvantage is that the equipment cannot be operated on a steady basis for many hours.  
           [0004]    On the other hand, it is well known that in order to further improve the quality of the filtrate, the filtrate may be recycled to the first reverse osmosis module to thereby reduce the ion concentration of the aqueous wash to the first reverse osmosis module. Furthermore, Japanese Kokai Publication Hei-9-206749 discloses a method which comprises supplying an antiscaling agent to the water to be treated and adding an acid to the concentrate obtained in the first module before feeding it to the second reverse osmosis module. However, this method is disadvantageous in that a filtrate of good quality cannot be obtained, for instance. In addition, neither of these methods offers a solution to the problem of said build-up of precipitates on the membrane-fluid interface.  
         SUMMARY OF THE INVENTION  
         [0005]    The object of the present invention is to provide a method and an apparatus for efficient recovery of a useful component and production of a filtrate of improved quality by means of reverse osmosis membranes from the aqueous wash produced in a phosphate process for surface chemical conversion of a shaped metal product.  
           [0006]    The present invention is relates to a method for recovery of aqueous wash in a phosphate chemical conversion of a shaped metal product involving carrying out chemical conversion and subsequent cleaning with water,  
           [0007]    wherein said cleaning with water is performed in one or more stages and comprises  
           [0008]    a step of withdrawing aqueous wash from a first cleaning stage and adjusting the pH of the wash with at least one acid selected from the group consisting of phosphoric acid, nitric acid, hydrofluoric acid, hydrosilicofluoric acid and fluoroboric acid,  
           [0009]    a step of treating said pH-adjusted aqueous wash with a first reverse osmosis membrane to separate it into a first filtrate and a first concentrate, and  
           [0010]    a step of neutralizing said first filtrate with an alkali and treating the alkali-neutralized filtrate with a second reverse osmosis membrane to separate it into a second filtrate and a second concentrate,  
           [0011]    said first concentrate being recycled for said phosphate chemical conversion,  
           [0012]    said second filtrate being recycled as aqueous wash for said aqueous cleaning, and  
           [0013]    said second concentrate being discarded from the system.  
           [0014]    In said pH adjusting step, phosphoric acid may be used as the acid and the pH is adjusted to 2.0 to 3.0.  
           [0015]    The apparatus for metal surface treatment according to the present invention is for use in a phosphate chemical conversion of a shaped metal product, which comprises  
           [0016]    a phosphate chemical conversion means,  
           [0017]    a means for performing aqueous cleaning in one or more stages,  
           [0018]    a means for withdrawing aqueous wash from a first stage of said aqueous cleaning means and adjusting the pH of the aqueous wash with an acid selected from the group consisting of phosphoric acid, nitric acid, hydrofluoric acid, hydrosilicofluoric acid and fluoroboric acid,  
           [0019]    a first reverse osmosis membrane module for treating the pH-adjusted aqueous wash,  
           [0020]    a means for alkaline neutralization of a filtrate from said first reverse osmosis membrane module, and  
           [0021]    a second reverse osmosis membrane module for treating the alkaline-neutralized filtrate.  
           [0022]    In said apparatus for metal surface treatment, a concentrate from said first reverse osmosis membrane module may be recycled for said phosphate chemical conversion  
           [0023]    and a filtrate from said second reverse osmosis membrane module may be recycled as aqueous wash for aqueous cleaning.  
           [0024]    The aqueous wash mentioned just above may be from the last stage of aqueous cleaning.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0025]    [0025]FIG. 1 is a flow diagram showing an embodiment of the apparatus for metal surface treatment in accordance with the present invention.  
       BRIEF DESCRIPTION OF NUMERIC SYMBOLS  
       [0026]    [0026] 1 . boat-shaped chemical conversion tank  
         [0027]    [0027] 2 . first cleaning tank  
         [0028]    [0028] 3 . last cleaning tank  
         [0029]    [0029] 4 . pH adjusting tank  
         [0030]    [0030] 5 . pH control agent reservoir  
         [0031]    [0031] 6 . first reverse osmosis membrane module  
         [0032]    [0032] 7 . neutralizing tank  
         [0033]    [0033] 8 . alkali reservoir  
         [0034]    [0034] 9 . second reverse osmosis membrane module  
         [0035]    [0035] 50 . apparatus for metal surface treatment  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]    Generally in a metal surface treatment of shaped metal products, such as automotive bodies, the product is transported by conveyer means serially through the degreasing stage, aqueous cleaning stage, surface conditioning stage, chemical conversion stage, and post-conversion aqueous cleaning stage. The method for recovery of aqueous wash and the apparatus for metal surface treatment, both in accordance with the present invention, pertain to said chemical conversion treatment stage and post-conversion aqueous cleaning stage.  
         [0037]    The present invention is now described in detail, reference being had to FIG. 1 which shows an example of the apparatus for metal surface treatment according to the invention.  
         [0038]    A shaped metal product undergoing the conventional degreasing, post-degreasing aqueous cleaning and surface conditioning is dipped in a chemical conversion solution in a boat-shaped chemical conversion tank  1 , in which said chemical conversion is carried out. The chemical conversion reagent solution for use in this process is not particularly restricted as far as it contains a phosphate but may for example be a zinc phosphate agent.  
         [0039]    The shaped metal product  20  subjected to this chemical conversion treatment is transported by conveyer means to an aqueous cleaning stage comprising a plurality of cleaning tanks, namely a first cleaning tank  2  ˜ a last cleaning tank  3 , where it is invariably cleaned with water. This cleaning can be carried out by the full-dip method, the spray method, or a combination thereof. If necessary, the last cleaning tank may be provided with a mist sprayer or the like. In the above multistage aqueous cleaning system, the last cleaning tank  3  is supplied with a predetermined amount of fresh cleaning water through a pipe  18  and the water so supplied overflows to the preceding cleaning tank and finally reaches the first cleaning tank  2  (indicated by the dot line in the figure). The amount of fresh aqueous wash is so selected that the concentration of the chemical conversion agent in said first cleaning tank  2  will be equivalent to a 10-fold dilution of the original chemical conversion agent.  
         [0040]    In the present invention, the cleaning water overflowing the first cleaning tank  2  is fed through a piping 10 to a pH adjusting tank  4 . In this pH adjusting tank  4 , the water is adjusted to a pH value within the range of, preferably, 2.0 to 3.0 with an acid stored in a pH control agent reservoir  5 . Adjusting the pH to less than 2.0 is objectionable for the water exerts a deleterious effect on the reverse osmosis membrane. Exceeding pH 3.0 is also objectionable, for zinc phosphate and other precipitates are deposited on the reverse osmosis membrane. By controlling the pH of the cleaning water within the above-mentioned range, the rate of permeation of nitrate and sodium ions through the membrane in the first reverse osmosis membrane module can be properly controlled to provide a filtrate suited for reutilization in the chemical conversion stage. The acid mentioned above may be an aqueous solution of at least one of phosphoric acid, nitric acid, hydrofluoric acid, hydrosilicofluoric acid, and hydrofluoroboric acid, although an aqueous solution of phosphoric acid is preferred.  
         [0041]    The pH-adjusted water is fed through a piping  11  to the first reverse osmosis membrane module  6 . In this first reverse osmosis membrane module  6 , the pH-adjusted water is subjected to reverse osmosis to give a first filtrate and a first concentrate. The first concentrate is withdrawn through a concentrate withdrawal pipe  12  connected at one end to the concentrate outlet of the first reverse osmosis membrane module  6  and fed to the chemical conversion tank  1 , whereby it is reutilized as a chemical conversion agent.  
         [0042]    On the other hand, the first filtrate is fed to an alkaline neutralizing tank  7  through a first filtrate withdrawal line  13  connected at one end to the filtrate outlet of said first reverse osmosis membrane module.  
         [0043]    The reverse osmosis membrane of said first module has a sodium chloride rejection rate of not less than 50% as determined under the conditions of pressure 1.47 MPa, 1500 ppm NaCl in water and pH 6.5. When the rejection rate is less than 50%, heavy metals permeate through the membrane and enter into the filtrate. The upper limit, if imposed, may be not more than 99.5%. When this limit is exceeded, nitrate and sodium ions hardly permeate through the membrane.  
         [0044]    In the alkali neutralizing tank  7 , an aqueous solution of the alkali stored in the alkali reservoir  8  is introduced through a pipeline  14  to neutralize the first filtrate to pH 6.0 to 8.0. The alkali may for example be sodium hydroxide or potassium hydroxide, and is preferably sodium hydroxide.  
         [0045]    The first filtrate neutralized in the alkali neutralizing tank  7  is fed to a second reverse osmosis membrane module  9  through a pipeline  15 . Here, the neutralized first filtrate is fractionated by the second reverse osmosis membrane of the module  9  into a second concentrate and a second filtrate. The second concentrate is discarded from the system through a discharge line  16 . This second concentrate to be discarded is the water obtained by the neutralization and concentration of the acidic filtrate available from the first reverse osmosis membrane treatment, thus being water substantially free of the heavy metal and other substances derived from the main components of the chemical conversion reagent and its volume having been reduced to only as small as about one-tenth, at most, of the volume of the washes withdrawn. Therefore, this water can be pooled with other plant effluents and easily treated together without imposing any substantial burden on waste disposal.  
         [0046]    On the other hand, the second filtrate has an electrical conductivity of about several tens of μS/cm and can be utilized as cleaning water without an untoward effect. This second filtrate is fed to a an arbitrary stage-cleaning tank, preferably said last cleaning bath tank  3  as fresh aqueous wash through a second filtrate withdrawal pipeline  17  connected at one end to the filtrate outlet of said second reverse osmosis membrane module  9 . When a mist spray is utilized in the last aqueous cleaning stage, the second filtrate may be optionally pooled once, subjected to a higher-order treatment such as ion exchange treatment, and reused.  
         [0047]    The second reverse osmosis membrane should be a sodium chloride rejection rate of not less than 90% as determined under the conditions of pressure=0.74 MPa, 500 ppm NaCl/H 2 O, and pH 6.5. When the rejection rate is less than 90%, the filtrate has too a high electrical conductivity to be used as aqueous wash.  
         [0048]    The method for recovery of aqueous wash according to the present invention utilizes the first concentrate and the second filtrate and the recovery rate may be as high as not less than 90% of the volume of the cleaning water.  
         [0049]    According to the described method for recovery of aqueous wash as applied to the reverse osmosis membrane treatment of washes in the phosphate process for surface chemical conversion of shaped metal products, the useful components in the washes can be efficiently recovered and, at the same time, a filtrate water of high quality could be obtained by adjusting the pH of the washes and of the filtrate.  
       EXAMPLES  
       [0050]    The following examples illustrate the present invention in further detail and should by no means be construed as defining the scope of the invention.  
       Example 1  
     Recovery of aqueous wash- 1   
       [0051]    A zinc phosphate chemical conversion solution (5 L) of the ion composition shown in Table 1 was diluted with 45 L of industrial water (pH 6.8) having an electrical conductivity of 234 μS/cm and the dilution was used as a model water overflowing the first cleaning tank. This model aqueous wash was adjusted to pH 2.5 with phosphoric acid and subjected to a first reverse osmosis membrane treatment with Membrane Master RUW-5A (Nitto Denko) using a commercial LF10 membrane module under the conditions of treating temperature: 25 to 30° C., pressure: 1.0 to 1.1 MPa, concentrate recycling flow rate: 6.2 to 6.3 L/min, filtrate flow rate 0.3 to 0.6 L/min to give 5 L of a first concentrate and 45 L of a first filtrate. The first filtrate thus obtained was adjusted to pH 6.2 with an aqueous solution of sodium hydroxide and subjected to a second reverse osmosis membrane treatment using Membrane Master RUW-5A (Nitto Denko) having a commercial ES20 membrane module as the second reverse osmosis membrane module under the conditions of treating temperature: 25 to 30° C., pressure: 1.1 to 1.2 MPa, concentrate recycling flow rate: 6.1 to 6.2 L/min, and filtrate flow rate: 1.2 to 1.4 L/min to give 4.5 L of a second concentrate and 40.5 L of a second filtrate. The analyzed ion compositions of the first filtrate, first concentrate, second filtrate and second concentrate are shown in Table 1.  
         [0052]    The first concentrate obtained could be reused as the chemical conversion agent and the second filtrate could be reused as aqueous wash. The electrical conductivity was measured with Conductivity Meter DS-12 (Horiba) and the ion concentration was measured with Ion Chromatograph Series 4000 (Dionex) or Atomic Absorption Spectrometer 3300 (Perkin Elmer).  
                                                                                                                     TABLE 1                           Zinc   Model water after   First       First filtrate after   Second   Second       Kind of water   phosphate   pH adjustment   concentrate   First filtrate   neutralization   concentrate   filtrate                                pH   3.1   2.5   2.5   2.4   6.2   6.7   6.1       Electrical   19480   3830   14330   2320   848   5060   66       conductivity       (μS/cm)            Ion composition (ppm)            Zn ion   1310   135   1010   0.3   0.2   1   0       Ni ion   950   99.5   650   0   0   0.7   0       Mn ion   450   52.5   356   0.1   0   0.4   0       F ion   1000   99.1   910   79.3   77.5   94.6   3.6       Na ion   2670   284.5   1970   8.3   132   900   4.9       Si ion   308   33   210   0   0   3.1   0       Al ion   119   79   55.9   0   0   0   0       NO 3  ion   9130   769   3077   368   352   2275   6       PO 4  ion   15616   2486   18596   11.3   81   51.9   1.1                  
 
       Examples 2 and 3  
     Recovery of washes- 2  and - 3   
       [0053]    The phosphate chemical conversion agents (5 L each) of the ion compositions indicated in Tables 2 and 3 were respectively diluted with 45 L of the same industrial water as used in Example 1 and the dilutions were used as model waters overflowing the first cleaning tank. Except that each model water was adjusted and neutralized to the pH value indicated in Table 2 or 3, the procedure of Example 1 was otherwise repeated. The ion compositions are shown in Tables 2 and 3. As in Example 1, a concentrate which could be reused as a chemical conversion agent and a filtrate which could be reused as an aqueous wash were obtained.  
                                                                                                                     TABLE 2                           Zinc   Model water after   First       First filtrate after   Second   Second       Kind of water   phosphate   pH adjustment   concentrate   First filtrate   neutralization   concentrate   filtrate                                pH   3.2   3   3.35   2.7   6.4   6.8   5.9       Electrical   23900   3440   15540   1096   515   3590   34.1       conductivity       (μS/cm)            Ion composition (ppm)            Zn ion   1120   110   755   0.2   0.3   1.7   0       Ni ion   515   52.5   346   0   0   0.8   0       Mn ion   339   32.6   239   0   0   0.5   0       F ion   1020   100   583   44   41   456   1.7       Na ion   4300   445   2620   25   65   213       Si ion   158   21   131   0   0   1.6   0       Al ion   23   2.5   1.9   0   0   0   0       NO 3  ion   11041   1063   5313   213   213   2125   6       PO 4  ion   15934   1768   12368   4   4   25   0.6                  
 
         [0054]    [0054]                                                                                                                     TABLE 3                           Zinc   Model water after   First       First filtrate after   Second   Second       Kind of water   phosphate   pH adjustment   concentrate   First filtrate   neutralization   concentrate   filtrate                                pH   3   2.9   3.4   2.5   6.2   6.8   5.9       Electrical   22000   3290   15300   1503   673   4090   25.8       conductivity       (μS/cm)            Ion composition (ppm)            Zn ion   1045   98   670   0.2   0.2   1.4   0       Ni ion   770   76   670   0   0   1   0       Mn ion   590   55   364   0   0   0.6   0       F ion   1076   105   752   47   42   101   1.8       Na ion   3820   412   2560   20   86   635   3.2       Si ion   223   24   172   0   0   0   0       Al ion   21   1.8   15   0   0   0   0       NO 3  ion   11875   1175   6750   313   258   1300   6       PO 4  ion   13139   1613   12224   5   6   32   1                    
       Example 4  
     Study of the adjusted pH of washes  
       [0055]    The same model water as used in Example 1 were adjusted to the pH values shown in Table 4 and subjected to the first reverse osmosis membrane treatment in the same manner as in Example 1. The results are shown in Table 4.  
                                   TABLE 4                                   pH as adjusted   3.1   3.0   2.9                           pH of the first concentrate   3.4   3.3   3.3           pH of the second concentrate   2.3   2.7   2.5           Formation of crystalline   Some   None   None           precipitates                      
 
         [0056]    When the model water was adjusted to pH 3.1 and subjected to the first reverse osmosis membrane treatment, crystals of zinc phosphate were observed on the reverse osmosis membrane.  
       Example 5  
     Study of pH adjusted by alkaline neutralization  
       [0057]    The first filtrate in Example 1 were adjusted to the pH values indicated in Table 5 and subjected to the second reverse osmosis membrane treatment as in Example 1. The results are shown in Table 5.  
                                                                       TABLE 5                                       Electrical conductivity   Relative electrical           (μS/cm)   conductivity,                pH as   Aqueous   Filtrate   filtrate/aqueous wash           adjusted   wash   water   (%)                            2.5   1046   655   39.2           3.0   609   390   37.2           4.0   451   106   79.2           6.0   453   43   91.8           7.0   471   21.9   96.0           8.0   479   8.7   98.2                      
 
         [0058]    By neutralizing the filtrate from the first reverse osmosis membrane module, a filtrate of high quality could be obtained. Particularly, when the pH of the filtrate was pH 6.0 or higher, the electrical conductivity could be reduced to 50 μS/cm or less.