GM Corp.

OXSILAN - Update
Chemetall

iStockphoto

Page 1

France
30. March 2010
Thomas Willumeit

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process
Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 2

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 3

Cleaning - Basics

links: fettfrei
Clean
surface,
water break-free

Page 4

rechts: fettige Oberflche

Oily surface
with water-breaks

Cleaning - Basics

Substrate

after
cleaning

Substrate

Cleaning steps are required to remove

- particles (welding / sanding beads, dust from sand blasting etc.)
- oil

- grease

Good cleaning is the basis for good testing results

Page 5

untreated steel panel

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 6

FePh - Basics

Paint

Substrate

PO43-

Page 7

Fe

Ph

PO43-

Coating weight
Coating thickness
Composition
Morphology
pH range

0,1 1,0 g/m

0,1 0,8 m
Fe-Phosphate
amorphous
4,5 6,0

FePh pretreated steel panel

FePh Line Layout (2 Examples)

Cleaner

FePh

Heating energy consumption

Water consumption
Effluent generation
Full multi-metal process
Short process (no Activ. / Passiv.)
Testing performance
Process monitoring

FePh

Rinse

FePh

Rinse

Rinse

DIW Rinse

DIW Rinse

Process costs
Chemical consumption
Low sludge generation
No heavy-metal ions (Ni, Cr,)
Working temperature

30- 70C

Contact Time

90 - 180

Simple process for mean specifications

Page 8

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 9

ZnPh - Basics

Paint

Substrate

PO43-

Page 10

Fe

ZnPh
Zn2+

Coating Weight
Coating Thickness
Composition
Morphology
pH range

1,5 4,5 g/m

1 2 m
Hopeite, Phosphoph.
cristalline
2,8 3,3

ZnPh pretreated steel panel

ZnPh Line Layout (Example)

Cleaner

Rinse

Heating energy consumption

Water consumption
Effluent generation
Full multi-metal process
Short process (no Activ. / Passiv.)
Testing performance
Process monitoring

Activate

ZincPhosphate

Rinse

Process costs
Chemical consumption
Low sludge generation
No heavy-metal ions (Ni, Cr,)
Working temperature
Contact Time

High quality technology with some disadvantages

Page 11

Passivate
(optional)

DIWRinse

48- 55C
120 - 180

SHE - Ratings of Nickel Salts in Mixtures

Ni hazard under consideration:

Germany
Water Hazard Class

Typical trication phosphate bath: WGK 1

will remain unchanged under the
31th ATP
Typical trication phosphating conc.: WGK 2 will
be WGK 3 under the 31th ATP

carcinogen
mutagen
reproductive toxicant
environmental toxicity
sensitization (metallic)
Risks caused by Ni

during pretreatment
when coating is sanded
in effluents

Europe
31th ATP proposes all nickel salts

(PO42-, NO3-,Cl-,SO42-):
Carcinogen, Cat. I: R49
May cause cancer by inhalation
Repro-toxic, Cat. 2: R61
May cause harm to the unborn child
Mutagen, Cat. 3: R68
Possible risk of irreversible effects
Corresp. classification for all Ni comp. proposed

USA
(Environmental Protection Agency /
EU Adaption Directive to Techn. Progress)
Page 12

EPA studies nickel toxicity

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process
Basics

Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 13

OXSILAN - Basics

Paint
Substrate

Coating weight
Coating thickness
Composition
Morphology
pH range

Page 14

30 - 200 mg/m
in nm scale
Silane polymere, Zr
amorphous
3,8 4,8

OXSILAN pretreated
steel panel

OXSILAN Line Layout (Example)

Cleaner

Rinse

Heating energy consumption

Water consumption
Effluent generation
Full multi-metal process
Short process (no Activ. / Passiv.)
Testing performance
Process monitoring

DIW Rinse

OXSILAN

Process costs
Chemical consumption
Low sludge generation
No heavy-metal ions (Ni, Cr,)

Working temperature

20 - 45C

Contact Time

30 - 240

High potential ZnPh replacement process

Page 15

DIWRinse

OXSILAN Visual Appearance

Page 16

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process
Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 17

OXSILAN - Basis of Chemistry

Molecular Base Structure
O
C Si O
O
C

Si

O
C

Silane

Silicone

R
O

OXSILAN Production

R' C Si O R
O
R

Si O
O

Silicate

Hydrolysis

H
O

Condensation

R' C Si O H
O
H

O
R' C Si O
O
H

Chemistry completely different to Silicones or Silicates

Page 18

H
O
Si C R'
O

OXSILAN - Basis of Chemistry

Cross linking to E-Coat
Silane with functional group

Epoxy resin

H
n

N H

O
Si O

Amine modified epoxy resin (-polyepoxyde)

H
O

HO

Si O
O

Page 19

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process
Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 20

OXSILAN - Rinse Water Control

maintain bath level

Cleaner

fresh DIW

Rinse

DIW
Rinse

Waste water treatment

maintain bath level

fresh DIW

OXSILAN

Waste water treatment

fresh DIW

Cleaner

Rinse

DIW
Rinse

fresh DIW

OXSILAN

Waste water treatment

Less water consumption, less waste water

Page 21

Rinse

Rinse

OXSILAN - Waste Water Situation

Silanes are fully condensed and absorbed to the generated precipitation
when treated with milk of lime or caustic solution*.
(i.e. Silane < 0,1 ppm, Zr < 0,1 ppm, F < 5 ppm, Fe < 0,1 ppm)
Hydrolised (condensed) Silanes can be considered as polymeres. After the
mentioned effluent treatment there are no subject to legal restrictions.
There are no country-specific limits for Silanes respectively Polysiloxanes

* 0,2 L/m 40% FeCl3solution and milk of lime to pH 8,5 - 9,5

Uncomplicated discharge after precipitation with milk of lime

Page 22

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process
Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 23

OXSILAN - Product Family

Prior to Paint
OXSILAN System

Constituents

Application

Most suitable Paint

Substrates

Replaces

OXSILAN
OXSILAN
OXSILAN
OXSILAN
OXSILAN
OXSILAN
OXSILAN
OXSILAN

Silane
Silane
Silane + Inorganics
Silane + Inorganics
Silane + Inorganics
Silane + Inorganics
Silane + Inorganics
Silane + Inorganics

Spray / Dip
No-Rinse
Spray / Dip
Spray / Dip
Spray / Dip
Spray / Dip
Spray / Dip
Spray / Dip

Powder, Liquid
Powder, Liquid
Powder, Liquid
E-Coat
Powder
E-Coat
All
E-Coat

Mg
Multi-Metal
Multi-Metal
Multi-Metal
Steel, AL
Multi-Metal
mainly Alu
Multi-Metal

ZnPh
ZnPh
ZnPh
ZnPh
ZnPh
ZnPh Autom.

MG-0610
MM-0706
9810/1
9810/2
9810/3
9810/4
9812/1
9831

Bare Corrosion Protection

OXSILAN System

Constituents

Application

Substrates

OXSILAN MG-0610
OXSILAN 9850

Silane
Silane + Inorganics

Spray / Dip
Spray / Dip

Mg
Steel

Metal-free products available

Page 24

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process
Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 25

Estimated Cost Savings (OXSILAN vs. ZnPh)

3,15

max.

2,7

Euro / 100 m

min.
2,4
1,44

2,1
1,8
1,5

0,80
1,2
0,54

0,9
0,6
0,3

at
h
(b

0,23

0,08

al

0,03

ci
rc
ul
at
io
n)
Ri
Ph
ns
os
in
ph
g
at
w
e
at
Ne
s
er
ut
lu
dg
ra
li s
e
at
di
sp
io
n
os
sl
al
ud
ge
M
ai
di
nt
sp
en
os
an
al
ce
(b
oi
l -o
ut
s)

gy
en
er
in
g

0,12

To
t

0,15

en
er
gy

He
at
c
tri
El
ec

0,96

0,06
0,35

Page 26

0,17

0,14

OXSILAN - Process Cost Savings

Potential cost savings with OXSILAN for new plant
Installation costs
(shorter pre-treatment, no activation/passivation)
Energy costs
(less agitation and heat exchanger operations in OXSILAN bath)

Water costs
(waste water treatment, capacity)
Total savings

12%

3%

5%

20%

20% investment savings on new plants due to OXSILAN Technology

Page 27

OXSILAN - Required Resources

Energy and water consumption per 100 m

Energy consumption

(kWh)

Water consumption
(Liter)

Zinc-Phosphate
Process

OXSILAN

57 kWh

35 kWh

~ 250 L

~ 75 L

Savings potential with OXSILAN: 60% Energy and 70% Water

Page 28

OXSILAN - Process Cost Savings

Energy and water consumption per 100 m (in Euro)

Zinc-Phosphate

Process
Energy consumption

OXSILAN

3,42

2,10

0,38

0,11

3,80

2,21

( 0,06 Euro per kWh)

Water consumption
1,50 Euro per m (water mix)

Total costs

60% process cost savings with OXSILAN (40% Energy and 70% Water)
Page 29

OXSILAN - Process Cost Savings

Potential cost saving with OXSILAN - practical experience*
Reduction of heating energy in phosphating bath (bath size 10 m3)
No disposal costs for sludge

90 k EUR
5 k EUR

Reduction of VE water consumption

15 k EUR

Reduction of heater circuit maintenance

30 k EUR

No acid rinsing with extra manpower

25 k EUR

No electrical energy

20 k EUR

Savings in waste water treatment

175 k EUR

Total cost reduction due to OXSILAN

360 k EUR

* German automotive components manufacturers

OXSILAN offers high potentials on savings

Page 30

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 31

OXSILAN - Testing Results General Industry

OXSILAN as ZnPh replacement
CRS + Powder Paint
SST:
CH 240h:

1008 h <2,0 mm
U0 / GT 0

CRS + E-Coat
SST:

1008 h = 2,0 mm

CRS + E-Coat + Powder Paint

SST:

1008 h = <1,0 mm

HDG + Powder Paint

ESS:

504 h = <1,0 mm

AL + Powder Paint
CASS:

Page 32

504 h = <1,0 mm

OXSILAN - Testing Results Automotive

Z

ZnPh

ZF

ZE

OXSILAN

ZnPh

CRS

OXSILAN

ZnPh

Al

Product:
Paint:

Tests:
ZnPh

OXSILAN

OXSILAN

ZnPh

OXSILAN 9830 +
Additive H 9906
E-Coat, Primer,
Topcoat, ~ 100 m
Outdoor Exposure +
NaCl, 12 Months

OXSILAN

Outdoor exposure testing results comparable to ZnPh process

Page 33

OXSILAN - Testing Results Automotive

CASS
(mm, 240 h)

VDA Cycle Test

(mm, 10 Cycles)

CRS

ZE

0
ZnPh

9812

9810/1

9830
GTP
10818

ZnPh

9812

9810/1

GTP
10818
9830

Wet Adhesion
(Gt Note)

Al
1
0
ZnPh

VDA Stone Chipping

(Note, 10 Cycles)

9812

9810/1

GTP
10818
9830

Outdoor Exposure
(mm, 1 year)

5
4

3
2

1
0

ZnPh

Page 34

9812

9810/1

GTP
10818
9830

ZnPh

9812

9810/1

GTP
10818
9830

OXSILAN - Testing Results Automotive

Constant humidity climate acc. DIN EN ISO 6270-2 (240 h CH + 24 h RT)
AA 6014

AA 6016

not grinded

grinded

not grinded

grinded

GT 0 bis GT 1

GT 0

GT 0

GT 0

CASS Test acc. DIN EN ISO 9227 (504 h)

AA 6014
Not grinded

AA 6016
grinded

not grinded

grinded
U 1 bis U 1,3

U <1

U 1,5 to U 2,3

U <1 to U 1

U 2,5 to U 3

U <1

U <1 to U 1

U <1 to U 1

U <1 to U 1,3

Page 35

OXSILAN Potential of Technologie

mm

6
5
4
3
2

Maximum

1
0

Average
Without Silane

With Silane

Creepage on CRS + Zr-based Pretreatment + E-Coat after 15 Cycles GMW 14872

Polysiloxanes offer the chance to further improve performance

of Thin Film Technology specifically on Cold Rolled Steel

Further improvements in testing performance expected

Page 36

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 37

OXSILAN Case Study: Trailer Chassis

Steel trailer chassis and Aluminum components:
OXSILAN 9810/1 + E-Coat + Powder Coat
In operation: since June 2008
Customer: Brggen Fahrzeugwerk & Service
GmbH, Lbtheen, Germany
Process cost savings: >150.000 Euro p.a.
Chemetall

Advantages:

Cool Liner Trailer of Fahrzeugwerk Bernard KRONE GmbH

Lower investment required for new production plant

Higher production rate
50% reduction in fresh and waste water by using a

cascade rinse system

Significant reduction in energy use as no heating
required
Simple filtration treatment sufficient for waste water
Multi-metal process: steel chassis and aluminum
profiles are pretreated in the same line

Page 38

OXSILAN Case Study: Opel Insignia Axles

Front and rear axes of Opel Insignia:
OXSILAN 9820 + E-Coat DuPont EC 3000
In operation: since February 2009

Process meets GM specs GMW 14671

Customer: Adam Opel GmbH,
Kaiserslautern, Germany
Process cost savings: six figure range
Advantages:
30% productivity increases
No heating for phosphate stages
Intelligent recycling of rinse water
No separate waste water treatment required
Quality corresponds to ZnPh

Page 39

GM Corp.

OXSILAN Case Study: Motorbikes

Motorbikes:
OXSILAN 9810/2 + OXSILAN Additive 9905
In operation: since January 2007

Customer: Yamaha, Barcelona, Spain

Production: 600 700 motorbikes/day
Process cost savings : 90.000 /year

Yamaha

Advantages:
Lower investment of new production plant
Reduction of residues
Less CO2 emission
Improved working conditions
Easiest process control

Page 40

Chemetall

OXSILAN Case Study: Washing Machine Housing

Washing machine housing:
OXSILAN 9810/1 + E-Coat + Powder Coat
In operation: since January 2008
Customer: Electrolux, Alcal de Henares, Spain
Total process cost savings:
76.000 /year 2,6 per 100 m
Chemetall

Advantages (per year):

Maintenance: No filter press, no acidic cleaning,

no maintenance for cleaning nozzles and no sludge

removal required (12.000 )
Energy savings: 41.000 energy savings as no
heating necessary and 8.000 in electricity savings
Environmental aspects: reduced water consumption
6.000, reduced atmospheric emissions, less
packaging, reduction in harmful metals, less sludge
and fewer residues

Page 41

Oxsilan Case Study: Agriculture

Harvest machine for agriculture
Oxsilan 9810/3 + Powder Coating
In operation: since April 2009
Customer: Case New Holland, Belgium
Process cost savings: 30.000 Euro
Advantages:

Page 42

- 15% energy saving

- 17% cleaning + sludge
- 18% waste water
- 50% costs for chemicals

Case New Holland

OXSILAN Case Study: Oil Filter Housing

Housing for oil filter:
OXSILAN 10738 + Liquid Coating
In operation: since April 2008

Customer: Mann+Hummel, Marklkofen, Germany

Advantages:
Environmental aspects: no phosphate sludge,

Page 43

no hazardous heavy metals,

simple waste water treatment
Improved quality
Energy savings
Less maintenance per quarter
Simplified process, increased productivity

OXSILAN Case Study: Car Body

Car bodies
Peugeot 407 und Citron C5
OXSILAN + E-coat
In operation: since August 2009
Customer: PSA, Rennes, France
Citron

Advantages:
Less energy costs (heat + pump energy)
No phosphate sludge disposal
Nickel-free process
Simplified process

Page 44

OXSILAN Case Study: Car Body

Replenishing
OS 9831
OS 9907R

D1

D2

D3

R1

R2

R3

OXSILAN

R4

R5

empty

R6

Bag filter

DIW Cascade

GC S 5176

OS 9831

SOP: Week 35, 2009

Models: Citren C5, C6 and Peugeot 407
Substrates: HDG 90%, Al 5%, CRS 5% (inside body parts)
OXSILAN 9831 with 2 replenishing components (OS 9831 & OS 9907 R)
E-Coat: BASF Cathoguard 500
Production: 700 units / day in 2 shifts
Testing results within specs
Throw power performance and E-Coat distribution within specs

>70.000 cars produced by end of Jan. 2010

Page 45

DIW Cascade

R7

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 46

Agenda
Cleaning Process

(Basics)

FePh Process

(Basics)

ZnPh Process

(Basics)

OXSILAN Process

Basics
Basis of Chemistry
Rinse Water Control / Waste Water
Product Family
Cost Savings
Testing Results
Case Studies
Status of the OXSILAN Technology / References

Summary

Page 47

Summary

Advantages

ZnPh

Well tested
High quality
Global standard

Disadvantages
Contains heavy metal ions (Ni, Zn,)
Limited in throughput of Aluminium

Disadvantages
Good cleaning (rinsing) required

Advantages

OXSILAN

Drop-in replacement in existing lines

Smaller footprint of new lines
Full multi-metal process (no limits in %Al)

Free from hazardous metals such as Ni, Cr,

Low water consumption (~75 L/100 m)

Energy consumption (~57 kWh/100 m)

Low amount of effluent (~25 L/100 m)

Water consumption (~250 L/100 m)

Virtually free of sludge (< 0,2 g/m of

Amount of effluent (>100 L/100 m)

Produces sludge
(3 bis 12 g/m of material throughput)
Activation (Passivation) required
Complex to operate
High demand for human resources

(Chemical) line cleaning required

Page 48

material throughput)
Low energy consumption (less heating,
less pumps)
No activation, passivation, accelerator
No hazardous acidic cleaning required
Less demand for human resources
Phosphate-free
Process cost savings 1 3 /100 m

Summary
OXSILAN technology
Reduce process costs, increase productivity
Comply with increasing environmental aspects
Meet high quality standards

Close to 200 customers worldwide confirm product quality

Europe (France, Germany, Italy, Portugal, Spain, Sweden, Turkey, UK), Americas (USA,

Brasil, Mexico), Asia / Pacific (Australia, China, Indonesia, India, New Zealand)
Industries: Automotive, Automotive Components, Heavy Equipment, General Industry,

Electronics, Job Coaters etc.

Prior to E-Coat, powder paints, liquid paints and paint systems
Joint test programs started with most OEMs in early 2007
Car body line trials conducted with FIAT, Renault, PSA, Daimler, BMW, AUDI, VW

Several SOPs in Automotive / Automotive Component Industry

Opel Germany (components), Brggen Germany (truck trailers), PSA France (car bodies)

Next Steps in 2010/2011: Convert lines at PSA, Daimler, Renault, FIAT, DAF
More than 70.000 cars pretreated with OXSILAN on the road in Europe
Page 49