Metal cleaning agent development method II

The development of metal cleaning agents is a systematic and complex process, involving multiple aspects of consideration and operation.

First, the importance and integrity of the development process

1. Basic planning

<!--[if !supportLists]-->·       <!--[endif]-->Defining the cleaning object, requirements and dosage form is the beginning of development. This link is like the blueprint planning of the building, determining whether the requirements such as rust removal or oil removal are determined, and setting the direction for the subsequent work. In metalworking, for example, this initial decision will guide the entire development direction for different metal products and dirt types.

<!--[if !supportLists]-->·       <!--[endif]-->Data search and market research are key to avoiding duplication of effort and positioning products accurately. By searching for relevant information and patents, we can understand the development level of the existing technology, and at the same time conduct market research to grasp the market demand for metal cleaning agents in terms of performance, price, environmental protection, etc., so as to provide a basis for product research and development and ensure that the developed products are competitive in the market.

2. Construction of core links

<!--[if !supportLists]-->·       <!--[endif]-->The determination of cleaning process and evaluation method is the core link of development. Establish appropriate laboratory performance evaluation methods, such as cleaning power, corrosiveness, rust resistance, etc., to accurately measure the performance of cleaning agents. It's like establishing a precise testing standard for a product, and only by this standard can the qualified formula be screened out.

<!--[if !supportLists]-->·       <!--[endif]-->The determination and analysis of the basic composition is an important reference for the construction of formulas. Determining the basic components of the cleaning agent and dissecting the sample if necessary can determine which main components are needed, such as surfactants, alkaline and alkaline salts, rust inhibitors, etc., to lay the foundation for the initial formulation construction.

3. Recipe optimization and validation

<!--[if !supportLists]-->·       <!--[endif]-->Formulation screening and basic formulation establishment involve the complex selection and proportioning of multiple ingredients. Screening and proportioning of numerous surfactants, alkalis and alkaline salts and other ingredients to find a preliminary feasible basic formula through a large number of experiments. It's a process of trial and error, and it takes into account the interactions and influences of the various ingredients.

<!--[if !supportLists]-->·       <!--[endif]-->Field application testing and validation is the bridge from the laboratory to the actual application. Testing the basic formula in a real-world use scenario can uncover problems and deficiencies that cannot be exposed in a laboratory environment, such as in an actual metalworking shop, where different metal materials, dirt levels, cleaning equipment, etc., may be encountered, which can affect the effectiveness of the cleaning agent.

<!--[if !supportLists]-->·       <!--[endif]-->Formulation improvement and styling should take into account performance and price. Based on the results of field application trials, the formulation is improved to achieve the best performance of the product, while also considering the cost factor to ensure that the product is competitive in the market. For example, if an ingredient improves performance but costs too much, you need to look for more cost-effective alternatives.

4. Product improvement and market access

<!--[if !supportLists]-->·       <!--[endif]-->The measurement of performance indicators and the test of use conditions provide users with accurate usage guidelines. Determine the performance indicators of the product, such as PH value, high and low temperature stability, etc., and determine the precautions under different use conditions, such as the best use temperature, cleaning time, etc., which helps users to use the product correctly and improve the use effect and life of the product.

<!--[if !supportLists]-->·       <!--[endif]-->The field application scale-up test further verifies the feasibility and stability of the product. Test products in larger-scale real-world application scenarios to ensure that there are no problems during mass production and use, such as trials in large metal processing companies to verify the performance and stability of products in large quantities.

<!--[if !supportLists]-->·       <!--[endif]-->The drafting of enterprise standards regulates the production and quality control of products. Through the formulation of enterprise standards, clear product quality requirements, production processes, inspection methods, etc., to ensure the quality of products is stable and reliable, but also to provide a basis for the production management of enterprises.

<!--[if !supportLists]-->·       <!--[endif]-->Promotion, application and technical services are the key steps for products to enter the market. Through the promotion of products, trial marketing and the provision of technical services, let users understand and accept the products, solve the problems encountered by users in the process of use, and improve the reputation and market share of the products.

<!--[if !supportLists]-->·       <!--[endif]-->The identification and sale of new products marks the final completion of product development. After strict appraisal, the product meets the sales conditions, officially enters the market, and realizes the transformation from R&D to the market.

2. Careful consideration of the characteristics and components of water-based metal cleaning agents

5. The comprehensiveness of the feature requirements

<!--[if !supportLists]-->·       <!--[endif]-->The good surface activity of metal cleaners is the basis for effective cleaning. With the ability of wetting, solubilization and emulsification, it can make the cleaning agent better contact with the oil stain and remove it, and at the same time, there is no oil film or oil spot after cleaning, ensuring the high quality of the cleaning effect.

<!--[if !supportLists]-->·       <!--[endif]-->Non-corrosive to metal and maintaining luster is an important requirement for the protection of metal products. In the cleaning process, the cleaning agent can not cause damage to the metal, and the cleaned metal surface should maintain the original luster, which is particularly important for some metal products with high requirements for appearance, such as precision instruments, decorations, etc.

<!--[if !supportLists]-->·       <!--[endif]-->A certain anti-rust ability prevents the metal from rusting. After cleaning, the metal will not appear rust spots when the supply and demand are transferred during processing, and no additional anti-rust treatment is required, which not only facilitates the production process, but also reduces production costs.

<!--[if !supportLists]-->·       <!--[endif]-->Good process performance makes cleaning operation convenient and efficient. It is easy to operate, low in temperature, easy to wash clean, does not pollute the environment and is convenient for the treatment of three wastes, which meets the requirements of modern industry for environmental protection and efficient production. For example, low operating temperatures reduce energy consumption, and easy cleaning reduces the number of post-cleaning treatment steps.

6. Scientific consideration of components

<!--[if !supportLists]-->·       <!--[endif]-->The choice of surfactant depends on the structure of the dirt and a variety of factors. Aliphatic or aromatic derivatives with aliphatic hydrocarbons are selected as surfactants, depending on the main composition of the dirt to be cleaned, and the HLB value is controlled between 8 and 16. At the same time, considering that the compound effect of a variety of surfactants is better, it is also necessary to take into account the resource and cost factors, and choose commonly used surfactants such as triethanolamine oleate and alkyl phosphate to achieve the best cleaning effect.

<!--[if !supportLists]-->·       <!--[endif]-->The effects of alkalis and alkaline salts coexist with limitations. Alkali and alkaline salts can have a significant cleaning effect on dirt such as animal and vegetable oils and fats, but have a corrosive effect on some metals. Therefore, when selecting, it is necessary to weigh according to the metal material of the cleaning object, and the commonly used caustic soda and sodium carbonate have different applicability in different cleaning scenarios.

<!--[if !supportLists]-->·       <!--[endif]-->Anti-rust and corrosion inhibitors meet the dual needs of cleaning and rust prevention. It contains two types of inorganic and organic anti-rust and corrosion inhibitors, which can be used in combination, such as sodium nitrite, sodium benzoate, etc. These corrosion inhibitors can ensure that there is no corrosion to the metal during cleaning, and form a protective film on the metal surface after cleaning, which plays a role in corrosion inhibition and rust prevention.

<!--[if !supportLists]-->·       <!--[endif]-->The choice of defoamer takes into account the ability to remove grease stains. Since low foaming or no foaming is required for cleaning, it is necessary to add defoamers, such as polyether 2010, tributyl phosphate, etc. However, when screening defoamers, consider their impact on the ability to remove grease stains to ensure that the foam is eliminated without compromising the cleaning effect.

3. The accuracy and completeness of the cleaning effect measurement method

7. Standardization of metal specimen preparation

<!--[if !supportLists]-->·       <!--[endif]-->Detailed specifications and dimensions are specified for a variety of metal specimens, such as 50mm×50mm× (3 - 5) mm for 45 gauge steel sheets, and there are strict grinding, cleaning and drying steps. These standardized practices ensure the consistency and accuracy of the specimens, providing reliable samples for subsequent tests.

8. The pertinence of the preparation of the test solution

<!--[if !supportLists]-->·       <!--[endif]-->According to different test types, distilled water or deionized water is prepared at 3% for corrosiveness, rust resistance, etc., and 250mg/kg hard water is prepared at 3% for cleaning power, foam and other tests. This targeted preparation of test solution can more accurately simulate the actual cleaning environment and conditions, making the test results more valuable for reference.

9. Meticulous process for determining cleaning power

<!--[if !supportLists]-->·       <!--[endif]-->The pendulum washing machine is used to measure the cleaning power, and the swing frequency of the pendulum washing machine is specified to be (40±2) times/minute, and the swing distance is (50±2) mm, and the detailed steps such as preparation, coating, test procedure, cleaning power calculation and result evaluation of artificial oil stain are also included. This meticulous process ensures the accuracy and reproducibility of the cleaning power determination, providing a reliable way to evaluate the cleaning capacity of the cleaning agent.

10. Systematization of other performance tests

<!--[if !supportLists]-->·       <!--[endif]-->The corrosivity test evaluates the corrosivity by immersing the metal specimen in a certain temperature of the cleaning solution and observing the changes in the appearance and quality of the specimen, and there are detailed test procedures and result evaluation standards. This test accurately assesses the degree of corrosion of the cleaning agent to the metal, ensuring that the product does not cause damage to the metal during use.

<!--[if !supportLists]-->·       <!--[endif]-->In the rust resistance test, the test piece is immersed in the test solution, then dried, put into the humid heater, etc., and finally the appearance is checked and evaluated according to the standard. This kind of rust resistance test simulates the actual environment, which can effectively test the rust resistance of the cleaning agent.

<!--[if !supportLists]-->·       <!--[endif]-->The foam performance test is measured by a Roche foam meter, which requires the metal cleaning agent to be low foam and has a specific foam height standard. This test ensures that the cleaning agent does not produce too much foam during use, which affects the cleaning effect and the normal operation of the cleaning equipment.

<!--[if !supportLists]-->·       <!--[endif]-->The high and low temperature stability test includes a high temperature test (60 degrees Celsius constant temperature water bath for 6 hours) and a low temperature test (minus 5 degrees Celsius refrigerator for 24 hours) to observe the appearance change. This test can check the stability of the cleaning agent in different temperature environments to ensure that the product can be used normally in different use environments.

<!--[if !supportLists]-->·       <!--[endif]-->The determination of water volatiles determines the moisture and volatile content by calculating the weight loss number after drying the sample in an oven. This assay helps to understand the stability and quality of the product, ensuring that the product will not be affected by water volatiles during storage and use.

<!--[if !supportLists]-->·       <!--[endif]-->In the rinsing performance test, the specimen is immersed in the test solution, dried and washed in distilled water, and finally the appearance of the specimen is checked. This test can be used to check whether the cleaning agent is easy to rinse clean after cleaning and to avoid the adverse effects of residual cleaning agent on the metal products.

<!--[if !supportLists]-->·       <!--[endif]-->The pH value is measured by a PH meter or PH paper, and there are different PH requirements for detergents used for different metals. This determination ensures that the pH of the cleaning agent is within the appropriate range to meet the cleaning requirements without damaging the different metal materials.

Fourth, the multi-factor comprehensive consideration of metal cleaning agent formula screening

11. Complex properties of surfactants

<!--[if !supportLists]-->·       <!--[endif]-->The cleaning effect is affected by a variety of factors. The cleaning effect of surfactants is closely related to factors such as the type of object to be washed, the nature of the dirt and the temperature. For example, different types of dirt and different metal materials require different surfactants to achieve the best cleaning results.

<!--[if !supportLists]-->·       <!--[endif]-->Synergies of compound use. The combination of nonionic surfactants and anionic surfactants has a synergistic effect to enhance emulsification, solubilization, dispersion and cleaning. However, when using in combination, it is necessary to pay attention to factors such as HLB value and cloud point to ensure the stability and effectiveness of the surfactant in the cleaning process.

<!--[if !supportLists]-->·       <!--[endif]-->The contradiction between cleaning power and rust resistance. There is a contradiction between the cleaning power and rust resistance of surfactants, and these two factors need to be balanced when choosing surfactants. For example, some surfactants, although they have better cleaning power, may reduce rust resistance, and this problem needs to be solved through reasonable compounding.

<!--[if !supportLists]-->·       <!--[endif]-->soft and hard water and the effects of temperature. Hard and soft water and temperature have an impact on the cleaning power of surfactants, and nonionic surfactants have strong resistance to hard water, which is generally not affected by the hardness of water, but water hardness has a great impact on the cleaning power of anionic surfactants. At the same time, temperature also has different effects on the cleaning power of different types of surfactants, such as nonionic surfactants are basically not affected by temperature, but when the temperature exceeds the cloud point, the cleaning power will decrease.

12. Trade-offs between the performance differences of alkaline and alkaline salts

<!--[if !supportLists]-->·       <!--[endif]-->The properties of different bases and alkaline salts vary. Different alkalis and alkaline salts have differences in PH value, washing, penetration, dispersion, emulsification, flushing, hard water resistance and corrosion resistance, etc., for example, sodium carbonate will generate insoluble calcium carbonate in hard water, and sodium bicarbonate will react with calcium ions to form soluble calcium bicarbonate, which has a certain softening ability to hard water. Silicates have good hard water resistance and dirt dispersion ability, and have the effect of preventing dirt from re-adhesion; Polyphosphate has a low alkalinity, can soften hard water, has a strong dispersion force, can prevent metal corrosion, and also has the effect of preventing dirt adhesion. When choosing alkali and alkaline salts, there is a trade-off between the specific cleaning requirements and the metal material.

13. Analysis of the effect of surfactant compounding

<!--[if !supportLists]-->·       <!--[endif]-->Different surfactants have different compound effects. A variety of surfactants, such as AEO-9 and AES, were selected for compounding tests, and it was found that the cleaning power of the compound LAS-Na was poor, and the compounding effect of nonionic surfactants was good. This indicates that when formulating surfactants, it is necessary to select the appropriate combination of surfactants to improve the cleaning power.

14. Selectivity of surfactants in combination with alkaline salts

<!--[if !supportLists]-->·       <!--[endif]-->The combination of surfactants and alkaline salts can improve the cleaning power. Some surfactants are selective for alkaline substances, such as LAS-Na with sodium orthosilicate with the best cleaning power, while TX-10 with alkaline substances can greatly improve the cleaning power. This selectivity needs to be taken into account when formulating surfactants and alkaline salts in order to achieve the best possible cleaning power boost.

15. Reasonable addition of anticorrosive corrosion inhibitors and other additives

<!--[if !supportLists]-->·       <!--[endif]-->Different corrosion inhibitors are added for different metal parts. For different metal parts, such as sodium nitrite can be added to steel parts, benzotriazole and other corrosion inhibitors can be added to copper parts. This targeted addition ensures that different metal parts can be cleaned with both a cleaning effect and an effective prevention of metal corrosion.

<!--[if !supportLists]-->·       <!--[endif]-->The role of other additives. In addition to corrosion inhibitors, other additives such as defoamers and solubilizers can also be added, and sometimes substances such as flavors can be added to improve the appearance and quality of the product. The addition of these additives can further optimize the performance of the product and improve the overall quality of the product.

16. Comprehensive consideration of formulation screening results

<!--[if !supportLists]-->·       <!--[endif]-->In the development of weak alkaline aqueous agent type metal oil cleaning agent, it is very important to screen and compound surfactant, to ensure that the HLB value after compounding is in the range of 9.0 - 13, and the formulation of non-ionic surfactant is determined, compounded with anionic surfactant, and the synergy of alkaline salt additives is used to select the formula of specific corrosion inhibitors. This formula meets the requirements in terms of pH value, high and low stability and other properties, with an optimal use temperature of 60 degrees and a cleaning time of 2 minutes. The results of this formulation screening are based on a comprehensive consideration of the characteristics and interactions of various components such as surfactants, alkali and alkaline salts, rust inhibitors, etc., and can meet the various requirements of metal oil cleaning.