The VDM Metals Group, a German manufacturer of nickel alloys and special stainless steels, uses the next generation of Bonderite C-CP technology ("Cleanox"), whose pickling formulation is free of nitric acid (HNO3 ), for the manufacture of wire products. With the products of the Bonderite C-CP family, Henkel meets the requirements of the metal industry for significantly more sustainable production processes.
Cleanox technology has been used for decades in many sectors around the world, for example in the manufacture of wires, tubes, coils, rods and components. It is suitable for all stainless steels and many applications, including spray and immersion processes as well as batch-oriented or continuous processes. Werdohl-based VDM Metals uses Henkel's Cleanox technology for pickling wire rod made of high-alloy materials in order to comply with NOx limits.
Björn Lorenz, Sales Manager Metal Coil for Western Europe at Henkel, explains: "In line with our corporate strategy, Henkel is determined to drive sustainability forward. That's why we offer our customers in the metal coil industry a reliable, flexible and environmentally friendly pickling process for stainless steel. Customers like VDM Metals benefit from competitive production costs while making a significant contribution to greater environmental compatibility and product safety. We offer a specially tailored package to customers who focus on greater sustainability: In addition to chemical and electrical pickling processes, this also includes our systems for the automatic control and dosing of chemicals."
High-alloy nickel-chromium alloys are used in many industries, including the automotive, petrochemical, aerospace, power generation, electrical, chemical and household appliance industries. However, the common mixed acid-based pickling systems are problematic due to the nitric acid used. In these cleaning processes, high quantities of nitrate ions are generally released into the wastewater in the intermediate and final rinsing steps. Nitrate and nitrite levels are subject to legal regulations, meaning that complex wastewater treatment is necessary to ensure compliance.
Another disadvantage of mixed acid-based pickling processes is the nitrogen oxide vapors (NOx) produced. These must also be treated as part of air pollution control. Although there are technical processes for removing nitrogen oxides, these involve considerable investment in systems, process control and maintenance services.
Both factors also have an impact on the productivity of the pickling process, waste water treatment and waste disposal.
Henkel's Bonderite C-CP offers a good alternative to the cost and environmental hurdles with the latest nitric acid-free cleaning technology. Another advantage in terms of sustainability is the lower sludge formation of the new technology compared to the conventional process. In addition, the overall process costs are the same or lower when using this fully automated technology compared to conventional processes. Bonderite C-CP can be used in spray or immersion systems and is suitable for all stainless steel grades based on austenite, ferrite, martensite, duplex or super duplex, including AISI/SAE 4XX chromium steel.
Olaf Kazmierski, Senior Vice President of Production at VDM Metals in Werdohl, is extremely positive about the sustainability potential of the new technology and the collaboration with Henkel: "Bonderite C-CP has enabled us to optimize our pickling process. Henkel gave us good advice on process management and consumption optimization. This enabled a smooth changeover from the mixed acids to the Bonderite technology. The problem of nitrate contamination has been significantly alleviated. The process is now running smoothly and the new pickling process is well established."
The latest innovation in the Cleanox division is acid recovery systems. They make the technology even more cost-effective and sustainable. The systems offered by Henkel fulfill many purposes, but the primary aim is to reduce the sludge remaining in the production system and to recycle used Bonderite C-CP products. Customers can save significant consumption costs and further reduce their environmental footprint.
Bonderite C-CP technologies have been on the market since the 1990s. They were Henkel's answer to the increasing demand for nitric acid-free pickling technologies for stainless steel. Since then, legislation in this area has become stricter in the EU. For example, EC Directive 96/82/EC ("Seveso Directive") further restricts the use and storage of hydrofluoric acid. The new generation of Bonderite C-CP is fully compliant with these regulatory requirements. VDM Metals is one of the first manufacturers of high-alloy non-ferrous metals to use this process in its production.
Aziz Mabrouki, Head of Metal Coil Europe at Henkel, concludes: "Cleanox technology has been introduced not only in Europe, but all over the world. We offer integrated solutions that include chemical products, know-how, systems and equipment. In this way, we support manufacturers and users of stainless steels in complying with the new guidelines, for example those of the Chinese central government on nitrite emissions."
Bonderite is a registered trademark of the Henkel Group with protection in Germany and other countries.
