Wet process

Wet blasting processes can incorporate a phosphate conversion coating. Such systems are ideally suited to be used in conjunction with aqueous degreasing and wet blasting processes and produce a surface to which rubber can be securely bonded. The resistance to under-bond corrosion is one measure of how well the surface has been prepared. A phosphated metal can show superior performance in this respect over one prepared by poorly controlled dry grit blasting. 

For bonding there are two principle phosphates available. These are calcium modified and tri-cation modified zinc processes. Both are designed to yield low coating weights and fine crystal structures. Each system has its merits and is critical for the control of the baths. 

The word steel covers a wide variation in the carbon, silicon, manganese and phosphorus contents of the materials selected for insert manufacture. The proportion of these and various other elements, which may be present could affect the rate of build of the phosphate coating and also affects the crystal structure. 

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The mats are moved along the line to the press loader. When the loader is filled and the press opens to remove the load of freshly pressed boards, the loader pushes the new boards into the unloader and deposits the load of mats on the press platens. The press closes as quickly as possible to the desired panel thickness. More pressure, as much as 4.8—6.9 MPa (700—1000 psi) is required to press high density dry-process hardboard, because the dry fiber exhibits much more resistance to compression and densification than wet fiber. Press temperatures are also higher, in the range of 220—246°C. No screens are used in the dry-process, but the moisture in the mats requires a breathe cycle during pressing to avoid blowing the boards apart at the end of the cycle. Because no screens are used, the products are called smooth-two-sides (S-2-S), in contrast to the wet-process boards, which have a screen pattern embossed into the back side and are known as smooth-one-side (S-l-S). 

Wet-Process Phosphoric Acid. As indicated in Figure 7, over 95% of the phosphate fertilizer used in the United States is made by processes that require an initial conversion of all or part of the phosphate ore to phosphoric acid. On a worldwide basis also, the proportion of phosphate fertilizer made with phosphoric acid is very high. Thus processes for production of phosphoric acid are of great importance to the fertilizer industry (see PHOSPHORIC ACID AND THE PHOSPHATES). 

There are numerous variations of the wet process, but all involve an initial step in which the ore is solubilized in sulfuric acid, or, in a few special instances, in some other acid. Because of this requirement for sulfuric acid, it is obvious that sulfur is a raw material of considerable importance to the fertilizer industry. The acid—rock reaction results in formation of phosphoric acid and the precipitation of calcium sulfate. The second principal step in the wet processes is filtration to separate the phosphoric acid from the precipitated calcium sulfate. Wet-process phosphoric acid (WPA) is much less pure than electric furnace acid, but for most fertilizer production the impurities, such as iron, aluminum, and magnesium, are not objectionable and actually contribute to improved physical condition of the finished fertilizer (35). Impurities also furnish some micronutrient fertilizer elements. 

In addition to the main acidulation reaction, other reactions also occur. Free calcium carbonate in the rock reacts with the acid to produce additional by-product calcium compounds and CO2 gas which causes foaming. Other mineral impurities, eg, Fe, Al, Mg, U, and organic matter, dissolve, the result being that the wet-process acid is highly impure. 

Numerous purification processes have been developed for appHcation to wet-process acid (43—49) but these are not appHed to most acid used in fertilizer production. 

The complete chemistry of TSP production has been studied and reported in great detail (34). As in the production of NSP there are also reactions with impurity minerals. In fact, the increasing amounts of such impurities in U.S. commercial phosphate rocks, especially those from Florida, are now reflected in somewhat lowered amounts of citrate-soluble P2O5 product. The range of constituents in commercial TSP from wet-process acid and phosphate... 

A flow sheet of the basic TVA process for granular diammonium phosphate is given in Figure 12. The raw materials are wet-process phosphoric acid and anhydrous ammonia. Feed acid concentration of at least 40% P2 5 required to give a satisfactory water balance. This average concentration usually is provided by two separate feed streams, one of 54% P2 5 concentration and one of about 30% P2 5 arrangement shown, the 54% acid is... 

Production of nitric phosphates is not expected to expand rapidly ia the near future because the primary phosphate exporters, especially ia North Africa and the United States, have moved to ship upgraded materials, wet-process acid, and ammonium phosphates, ia preference to phosphate rock. The abundant supply of these materials should keep suppHers ia a strong competitive position for at least the short-range future. Moreover, the developiag countries, where nitric phosphates would seem to be appealing for most crops except rice, have already strongly committed to production of urea, a material that blends compatibly with sulfur-based phosphates but not with nitrates. 

Fig. 24. Routes of wet-process phosphoric acid into solution-type and suspension-type mixed fertilizer.

Fig. 25. TVA pipe reactor process for production of 9-32-0 and 12-36-0 grade base suspensions directly from wet-process orthophosphoric acid.

A. W. Frazier,. R. Lehr, and E. E. DiUard, Chemical Behavior of Eluorine in the Production of Wet-Process Phosphoric Acid, Bulletin Y-113, TVA, Muscle... 

Alternative Processes. Because of the large quantity of phosphate rock reserves available worldwide, recovery of the fluoride values from this raw material source has frequently been studied. Strategies involve recovering the fluoride from wet-process phosphoric acid plants as fluosiUcic acid [16961-83-4] H2SiFg, and then processing this acid to form hydrogen fluoride. 

Phase Materials. Phase holograms can be recorded in a large variety of materials, the most popular of which are dichromated gelatin, photopolymers, thermoplastic materials, and photorefractive crystals. Dichromated gelatin and some photopolymers require wet processing, and thermoplastic materials require heat processing. Photorefractive crystals are unique in that they are considered to be real-time materials and require no after-exposure processing. 

Most carbide acetylene processes are wet processes from which hydrated lime, Ca(OH)2, is a by-product. The hydrated lime slurry is allowed to settle in a pond or tank after which the supernatant lime-water can be decanted and reused in the generator. Federal, state, and local legislation restrict the methods of storage and disposal of carbide lime hydrate and it has become increasingly important to find consumers for the by-product. The thickened hydrated lime is marketed for industrial wastewater treatment, neutrali2ation of spent pickling acids, as a soil conditioner in road constmction, and in the production of sand-lime bricks. 

The formation of the metallic salts is a pyrometaHurgical process, and is commonly referred to as the dry process. The separation of the salts from each other is accompHshed by selective dissolution in water, and is named the wet process. 

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