ZERMEG II – Zero emission retrofitting method ... - Fabrik der Zukunft

ZERMEG-Grid Case study Anodisieranstalt Heubergerrinsing criterium108recycling rate64drag out20idealstartresultlife timespecific rinsing water meetdesolved metalFigure 1: ZERMEG Grid for the anodizing plant of Anodisieranstalt HeubergerThe example of Figure 1 shows the application of the ZERMEG-Grid for the six basicparameters in the case of Anodisieranstalt Heuberger (see ZERMEG, 2004) to compare theinitial situation (red line) to the results of the optimisation (blue line). The ideal values arerepresented by the green line.ZERMEG focussed on understanding the processes involved in pickling and degreasing ofdifferent metals. For this, a detailed literature research was undertaken to describe theinfluences on quality of pickling and degreasing and to prepare models for the use in thecalculations.The programme routine ZEPRA to calculate ideal consumptions in advance was improved:Each bath and each separation operation are treated as a blackbox, a closed unit, asdescribed in the final report of ZERMEG 5 . This allows to add other baths and operationscomparatively easily. For each of these elements a template is programmed, in which thecalculation of the output streams is done from the input streams and all necessaryparameter. Each of these templates characterises a new type which has to be defined in theprogram.In projects like ZERMEG where a lot of very specific knowledge has to be translated tomodels this allows for a quick integration to the programme without interfering with othermodules.5 Fresner, J. et al., ZERMEG - Final report, BMVIT, 2004ZERMEG - Ein Projekt der Fabrik der Zukunft gefördert von BMVIT und FFFEndbericht ZERMEG IISeite 17