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

No. ofstepDescriptionShows following potentials for optimisation1 Analysis of current situation: collection of actual process data (water consumption,Measuring the waterchemicals consumption, production)consumption and the usage implementation of indicators,of chemicals daily measuring of the concentration of process tanks feedback to the operators2 Analysis of current situation: too short drain-times and lift-out-times,Measuring of the drag out construction of parts which reduces drag out improvement of the mounting of the parts,3 Analysis of current situation:Definition of the rinsingcriteriaimprovement of rack geometry and surfaceimproved quality criteria control,control and controlled reduction of the volume of water4 Calculation for comparison: comparison with the actual water consumption,Calculating the waterconsumption measuring the conductivity in order to control thevolume of rinsing water, manual control of the volume of rinsing waterimprovement of rinsing technologies (two stagecounterflow rinses, three stage counterflow rinse, staticrinse tank for recovery of chemicals)5 Calculation for comparison: improved chemical analysesCalculation of the improved dosage of chemicals,consumption of chemicals minimisation of overpickling minimisation of contamination by organic compounds ormetals reduced viscosity of baths (by reducing concentration ofchemicals, and reducing impurities) use of simple filtration technologies6 Definition of possibleexternal disposal andrecycling7 Definition of possiblerecyclingtechnical measures in order to enlarge the useful lifetimeidentification of useful by-products and clientsimproved management of chemicals so that they suitthe requirements of potential clientsrecycling of baths after cleaning with processessuggested by the technology data base8 Evaluation of the options pay-back calculations and evaluation of sustainability ofalternatives9 Optimisation of the wastewater plantTab. 2: Potential options out of ZERMEGThis sequence guarantees that the most effective measure which at the same time requirethe least investments and operating costs are selected first. From an analysis of Austriancosts and prices, it was shown that it is mostly more cost effective to look for external use ofconcentrated spent baths than to employ recycling technologies (especially in existing,relatively small plants) (Fresner 2004).13