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

The following fields of action for future work could be identified: simple, easy to use, and cheap analysis methods collection of real experience with the operation of existing plants to enlarge theuseful life of galvanic baths testing and further developing combinations of processes to enlarge the useful life ofgalvanic plants (combinations of precleaning and membranes, precleaning and ionexchangers) to take care of impurities in the practical processes (organic materials,process chemicals, and metals) programming of corresponding models to supplement the calculation routines focused analysis of the potential to use the spent process baths externally andanalyse the possibilities to create the infrastructure to collect the materials andrealize the potential for reuse and recycling actuallyCompanyA. HeubergerEloxieranstalt GmbHAT&S AGReduction ofspecific waterconsumptionJoh. Pengg AG 50 %Mosdorfer GmbHReduction of specificconsumption ofpickling medium(acid, caustic soda)95 % 50 %2 2Rotoform GmbH 40 % 50 %Tab. 4: Summary of the ZERMEG results43OtherRecovery of 20 kg/d copper,savings of 20 tons/a of causticsoda, external use of sludgeComplete external use of spentacids planned50 % Complete external use of spentacids realizedIt could be shown that it is feasible to approach the goal of an (almost) zero wastegalvanizing industry. Important steps towards the realization of the concept were achieved inthe case studies (table 4) by implementing good housekeeping options and simpletechnology transfer. The implementations included measures which pay back in between 0,5and 3 years. Additional measures to further decrease disposal of acids and caustics to thewaste water are technically feasible, however too expensive.If measures with a pay back time of more than 3 years should be implemented subsidies areneeded, which reduce the risk for the investor. Considering present economic boundaryconditions in the form of prices for water and energy, this is relevant for most technologiesto recycle process baths internally (such as membrane technologies, evaporators).2 not relevant, because only the waste water treatment was analysed3 not yet analysed4 no waste water from rinsing, because rinses are used as makeup for pickling baths completely31