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

aths are described in details showing their areas of application and cost. The programwas used in different case studies. In these cases pronounced improvement potentialcould be identified.In the anodizing company, the specific water consumption could be reduced by 95%(see figure 1). The consumption of caustic soda and sulfuric acid could be reduced byhalf! During the project different unit operations for cleaning process solutions weretested. This includes filters for cleaning of the degreasing, membranes and evaporators.It was shown that for the perfect closing of loops and/or for a complete Zero emissionconcept concentrated research of the degreasing, as well as the pickling and etchingprocesses are necessary in surface-treating enterprises. These investigations includethe development of empirical, semi empirical and theoretical parameters, theconsideration of non ideal conditions in existing plants and computerized modelling inclose co-operation with enterprises from the steel processing, the aluminium-processingand the printed circuit board industry. Thus the problem of most diverse materials (steel,aluminium, copper) and their pre-treatment are considered when degreasing, rinsingand pickling are systematically researched. Identified measures are implementeddirectly by the industrial partners.Another main point of our work is to improve the bath care for service life extension andfor removing of impurities in such a form that they become applicable in other industriesas raw materials. Identified measures are again implemented directly by the industrialpartners.Further research aims at diversifying the results. This is done via the purposefulintegration of two large-scale enterprises with more diverse operations. At the sametime the feedback from early applications will be evaluated and integrated into a morecomprehensive method. The end result of this research will be comprehensible wayswith which companies can self evaluate their processes with the help of manuals, benchmarks and computer programmes.