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

Optimization Of Water Management In GalvanizingPlantsChristoph Brunner, H.Schnitzer, G.Gwehenberger, M. Planasch, H. Fresner;Joanneum Research Forschungsgesellschaft, Institute of SustainableTechniques and Systems, AustriaABSTRACTThis work presents a tool that helps to minimize the non profitable output ofgalvanizing plants. The program is based on Excel-VBA and allows simulatingdifferent kinds of galvanic plants. The application of a widely used spreadsheetprogram allows for simple variation and expansion of the program which resultsin easy adaptation and integration of new knowledge. We applied this programin two companies where with the help of this tool the usage of water andchemicals in the anodizing plant and a hot-galvanizer near the Austrian cityGraz was substantially reduced.In the anodizing company the specific water consumption could be reduced by95%. The consumption of caustic soda and sulfuric acid could be reduced byhalf. During the project different unit operations for cleaning process solutionswere tested. This included filters for cleaning of the degreasing, membranesand evaporators.Water is the most important solvent and cleaning agent in industrial andcommercial processes. It is the most common means of transporting energy(heating and cooling) and materials (hydraulic transport) and also the mostimportant reactant. At the same time, water is one of the key environmentalmedia and is thus crucial for all life forms. Safeguarding water resources is ofgreat significance for companies, above all from the economic viewpoint ofwater usage. Costs of fresh water, treatment, cleaning and sewers are just afew examples of why the way we handle this valuable matter should beoptimized in every respect.With this computer model it is now possible to represent existing galvanic plantsand to calculate all material and energy flows without big effort. These resultsare the basis for further process analyses and for creating optimizationstrategies by using an expert database. The use of the program leads to:Better knowledge of the process flow in the tanks and the companyProcess modeling and calculation of material flow balancesOptimization strategies using an expert databaseMohler J. (January 1975),"Spray Rinsing", Metal Finishing Integrated PollutionPrevention and Control (IPPC), Reference Document on best availabletechniques, Surface treatment of metals and plastic materials using electrolyticor chemical process (volume of treatment vats > 30 m³), May 2002, BATreference document, May 2002, European committee for surface treatmentWernick S., Eugen G. (1977), Die Oberflächenbehandlung von Aluminium,Leuze Verlag, Bad Saulgau,