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Zero Discharge Electroplating

Relevancy:  

Case study of plating shop in environmentally sensitive area where operation was allowed only subject to zero effluent discharge. Plant is described incl. use of compressed air for drag-out removal & vacuum evaporator to aid recycling. Some cost figures suggest that operating costs are no higher than conventional plants. Equipment was German Federally funded.

Zero Discharge Electroplating - A Role for the In-House Power Plant ?

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The benefits of in-house electrical power generation for electroplating plants are described (CHP = combined heat & power). Tables detail typical figures of performance & cost (capital & running). The key is the need, in plating plants, for low-grade heat for sludge drying and vacuum evaporation for rinse water recycling.

Zero Discharge Electroplating Based on Three Actual Case Studies

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Three companies whose operations involve metal finishing are described and costs summarised. Ion exchangers allow virtually closed loop operation.

Zero Discharge Electroplating of Steel with Copper Nickel Chromium

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"Mercedes-Benz" perspective discusses general economic factors. Cascade rinsing is treated, with process flowsheet showing metal finishing of car radiators. Rinsing for baths operating at above-ambient temperatures (hot) and for ambient baths is summarised. Rinsing & evaporation flowsheets for copper (acid & cyanide) & Cr. Bath management in cyanide Cu with graph showing carbonate, cyanide & Cu concentrations as function of bath life (A/hr). Closed (zero discharge) Ni plating system is described. Electrolysis cells for metal contaminant removal from chloride containing baths (membranes required) & from Cr plating baths. Mass balance for bright Ni is given, costs are shown in detail for 3 rinsing options. 6 refs.

Zero Discharge Electroplating Thanks to Recycling

Relevancy:  

Case study of a plating plant in Germany fitted with selective ion exchangers to reduce effluents and effectively recycle water and other chemicals. Block diagram shows how ion exchange deals with cyanides & complexed metallic species. Electrolytic copper recovery & electrolytic hypochlorite generation are also used. Calcium hydroxide is prepared from chalk on-site.

Zero discharge electroplating. Four case studies

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4 case studies include hard chromium plating plant, a general jobbing plater in central Paris (copper, brass, nickel, silver, gold), a barrel zinc line and a nickel +chromium plant. Descriptions of each with process flowsheets.

Zero discharge hexavalent chromium plating

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Brief note reports new plant at Messrs Poeton, Gloucester.

Zero discharge in metal finishing & surface treatment using vacuum distillation

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Title evaporators are compared with other types, emphasises energy savings. Distillation of 1 litre water requires of order 1 KWhr in normal evaporator. Title system with heat pump reduces this to 0.05 KWhr. Sketches & process flow sheets show systems & application areas in surface finishing are noted.

Zero discharge of process water from phosphating pretreatment tunnel

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Ultrafiltration technology, used by Italian contract coater, is described.

Zero discharge operation of zinc nickel plating lines

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Closed-loop operation using evaporators & other methods is briefly noted.

Zero discharge paint shop

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Case study of dip-painted steel switchgear housings where zero effluent was achieved with recirculation of water using nanofiltration membrane technology, the filtrate can be used in bio-gas production.

Zero Discharge Plants for Electroplating Nickel & Chromium

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Report on a meeting to promote commercial plants of Messrs Galvani, Dresden gives physical sizes, capacity of plant, describes high pressure cyanide destruction unit (hydrolysis) &use of low pressure evaporator to achieve zero-discharge operation .

Zero discharge pretreatment

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Avoidance of effluent discharge & solid waste is state of art in Germany. 6 stage continuous iron phosphating line is shown. Chromate-free passivation of aluminium can be done in same plant. Oscillating spray matrix and water mist generation from an annulus through which work passes. Controlled drop-off time minimises drag-over. Triple rinse can be fitted into a single chamber. Variants are 4 or 3 stage plants.

Zero discharge production by combining new environmental technologies

Relevancy:  

Case study of Flemish metal finishers Malmar NV who operate phosphating, primer painting & powder coating. Flow sheet shows water use, incl. rainwater capture, use of "grey" water in toilets, reverse osmosis, vacuum evaporators (3) and sludge filter press. Separate flowsheet shows water & effluent treatment

Zero discharge recovery

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Activities of US Enviro-Chem Inc are described, incl. gold recovery from printed circuit board scrap. Chemical dissolution is coupled with physical process "Slurry-Mizer", a type of sludge dryer using a heated tank and helical screw. After drying, process residues are smelted when cyanide is destroyed and gold & other precious metals recovered.