Unit 11 : CP-Examples: Metal working

Industrial Environmental
Protection
11. Unit:
CP-Examples:
Metal working
Machining, Painting, Electroplating
Chair of Industrial Material Cycles
Prof. Dr. L. Schebek, Wilfried Denz
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 1
Cleaner Production Measures
in Metal Working
Mesures de production plus propre dans le travail des
métaux
Metal Working Process Flow Diagram
Expl. 2
Expl. 1
Crude
Metal
Foundry
Mechan.
Process
Painting
Finished
product
Electroplating
Finished
product
Cleaning+
Pre-Treatm.
Structure of lecture:
Expl. 3
CP Expl. 1: Mechanical Processes (Cutting)
CP Expl. 2: Spray Painting Structure de la conférence:
CP Expl. 1: Procédés mécaniques (découpage)
CP Expl. 3: Electroplating
CP Expl. 2: Peinture au pistolet
CP Expl. 3: galvanisation
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 3
Mechanical Processes
 Plastic deforming, e.g. Extrusion, Forging
 Sheet metal forming, e.g. Bending, Coining,
Rolling
 Cutting processes, e.g.
Milling, Turning, Drilling,
Sawing, Grinding
 Others like Welding, Brazing,
Soldering, Heat Treatment
Plastique déformant, EX. Extrusion, le forgeage
Feuille formage des métaux, EX. Pliage, Coining, Rolling
Processus de coupe, E.G. Fraisage, tournage, perçage, sciage,
meulage
D'autres, comme de soudage, brasage, soudage, traitement thermique
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 4
Mechanical Processes: Cutting
Drilling
Turning
Sawing
Milling
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 5
Metal Sawing (Cairo)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 6
Metal Working (Cairo)
Turning (dry)
Drilling
(manual minimum lubricating)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 7
Cutting Liquids
Cutting liquids cool and lubricate workpiece and cutter to:
 keep the workpiece at a stable temperature
(critical when working to close tolerances)
 prevent rust on machine, parts and cutters
 maximise the life of the cutting tip
 remove the metal chips
Liquides de coupe refroidissement et la lubrification la pièce et la fraise à:
maintenir la pièce à une température stable (critique lorsque l'on travaille à des tolérances serrées)
prévenir la rouille sur les machines, les pièces et outils de coupe
maximiser la durée de vie de la pointe de coupe
enlever les copeaux de métal
The cutting liquids should ensure
safety for the people handling it
(toxicity, bacteria, fungi) and for the
environment upon disposal
Les liquides de coupe doit assurer la sécurité de sa manipulation pour les personnes (toxicité,
bactéries, champignons) et pour l'environnement en cas d'élimination
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 8
Cutting Liquids
Cutting Liquids (CL)
non-aqueous CL
„Cutting-Oils“, ready for use
water-miscible CL
water-mixed CL-Emulsion
Concentrate, mixed with water
Oil types:
- Mineral Oil
- Synthetic Oil
- Vegetable Oil / Esters
CL-Emulsion
ready for use
Oil content:
2-15 %
CL-Solution
Most common additives: Fatty Acids, Phosphorus com-pounds, Sulfur
compounds, Antifoam, Emulsifiers, High-pressure additives, Solubilizer,
Corrosion Inhibitors (inor-ganic salts), Microbicides, Wetting agents
(detergents), Water-soluble organ. substances
Additifs les plus courants: acides gras, phosphore, des composés soufrés, antimousse, émulsifiants, des additifs haute pression, les solubilisant,
inhibiteurs de corrosion (sels inorganiques) les microbicides, des agents mouillants (détergents), soluble dans l'eau d'organ es. substances
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 9
Cutting costs
Operational Costs for Cutting Liquids:
 Purchasing and storage of CL
 Preparation of CL
 CL changeout and cleaning
of the CL-circuit
 Machine downtime
 Personnel costs
 Pre-treatment of CL
before disposing
cutters
 Disposal of CL
Coûts opérationnels pour liquides de coupe:
Achats et le stockage de CL
Préparation de la CL
Changeur CL et le nettoyage de la CL-circuit
les temps d'arrêt machine
Les frais de personnel
Pré-traitement de CL avant de jeter
Élimination des CL
overhead
staff
cutting
liquids
machinery
Typical distribution of cutting costs
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 10
Wastes from Cutting Processes I
According to EWC - European Waste Catalogue
EWC
Waste Type
wastes from shaping and physical and mechanical surface treatment of metals
120101
ferrous metal filings and turnings
120102
ferrous metal dust and particles
120103
non-ferrous metal filings and turnings
120104
non-ferrous metal dust an d particles
120106*
mineral -based machining oils containing halogens (except emulsions and solutions)
120107*
mineral -based machining oils free of halogens (except emulsions and solutions)
120108*
machining emulsions and solutions containing halogens
120109*
machining emulsions and solutions free of halogens
120110*
synthetic machining oils
120114*
machining sludges containing dangerous substances
120115
machining sludges other than those mentioned in 120114
*: Hazardous Waste
Bold formatted: quantity relevant waste
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 11
Wastes from Cutting Processes II
EWC
Waste Type
wastes from shaping and physical and mechanical surface treatment of metals
120118*
metal sludge (grinding, honing and lapping sludge) containing oil
120119*
readily biodegradable machining oil
120120*
spent grinding bodies and grinding
120121
spent grinding bodies and grinding materials other than those mentioned in 12 01 20
materials containing dangerous substances
wastes from cleaning and degreasing
110113*
degreasing wastes containing dangerous substances
140601 -05*
waste organic solvents, refrigerants and foam/aerosol propellants
diverse wastes
150202*
absorbents, filter materials (including oil filters not otherwise specified), wiping cloths,
protective clothing contaminated by dangerous substances
150203
absorbents, filter ma terials, wiping cloths and protective clothing other than those
mentioned in 15 02 02
*: Hazardous Waste
Bold formatted: quantity relevant waste
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 12
Cost savings
[1.000 €/year]
CP and Cost Reduction by
Extending Operating Life of CL
35
30
25
20
15
10
5
0
extending operating life
by 20 %
extending operating life
by 40 %
extending operating life
by 100 %
0
5 10 15 20 25 30 35 40
CL amount [1.000 litres/year]
Proper CL management leads to less sick leave also
La gestion adéquate CL conduit aussi à moins de congés de maladie
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 13
CP and Cost reduction by
extending operating life of CL










Alignment of the machine oil on the CL
Avoidance of tramp oil and dirt impact on the CL
Proper mixing and re-sharpening of the CL
Use deionized water for re-sharpening
Use stable emulsions
Reducing the types of CL (also less cleaning necessary)
Regular ventilating or circulating of CL esp. on weekends
Regular monitoring of the CL and its chemistry
Use of skimming, filtration and/or separation systems
Proper cleaning of machine during CL change
Alignement de l'huile de machine sur la CL, Prévention de l'huile de tramp et de l'impact de la saleté sur la CL
Un bon mélange et l'affûtage de la CL, Utiliser de l'eau déminéralisée pour l'affûtage
Utilisez des émulsions stables, Réduire les types de CL (aussi moins de nettoyage nécessaire)
Ventilation régulière ou de circulation du CL esp. fins de semaine, Un suivi régulier de la CL et sa chimie, Utilisation de s ystèmes d'écumage,
filtration et / ou de séparation, Un bon nettoyage de la machine pendant le changement CL
The dimensions of the initial semi-finished product should be as close as
possible to the final measurements of the finished part Les dimensions de la formation initiale produit
semi-fini devrait être aussi proche que possible aux mesures finales de la pièce finie
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 14
Extending operating life of CL
through bath maintenance
Other separators are:
filtres, sedimentation, magnetic
filtres, centrifuges, decanters,
ultrafiltration etc.
D'autres séparateurs sont:
filtres, la sédimentation, filtres magnétiques,
centrifugeuses, décanteurs, etc ultrafiltration
Oil skimming disk / band
Lamella separator
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 15
Extending operating life of CL
through bath maintenance
Tabel: implementation criteria for methods for CL-cleaning
sedimentation basin
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 16
Energy efficiency
Conventional machines:
Control of the coolant flow via the bypass, i.e.
coolant pump operates continuously at high flow
rate far beyond the needs.
Machines conventionnelles:
Contrôle de la circulation du liquide de ref roidissement via le bypass, pompe à eau f onctionne en continu à un débit élevé bien au-delà des besoins.
CP-optimised:
Control of the coolant flow rate by speed controlled
high-pressure pump.
-> Up to 45% power savings.
CP-optimisé:
Réglage de la vitesse d'écoulement du liquide de refroidissement par la vitesse contrôlée pompe à haute pression.
-> Jusqu'à 45% d'économies d'énergie.
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 17
Dry processing /
Minimal quantity lubrication I
Check whether MQL or dry processing can be used for
the material, cutting technique and cutting tool.
Vérifier si le traitement MQL ou sec peut être utilisé pour le matériau, la technique ou l'outil de
coupe.
MQL / dry processing has several advantages:
 Consumption of auxiliary
materials is reduced
 Waste production is minimised,
no machining liquids or sludges,
clean metal chips
 Hydrocarbon emissions are greatly
decreased
MQL
Traitement MQL / sec présente plusieurs avantages:
Consommation de matières auxiliaires est réduite
La production de déchets est réduite au minimum, pas de liquides ou de boues
d'usinage, des copeaux métalliques propres
Les émissions d'hydrocarbures sont fortement réduites
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 18
Dry processing /
Minimal quantity lubrication II
 Higher processing rates may be possible through the use of
new types of tools
 Workplace and workpieces are much cleaner
 Costs of purchasing, storage, monitoring,
maintenance and disposal of CL is
minimised
 Skin diseases and other health problems
are reduced
 But metal chips removal needs
to be resolved
Taux de traitement plus élevées peuvent être possible grâce à l'utilisation de
nouveaux types d'outils
En milieu de travail et les pièces sont beaucoup plus propres
Le coût des achats, le stockage, la surveillance, l'entretien et l'élimination des
CL est réduite au minimum
Les maladies de peau et autres problèmes de santé sont réduits
Mais enlèvement des copeaux métalliques doit être résolu
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 19
Dry processing /
Minimal quantity lubrication III
MQL - Areas of application
manufacturing process
saw, band- and circularsaw
punching, fine stamping,
nibbling
experience
good experience
comments
chip transport must be ensured
good experience, for
big material thickness too
broaching
problems with large multi-section
composite tools for inaccessible
cutting punches
good experience with cast iron, deep-hole drilling because
steel and non-ferrous metals
chip transport not realisable
good experience with
chip transport and accurate CL
steel and non-ferrous metals application must be secured
with big restrictions
grinding, lapping, honing
any or negative experience
drilling,
thread cutting
milling, rotating
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 20
Dry processing /
Minimal quantity lubrication IV
Dry processing (dry machining)
Traitement par voie sèche (usinage à sec)
The lubricating effect of the emulsion is replaced with the hard material
layer of today's tools. On the smooth surfaces the chips run off easily.
L'effet de lubrification de l'émulsion est remplacé par la couche de matériau dur des outils actuels. Les surfaces lisses les copeaux de
fonctionner facilement.
dry processing
parameter
method
workpiece material
cutting unit material
machine tool
practicable by
rotating, milling, drilling
cast iron, steel, rarely NE-metals
coated carbide metal,
cutting ceramics, CBN a.o.
NC -machine a.o.
condition of fabrication single machine,
pre-machining line
not practicable by
grinding, honing, lapping,
deep-hole drilling
VA -steel
soft metal
multispindle turning machines:
chip transport difficult
fine machining, continuous
changing components
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 21
Sources / Links
 Reference Documents on Best Available Techniques (BREFs)
for Ferrous Metals Processing Industry and Non-Ferrous Metals Industries; EC; 2001
 Shop Guide to Reduce the Waste of Metalworking Fluids; Waste Reduction and Technology
Transfer Foundation / US EPA; 1996
 Shop Guide to Reduce Wastewater from the Machining and Metal Fabrication Industry; Waste
Reduction and Technology Transfer Foundation / US EPA; 1996
 Metal Machining Sector - A Pollution Prevention Assessment and Guidance; Washington State
Department of Ecology; 1999
 Profile of the Fabricated Metal Products Industry; EPA Office of Compliance Sector Notebook
Project; 1995
 Source Reduction opportunities for small machine shops; Pennsylvania source reduction
program; 1994
 10 ways to reduce machine coolant costs; Michigan Office of Waste Reduction Services; 1994
 www.pius-info.de + www.cleaner-production.de (engl.)
Documents de référence sur les Meilleures Techniques Disponibles (MTD) pour les métaux ferreux et l'industrie de transformation des métaux non ferreux Industries, EC, 2001
Shop Guide pour réduire le gaspillage des fluides de coupe; la réduction des déchets et de la technologie de transfert de la Fondation / US EPA, 1996
Shop Guide pour réduire les eaux usées de l'usinage et de l'Industrie métallurgie; la réduction des déchets et de la technologie de transfert de la Fondation / US EPA, 1996
Secteur usinage des métaux - Une évaluation prévention de la pollution et d'orientation; Washington State Department of Ecology, 1999
Profil de l'industrie des produits métalliques, le Bureau de l'EPA Projet portable en conformité des secteurs, 1995
Possibilités de réduction à la source pour les ateliers d'usinage de petite taille; programme de la Pennsylvanie réduction à la source, 1994
10 façons de réduire les coûts de refroidissement de machines; bureau du Michigan des services de réduction des déchets, 1994
www.pius-info.de + www.cleaner-production.de (angl.)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 22
Metal Working Process Flow Diagram
Crude
Metal
Foundry
Mechan.
Process
Painting
Finished
product
Electroplating
Finished
product
Cleaning+
Pre-Treatm.
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 23
Spray Painting solvent- or water-borne coatings
High surface quality;
e.g. in carpentries
Haute qualité de surface;
EX. dans Carpentries
Spray guns:
1930 and 2000
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 24
Automated and manual spray
painting in aviation industry
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 25
Paint
Pigments and dyestuffs, binders, reactive diluents,
crosslinking agents, solvents and additives like:
Colorants et pigments, liants, diluants réactifs, des agents de réticulation, des solvants et des
additifs tels que:
Acids
Amines
Polyalcohols and Derivatives
Specialty Solvents
Vinyl Ethers and N-VinylCompounds
 Catalysts





acides
Amines
Poly-alcohles et dérivés
solvants spécialisés
Ethers vinyliques et composés N-vinyliques
catalyseurs
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 26
Wide variety of colours
and fields of application
Metal, plastic, wood, buildings,
paper, textile, leather...
Métal, plastique, bois, bâtiments,
Papier, Textile, Cuir ...
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 27
Paint systems
 Solvent-borne Coatings
(one- or two-component systems)
 High-solids Coatings (50-70 %
solids, low VOC, evtl. heated)
 Water-borne Coatings
 Powder Coatings
 UV Coatings (solvent-free,
require low energy for curing)
peintures en phase solvant (système d’un ou de deux composants)
Haute-Solides revêtement (50-70% solides à faible COV, evtl. Chauffée)
peintures en phase aqueuse
peintures en poudre
Vernis UV (sans solvant, nécessitent de l'énergie à faible pour le séchage)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 28
Paint systems
Water
Solvent
Solids
Convent. Powder Water
High solid
UHSolid
Source: brocolor LACKFABRIK
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 29
Paint required for coating
To be considered in economic analysis!!
Pour être pris en compte dans l'analyse économique!
Bei Wirtschaftlichkeitsbetrachtung berücksichtigen!
conventional
varnish
high-solid
varnish
Solid
content
coating
efficiency
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 30
powder
varnish
Material flows during painting
Electricity
Heat
Input
Air
Water
Material (Paint,
Cleaning agents)
Workpiece,
unpainted,
after pretreatment
Spray booth
Paint application
Dryer
Trockner
Workpiece,
painted
Waste
(Overspray, paint sludge etc.)
Output
Waste water
Emissions
(VOC, Heat loss etc.)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 31
Spray painting –
Typical mass balance
Purchase
100 %
Cleaning losses
Unused paint
Overspray
Surface of
Workpiece
15 %
Losses
40 - 80 %
9%
38 %
Efficiency:
(20 – 60 %)
38 %
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 32
Dry Filtre and Water-Wash
Paint Booths
filtration efficiency –
80-95 % (dry) resp. 95-99,5 % (wet)
[In-process recycling of waterborne paint with ultrafiltration]
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 33
Wastes from Painting I
Origin
EWC
Waste type
0801
Wastes from Manufacture, Formulation, Supply, Use and Removal of Paint and
Varnish
waste paint and varnish containing organic solvents or other dangerous
substances
Painting
080111*
Painting
Painting
080112
080113*
waste paint and varnish oth er than those mentioned in 080111
sludges from paint or varnish containing organic solvents or other
dangerous substances
Painting
Painting
080114
080115*
sludges from paint or varnish other than those mentioned in 08 01 13
aqueous slud ges containing paint or varnish containing organic solvents or
other dangerous substances
Painting
080116
aqueous sludges containing paint or varnish other than those mentioned in
080115
According to EWC - European
Waste Catalogue
*: Hazardous Waste
Bold formatted:
quantity relevantste
Selon CEE - Catalogue européen des déchets
*: Déchets dangereux en gras f ormatée: Quantité de relevance
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 34
Wastes from Painting II
Origin
EWC
Waste type
Removing paint
080117*
wastes from paint or varnish removal containing organic solvents or
other dangerous substances
Removing paint
080118
wastes from paint or varnish removal other than those mentioned in 080117
Removing paint
080119*
aqueous suspensions containing paint or varnish containing organic solvents
or other dangerous substances
Removing paint
080120
aqueous suspensions containing paint or varnish other than those mentioned
in 080119
Removing paint
Divers
080121*
080199
waste paint or varnish remover
wastes not otherwise specified
Pre-Treatment
110108*
phosphatising sludges
Cleaning
110113*
degreasing wastes containing dangerous substances
Cleaning
Diverse
140601-05*
waste organic solvents, refrigerants and foam/aerosol pro
150202*
absorbents, filter materials (including oil filters not otherwise specified), wiping
cloths, protective clothing contaminated by dangerous substances
*: Hazardous Waste
Bold formatted:
quantity relevantste
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 35
pellants
CP measures I – Spray Painting












Check if (every part of) workpiece has to be coated
Check if less layers of paint are sufficient
Reduce paint types and colours
Purchase paint in reusable packages
Purchase economy packs, but only the required amount
Empty the paint containers accurately
Return residues and empty containers to the supplier
Use paint residues for pre-coating or repair work
Mix only paint quantities needed
Use color-mixing systems
Optimise change of paints / colours
Work dust-free and pre-inspect work pieces to prevent processing of rejects
Vérifiez si moins de couches de peinture sont sont suffisants, Réduire les types de peinture et des couleurs
Achat de la peinture dans des emballages réutilisables
Acheter des packs économiques, mais seulement la quantité nécessaire avec
Les contenants de peinture avec précision
Résidus et retourner les contenants vides au fournisseur
Utilisez les résidus de peinture pour le pré-enduction ou des travaux de réparation
Peindre Mélanger des quantités que les informations nécessaires
Utiliser des systèmes de mélange la couleur
Réaliser le changement de peintures et couleurs
Travail sans poussières et inspecter le pré-traitement de pièces à usiner en vue de prévenir rejette
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 36
CP measures II – Spray Painting
Main Starting Point for simple CP Measures:
Reduction of Overspray
 The spray pressure should be as low as possible
 The paint volume flow should be as low as possible
 The spray pattern should be optimised to the workpiece size, shape,
point de départ pour les mesures de CP simples:
and orientation. Principal
Réduction de la surpulvérisation
La pression de projection doit être aussi faible que possible
Le débit de la peinture doit être aussi faible que possible
 Spray at a
Le jet doit être optimisée pour la taille de la pièce, la forme et l'orientation.
Pulvériser à un angle de 90 degrés et avec distance fixe
90-degree
angle and
with fixed
distance
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 37
CP measures III – Spray Painting
 Reduce distance between workpiece and spray gun
 The workpieces should be positioned such that spraying is as
comfortable as possible for the operator. They should be positioned
close together so that overspray from one piece will fall onto another.
 Increase the voltage at electrostatic painting
 Control coating thickness
and quality regularly
 Train and control the staff
regularly
 Reduce air turbulences in
spray booth
Réduire la distance entre la pièce et le pistolet
Les pièces doivent être positionnés de telle sorte que la pulvérisation est aussi confortable que possible pour
l'opérateur. Elles doivent être positionnées de telle sorte que rapprochées surpulvérisation d'une pièce va
tomber sur un autre.
Augmenter la tension à la peinture électrostatique
L'épaisseur du revêtement de contrôle de qualité et régulièrement
Former et contrôler le personnel régulièrement
Réduire les turbulences de l'air dans cabine de peinture
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 38
CP measures IV – Spray Painting
Use spray methodes with higher application efficiency
Estimation of
overspray losses
Process related minimum losses
Workpiece-dependent areas
High
HVLP
press. LPLV
3-6 bar
0,5 bar
Airless High
Airless Paint
press.
bell
Electro
depos.
Powder
electrostatically supported
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 39
HVLP: high volume low pressure / LPLV: low pressure low volume
CP measures - HVLP
Calculation example HVLP:
Spray process:
primer and filler
top coat
application efficiency:
costs of:
purchase of paint
dry filtration:
filter mats (purchase
+ waste disposal)
wet filtration:
paint sludge (coagulant
+ haz. waste disposal)
total costs:
dry filtration
wet filtration
savings potential per
1000 l paint*:
*
high pressure
high pressure
35 % / 35 %
HVLP
high pressure
50 % / 35 %
HVLP
HVLP
50 % / 50 %
12.500 € (100 %)
11.250 € (90 % )
8.750 € (70 %)
150 € (100 %)
125 € (73 %)
80 € (54 %)
813 € (100 %)
583 € (73 %)
438 € (54 %)
12.650 € (100 %)
13.313 € (100 %)
11.375 € (90 %)
11.833 € (89 %)
8.830 € (70 %)
9.188 € (69 %)
-
1.275 – 1.480 €
3.820 – 4.125 €
350 l paint application on workpiece
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 40
Benefits of CP in painting
 Reduced paint consumption
 Reduced air pollution (volatile organic compounds-VOCs)
 Reduced hazardous waste
 Less frequent cleaning of guns, spray booths, and filters
 Reduced use of chemicals in water-wash spray booths
 Reduced discharge/treatment of water
 Reduced costs
Réduit la consommation de peinture
Pollution de l'air réduit (composés organiques volatils des COV)
Réduction des déchets dangereux
Un nettoyage moins fréquent des armes à feu, cabines de pulvérisation et les filtres
L'utilisation réduite de produits chimiques dans les cabines de pulvérisation de l'eau de lavage
Décharge réduit / traitement de l'eau
Réduction des coûts
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 41
Spray Painting Processes breathing protection
 For all spray painting
processes –
liquid or powder –
breathing protection
is an absolute must!
Pour tout le liquide peinture processus de
pulvérisation ou la poudre de protection respiratoire
est une nécessité absolue!
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 42
CP Painting Processes
Dip painting
Powder painting
 brush or roll coating
 HVLP, airless or electrostatic spray painting
 rotating disc and bell painting
brosse ou couchage au rouleau
 dip, flow and curtain painting HVLP, peinture au pistolet sans air ou électrostatique
disque rotatif et la peinture de cloche
peinture en poudre
 powder painting
revêtement en feuille
 foil coating
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 43
Powder Painting
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 44
Powder Painting –
Waste and Emission free
Powder coatings
 emit zero or near zero VOC.
 overspray can be recycled in-process and thus it is possible to
achieve nearly 100% use of the coating.
 produce no hazardous waste from painting process.
 can produce much thicker coatings than conventional liquid coatings
without running or sagging.
 Equipment and operating costs for a powder line are generally less
than for conventional liquid paint lines.
peintures en poudre
émettent zéro ou proche de zéro COV.
surpulvérisation peuvent être recyclés en cours et il est donc possible d'atteindre près de 100% d'utilisation du revêtement.
ne produisent pas de déchets dangereux à partir de processus de peinture.
peut produire des revêtements beaucoup plus épais que les revêtements liquides conventionnels sans courir ou l'af f aissement.
Les coûts d'équipement et d'exploitation d'une ligne de poudre sont généralement moins que pour les classiques lignes de pein ture liquide.
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 45
Powder Painting –
Waste and Emission free
Limitations:
Heat resistance (160-210°C) and size of workpieces limit
the range of application.
While it is relatively easy to apply thick coatings with
smooth, texture-free surfaces, it is not as easy to apply
smooth thin films. As the film thickness is reduced, the
film becomes more and more orange peeled in texture.
Limitations: Résistance à la chaleur (160-210 ° C) et la taille des pièces de limiter le champ d'application.
Bien qu'il soit relativement facile à appliquer des revêtements épais avec texture douce - surfaces libres, il n'est pas aussi facile à
appliquer douces films minces. Comme l'épaisseur du film est réduite, le film devient de plus en plus orange pelée dans la texture.
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 46
Powder Painting (Cairo)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 47
Paint sludge from Water-Wash
Paint Booths
Amount of paint sludge as a function of application efficiency per ton
applied paint (solids content)
(typical example, large variations depending on coagulants and the solids or
solvent content of the paint)
Quantité des boues de peinture en fonction de l'efficacité d'application de peinture appliquée par tonne (teneur en matières solides)
(typique, de grandes variations en fonction de coagulants et des solides ou du contenu en solvant de la peinture)
Application efficiency [%]
Paint consumption [t] (half solvent / half solids)
Paint application (solids content) [t]
Waste amount [t] at 50 % water content in paint sludge
Waste amount [t] at 80 % water content in paint sludge
30
6,7
1
4,6
11,5
40
5
1
3
7,5
50
4
1
2
5
Drain paint sludge as much as possible:
by evaporation, filter bags, basket presses, belt filter presses or
chamber filter
Égoutter boues de peinture autant que possible:
par évaporation, sacs filtrants, pressoirs, ceinture filtres-presses ou chambre de filtre
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 48
60
3,2
1
1,4
3,5
Sources / Links
 Reference Documents on Best Available Techniques (BREFs)
for Surface Treatment of Metals and Plastics and Surface
Treatment Using Organic Solvents; EC; 2006/07
 Metal Painting and Coating Operations; www.p2pays.org
 Pollution Prevention in the Paints and Coatings Industry; EPA;
1996
 Pollution Prevention Opportunities for Painting & Coatings
Operations; Pennsylvania Department of Environmental
Protection; 1997
 Operation and maintenance Techniques for Spray Coating;
North Carolina Division of P2 and Environmental Assistance;
1996
 www.pius-info.de + www.cleaner-production.de (engl.)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 49
Metal Working Process Flow Diagram
Crude
Metal
Foundry
Mechan.
Process
Painting
Finished
product
Electroplating
Finished
product
Cleaning+
Pre-Treatm.
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 50
CP Measures in
Electroplating and Pre-Treatment
Electroplating for the desired properties:
abrasion and wear resistance, corrosion protection, lubricity,
aesthetic qualities; usually < 50 µm layer thickness
Galvanisation pour les propriétés désirées: l'abrasion et résistance à l'usure, la protection de la corrosion, de
lubrification, les qualités esthétiques, le plus souvent <50 μm épaisseur de la couche
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 51
Electroplating process
electric current
e-
e-
2+
Cu
Cu2+
2+
Cu
Cu2+
Volumes pour le processus
bain: quelques litres (bijoux)
jusqu'à plusieurs 100 m³
(industrie aéronautique)
Anode =
Kupfer
Copper
SO42-
Cathode
Kathode==
Workpiece
Werkstück
Electroplating with Copper
Process bath volumes:
few litres (jewellery) up to several 100 m³ (aviation industry)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 52
Electroplating Process
The Electroplating Process consists of
Le processus de galvanisation se compose de
un ou plusieurs pré-bains de traitement: - dégraissage: habituellement
nettoyants alcalins, tantôt avec la chaleur ou de l'ultra-sonique de soutien, décapage, dérouillage, détartrage par voie électrolytique (chlorhydrique /
sulfurique / acide nitrique / acide citrique / acide acétique), de - [phosphatation
avant la peinture]
un ou plusieurs bains de galvanisation: Zn, Ni, Cr, Au, Cd, Cu, Sn, Ag ...;
 one or more pre-treatment baths:
- degreasing: usually alkaline cleaners;
sometimes with heat or ultra-sonic support,
- pickling, derusting, electrolytically descaling
(hydrochloric/sulphuric/nitric/citric/acetic acid),
- [phosphating before painting]
 one or more galvanisation baths:
Zn, Ni, Cr, Au, Cd, Cu, Sn, Ag...;
 several rinsing baths
 stainless drying; demineralised
water or white spirit in last rinsing step
plusieurs bains de rinçage
séchage inoxydable, eau déminéralisée ou du white spirit à l'étape de rinçage dernière
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 53
pickling
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 54
Finished Product
Unloading Racks
Drying
Rinsing
e.g. chromating
2. Galvanising
Rinsing
e.g. cyanidic Cu
1. Galvanising
Rinsing
Pickling
Rinsing
Degreasing
Loading Racks
Raw Material
Electroplating Process
Transport of Work Pieces
One-man Business in Old Cairo
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 55
Electroplating Companies
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 56
Production of Circuit Boards
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 57
Chemicals in Electroplating
„chemicals coctails with
secret recipes“
Exampels of electrolytic baths
and main chemicals I:
 Copper, acidic: copper sulfate, sulfuric acid, wetting agents,
brighteners
 Copper, cyanidic: copper cyanide, potassium or sodium cyanide, NaOH,
brighteners, possibly potassium tartrate
 Nickel: nickel salts (sulfate, chloride, sulfamate), boric acid, wetting
agents, brighteners, levellers
 Chromium: chromic acid, sulfuric acid, hydrosilicofluoric acid
Exampels de bains électrolytiques et les produits chimiques principales I:
Cuivre, acide: sulfate de cuivre, de l'acide sulfurique, des agents mouillants, des azurants
Cuivre, cyanurés: le cyanure de cuivre, de potassium ou le cyanure de sodium, NaOH, azurants, le tartrate de potassium éventuellement
Nickel: sels de nickel (sulfate, le chlorure, le sulfamate), l'acide borique, des agents mouillants, des azurants, des niveleuses
Chrome: acide chromique, l'acide sulfurique, l'acide silicofluorhydrique
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 58
Chemicals in Electroplating
Exampels of electrolytic baths
and main chemicals II:
 Zinc, cyanidic: zinc or sodium
cyanide, sodium hydroxide,
brighteners
 Zinc, acidic: zinc sulphate, ammonium chloride
 Zinc, alkaline: zinc oxide, caustic soda or caustic potash, brighteners,
surfactants
 Tin, acidic: tin(II)sulfate and tin(II)methanesulfonate, phenolsulfonic or
methanesulfonic acid, sulfuric acid, brighteners
 Tin, alkaline: sodium or potassium stannate, caustic soda or potash
Exampels de bains électrolytiques et chimiques principale II:
Zinc, cyanurés: zinc ou cyanure de sodium, l'hydroxyde de sodium, des azurants
Le zinc, acide: sulf ate de zinc, le chlorure d'ammonium
Zinc, alcaline: l'oxyde de zinc, de la soude caustique ou de potasse caustique, les azurants, les tensioactif s
L'étain, acide: l'étain (II) et du sulf ate d'étain (II) le méthanesulf onate, phénolsulf onique ou l'acide méthanesulf onique, l'acide sulf urique, azurants
Tin, alcaline: de sodium ou de potassium stannate, de la soude caustique ou de potasse
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 59
Wastes from Electroplating I
According to EWC - European Waste Catalogue
EWC
Waste type
wastes from chemical surface treatment and coating of
Group
metals and other materials (for example galvanic
Origin
1101
processes, zinc coatessing proces, pickling processes,
etching, phosphatising, alkaline degreasing, anodising)
110113* degreasing wastes containing dangerous substances
Cleaning /
110114
degreasing wastes other than those mentioned in 11 01 13
Degreasing
140601- waste organic solvents, refrigerants and foam/aerosol
05*
propellants
110105* pickling acids
110106* acids not otherwise specified
Pre-Treatment
110107* pickling bases
110108* phosphatising sludges
110111* aqueous rinsing liquids containing dangerous substances
Rinsing
110112
aqueous rinsing liquids other than those mentioned in 11 01 11
*: Hazardous Waste
Bold formatted: quantity relevant waste
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 60
Wastes from Electroplating II
According to EWC - European Waste Catalogue
EWC
110109*
Electroplating 110110
/ Bath
110115*
Maintenance
110116*
110198*
110199
150202*
diverse
150203
Waste type
sludges and filter cakes containing dangerous substances
sludges and filter cakes other than those mentioned in 11 01 09
eluate and sludges from membrane systems or ion exchange
systems containing dangerous substances
saturated or spent ion exchange resins
other wastes containing dangerous substances
wastes not otherwise specified
absorbents, filter materials (including oil filters not otherwise
specified), wiping cloths, protective clothing contaminated by
dangerous substances
absorbents, filter materials, wiping cloths and protective clothing
other than those mentioned in 15 02 02
*: Hazardous Waste
Bold formatted: quantity relevant waste
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 61
CP Measures
 Minimise oil, rust and dirt on the work pieces before pre-treatment; cooperate
with customer
 Pre-inspect work pieces to prevent processing of rejects
 Main Starting Point for simple CP Measures:
Reduction of drag-out / carry-over
 Main Starting Points for advanced CP Measures:
- closed process bath circuits, process bath treatment,
removing dirt and contaminating substances
- lead active substances from rinsing baths back into
process baths
- using of less hazardous chemicals, e.g. non-cyanide
systems for zinc (acid/alkaline), Cr3+ instead of Cr6+,
activators free of complexing agents, AOX-free agents
Réduire l'huile, la rouille et la saleté sur les pièces avant de pré-traitement; coopérer avec la clientèle
Pré-inspecter pièces pour empêcher le traitement des rejets
Principaux points de départ pour les mesures avancées: - CP des circuits fermés de bain processus, le traitement de processus bain, enlever la saleté et les
substances contaminantes - conduire des substances actives à partir de bains de rinçage de retour dans les bains de processus - en utilisant des produits chimiques
moins dangereux, par exemple, non-cyanure systèmes pour le zinc (acide / alcalin), Cr3 +, au lieu de Cr6 +, des activateurs libres d'agents complexants, AOX sans
agents
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 62
Organisational + Simple
CP Measures I
CP measures to reduce the carry-over
 Extend the dripping time of 5-10 sec. to up to 15 sec. (drums > 30
sec.) leading to up to 20% less carry-over
 Hang workpieces tilted to
improve draining
 Reduce the lift-out velocity
of the rack
 Shake / move jerkily / blow /
suck off the racks or drums
above the respective process
bath
CP mesures visant à réduire le report
Prolonger le temps de couler 5-10 sec. jusqu'à 15 secondes. (tambours> 30 sec.) conduisant à
un maximum de 20% moins de report
Accrochez pièces incliné pour améliorer le drainage
Réduire la vitesse de soulèvement hors du rack
Agiter / déplacer par à-coups / sauter / sucer les racks ou des tambours au-dessus du bain de
traitement respective
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 63
Organisational + Simple
CP Measures II
 Centrifugate, if electroplating small parts in drums
 Strip or squeeze ribbons, wires and circuit boards
 Rinse above process bath: rinsing water can be added as loss compensation
(loss caused by evaporation)
 Add surfactants to achieve lower viscosity
 Keep permanent minimum concentrations of metals and chemicals in the
process baths (see next but one page), mind: suppliers may recommend higher than
necessary concentrations
 Increase the temperature of process baths
 Move or swirl the cleaning, rinsing and process bath liquids
Centrifugat, si la galvanoplastie de petites pièces dans des tambours
Dépouiller ou de presser des rubans, des fils et des circuits
Rincer dessus du bain processus: de l'eau de rinçage peut être ajouté en tant que compensation des pertes (pertes causées par
l'évaporation)
Ajouter des tensioactifs pour atteindre une viscosité plus faible
Gardez permanents concentrations minimales de métaux et de produits chimiques dans les bains de traitement (voir la prochaine, mais une
seule page), de l'esprit: les fournisseurs peuvent recommander supérieures aux concentrations nécessaires
Augmenter la température de bains de traitement
Déplacer ou tourbillonner le nettoyage, le rinçage et le processus de liquides de bain
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 64
Organisational + Simple
CP Measures III
 Tilted drain sheets between process baths cause dripping liquids back
into the process bath; cover process baths
 Check the insulation of the racks,
otherwise metal is deposited on
the flaws and carried over
 Apply dripping optimised racks with
slight incline
 Higher-mounted parts must not drip
onto lower-mounted
 If you have any influence on the construction of work pieces:
minimise cup effects or add drain holes.
Feuilles de vidange inclinées entre bains de traitement égouttements de liquides dans le bain processus; couvrir bains de
traitement
Vérifier l'isolation des racks, sinon le métal est déposé sur les défauts et reportés
Appliquer dégoulinantes racks optimisés avec légère pente
Pièces montées supérieur ne doit pas dégoutter sur les bas-monté
Si vous avez une quelconque influence sur la construction de pièces: minimiser les effets tasse ou ajouter des trous de drainage.
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 65
Quasi-Continuous Minimum
Dispensing of Chemicals
in process baths avoiding overdose
cMo
Concentration of Chem.
Concentration of Chem.
(a)
(b)
cmax.
cmin.
cmin.
day
day
So Mo Tu
a)
We Th
Chem. addition weekly
So Mo Tu
We Th
b) Quasi-continuous dispensing
Less chemicals required, less chemicals in effluents,
less effort for waste water treatment, less haz. waste, uniform quality and
layer thickness!
Moins de produits chimiques nécessaires, moins de produits chimiques dans les effluents,
moins d'effort pour le traitement des eaux usées, moins de Déchets dangereux, la qualité uniforme et épaisseur de la couche!
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 66
Bath maintenance
and regeneration I
By galvanisation bath
regeneration the process
metals can be recovered and
contaminants are removed from
the baths:
- Cation exchanger for metal
ions such as Cu and Ni
(precondition: separate
collection for metallurgical
recovery)
Par la régénération de processus bain de galvanisation des métaux
peuvent être récupérés et les contaminants sont retirés des bains:
Échangeur de cations pour les ions métalliques tels que Cu et Ni
(condition sine qua non: la collecte sélective pour la récupération
métallurgique)
Source: wiki.biomine.skelleftea.se/
wiki/index.php/Ion_exchange
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 67
Bath maintenance and
regeneration II
By galvanistaion bath regeneration the process metals can be
recovered and contaminants are removed from the baths:
- Selective electrolysis against foreign metals
- Precoat filtre against solid contaminants
- Activated carbon filtre for organic contaminants
- Cooling crystallisation of sodium carbonate at alkaline and cyanide
electrolytes
Other methods with specific application areas:
Reverse osmosis, electrodialysis, dialysis, acid retardation (pickling),
cooling crystallisation (iron staining), electrolysis (precious metals).
Par régénération du processus bain galvanistaion les métaux peuvent être récupérés et les contaminants sont retirés des bains:
- L'électrolyse sélective contre les métaux étrangers
- Filtre à précouche contre les contaminants solides
- Filtre à charbon actif pour les contaminants organiques
Cristallisation de refroidissement de carbonate de sodium à électrolytes alcalins et le cyanure D'autres méthodes avec des domaines d'application spécifiques:
L'osmose inverse, électrodialyse, la dialyse, un retard d'acide (décapage), la cristallisation par refroidissement (coloration de fer), l'électrolyse (métaux précieux).
Par la régénération de processus bain de galvanisation des métaux peuvent être récupérés et les contaminants sont retirés des bains:
Échangeur de cations pour les ions métalliques tels que Cu et Ni (condition sine qua non: la collecte sélective pour la récupération métallurgique)
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 68
Bath maintenance and
regeneration
Review of methods for removing contaminants from aqueous
cleaning solutions Examen des méthodes pour éliminer les contaminants des solutions de nettoyage aqueuses
removing
system
method of
cleaner–oilseparation
skimmer
separation by
adhesive forces
gravity
separation by
separator
sedimentation
(centrifugal) separation by
separator
centrifugal
forces
Micro-/
Ultrafiltration
emulsion
separation in
membrane
suitable for
separation of
free oil
free oil; coarse
particles
free or low
emulsilfied oils;
fine- and coarse
particles
emulsilfied oils
(remove free oil in
advance);
microparticles
tramp
invesoil sepa- tition
ration
low
low
medium
operating
costs
low
high
medium low medium
high
high
high
high
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 69
medium high
Sources / Links /
more information
 BREFs Best Available Technique REFerence documents :
http://eippcb.jrc.es/reference/




- Surface treatment of metals and plastics
- Ferrous metals processing industry
- Non-ferrous metals industries
- Surface treatment using organic solvents
Pollution Prevention for the Metal Finishing Industry: A Manual for
Pollution Prevention Technical Assistance Providers; EPA; 1997
A Cleaner Production Manual for the Metal Finishing Industry;
UNEP/CRC; 1998
VDI Guideline 4075 Part 1: Cleaner production - Basic principles;
2004
VDI Guideline 4075 Part 2+3+4: Cleaner production – Expls.
Foundries, Painting, Printing
and the sources and links mentioned in the presentation and in Unit “CP”!
June 2012 | Chair of Industrial Material Cycles | Ind. Environm. Protection | Prof . Schebek | 70