evaled evaporators
TRANSCRIPT
WATER TECHNOLOGIES
Turn
ing
was
tew
ater
into
a re
sour
ceDionisio Visintin
New opportunities within the industrial wastewater market :
• Mechanical &
Surface Treatment(Automotive, Aviation, Furniture, Appliances)
• Photovoltaic & Microelectronic
EVALEDTM
EVAPORATORS
Marketing Departement
Today’s presenter & Housekeeping
Mechanical & Surface treatments | December 2015
o Attendees lines are muted. o Questions are handled by typing in the box as shown below. o Webinar is being recorded and will be made availableo Following the webinar, a short 5 question survey will be sent to
you. Please take 30 seconds and answer the questions.
Type your questions here at anytime during the webinar and we will see them and adress them at the end
Pamela Spada Product Manager
Cristina Del Piccolo R&D Process Director
Dionisio Visintin Marketing & Com. Director
Index
Mechanical & Surface treatments | December 2015
Scope
1. OpportunitiesIndustries : waste water focusMatrix table of ApplicationsReferences list Competitors
2. Challenges
3. Case studiesEVALED installation (materials, size , Pre and Post treatments)
The scope of this webinar
Mechanical & Surface treatments | December 2015
Evaporators applied in …
Mechanical and Surface Treatments
AutomotiveAviationFurnitureApplianceOthers
Photovoltaic &Microelectronics
Market Drivers & Main Issues
Mechanical & Surface treatments | December 2015
Process analysis (Mech &ST)
Mechanical & Surface treatments | December 2015
Big GroupsAutomotive, Aviation, Furniture, Appliance, Medical Devices
1. Main Components (motors , engines, compressors, transmission, gearboxes)
2. Assembly
Suppliers Sub suppliers (Tier 1-5)1. Body parts
2. Motor parts (body, valves, pistons, impellers, springs)
3. Pumps, Compressors
4. Starters and ignitions
5. Brakes, suspensions
6. Transmission-gear parts (gear boxes)
7. Frictions, steering systems
8. Exhaust pipes and silencers
9. Air conditioning, hating systems
10. Safety systems (air-bags)
11. Electrical components
The production process is divided into three phases:
The actors of this phases are:
1. Manufacturing Mechanical Treatments
2. Manufacturing SurfaceTreatments
3. Assembly
Manufacturing Process
Mechanical & Surface treatments | December 2015
Mechanical TreatmentCutting, Buckling, Drilling, Milling CastingForgingPressing TumblingQuality controls
Surface TreatmentCleaning, Degreasing
PicklingChemical hardening:Phosphate, NitrogenElectro chemical (galvanic):Al AnodizationNi, Cr, Zn, Cu, Ag, Cd plating PaintingCataphoresis
STEP 1 STEP 2 STEP 3AssemblyFinal cleaningProtections
Manufacturing Process (Mechanical Treatment)
Mechanical & Surface treatments | December 2015
Mechanical treatment
Water and Waste Water
Cutting, Buckling, Drilling, Milling
Process waterRO ConcentratesIER EluatesLubro refrigerating liquids (recycling)Exhausted oil emulsions
Casting Die lubricants
Forging Forging oily waterPressing Mould releaseTumbling Process cleaning water
Tumbling waterCleaning and degreasing
Degreasing BathsCleaning water (tunnels)
Quality controls Die penetrants rinsing and concentrate baths
Manufacturing Process (Surface Treatment)
Mechanical & Surface treatments | December 2015
Surface Treatment Water and Waste WaterCleaning, Degreasing Process water
RO Concentr., IER EluatesCleaning process (baths, tunnels)
Degreasing bathsPickling Acid/alkaline pickling bathsChemical hardening:Phosphate, Nitrogen
Process water Rinsing and working baths
Electrochemical process (Electroplating,Galvanic)
Al AnodizationPlating: Ni, Cr, Cd, Cu, Zn
Process water Rinsing and working bathsRecycling water and ZLDMetal recovery Cr
Painting Rinsing and water wallsCataphoresis Rinsing and working baths
The Matrix
Mechanical & Surface treatments | December 2015
For each of these industries we have created a matrix which lists:
• Segments;• Applications;• Parameters to control;• Average flowrate• Technology
In details, we analyse where and how EVALED is applied, discussing:
• Challenges• References • Case Studies
Mechanical and Surface Treatment Industry (Mec&ST) Segments
Mechanical & Surface treatments | December 2015
1. Automotive
2. Aviation
3. Furniture4. Appliance 5. Medical Device 6. Micromechanics7. Others Mechanical
Parts Manuf.
Surface Treatment
Mechanical Treatments
Matrix: Mechanical Treatment
Mechanical & Surface treatments | December 2015
Segments ApplicationsWaste Water
Parameters to Control (pH, Conductivity, DM 105°C, COD)
Average Flowrate (tons/day)
PCAC RV
Reference in red
MechanicalTreatment
Exhausted oil emulsions Oils, HM, Surfactants 1-50 x xMoulds release liquids baths (die casting)
Oils, HM, Surfactants 10-50 x x x
Quenching baths Oils, HM, Surfactants 1-10 x xTumbling baths Oils, HM, Surfactants, SS 1-10 xCleaning and Degreasing Oils, HM, Surfactants, SS 1-50 x x xParts rinsing waters(Dye penetrant, Deicing fluids)
Gycols, BOD, Solvents 1-50 x x
Precious metals ww streams (laundry &washings)
Precious Metals , NOx, Surfactants
1-5 x
IE regeneration (ZLD) Cl, SO4, TH, TDS, HM 10-100 x xRO concentrates (ZLD) Cl, SO4, TH, TDS, HM 10-100 x x
Matrix: Surface Treatment
Mechanical & Surface treatments | December 2015
Segments ApplicationsWaste Water
Parameters to Control (pH, Conductivity, DM 105°C, COD)
Average Flowrate (tons/day)
PC AC RV
Reference in red
SurfaceTreatment
Pre-treatment baths Alkalinity, NH3, TH, TDS, Oils 1-10 x xCleaning and Degreasing baths Alkalinity, TH, TDS, Oils 1-50 x x xPhosphate coating baths NH3, TH, TDS, Oils, PO4, HM 1-10 x xPickling baths (H2SO4 , HCl, HF, HNO3)
TDS, SO4 , Cl, F, NO3, HM 1-10 x
Cyanide rinsing baths Alkalinity, TH, CN, NH3 1-10 x xCopper, Zinc, Nickel rinsing baths Cu, Zn, Ni, Fe, TDS 1-10 x xCobalt, Cadmium rinsing baths Co, Cd, Fe, TDS 1-10 x xChromium rinsing baths Cr3, Cr6, Fe, HM, TDS 1-10 x xAluminium anodizing rinsing baths Alkalinity, TH, Al, NH3 5-50 x xSilver, Gold (precious metals) baths Precious Met. Alkalinity, TH, TDS 1-2 xGas Scrubber Blow-down NH3, TH, TDS, Oils 10-100 x xRO concentrate (ZLD) Cl, SO4, TH, TDS, HM 10-100 x xIE regeneration (ZLD) Cl, SO4, TH, TDS, HM 10-100 x xNew or Revamping WW Plants (Mixed streams)
NH3, TH, TDS, Oils, HM 10-100 x x
Mechanical Industry EVALED Reference
Mechanical & Surface treatments | December 2015 Case Studies in red
EVALEDTM Technology Flowrate m3/day (gpm)
Segment Applications production wastewater
Product recovery
Nation Year
Heat Pump Forc. Circ. 30 (5.5) Appliance Die Casting (Al) Italy 1998Heat Pump Forc. Circ. 4 (0.7) Aviation Metal Machining Oil Em. UK 1998Heat Pump Forc. Circ. 5 (1) Mec Parts Metal Machining Oil Em. Oil UK 2000Heat Pump Forc. Circ. 8 (1.4) Applaiance Parts Cleaning (tunnel) Italy 2000Heat Pump Forc. Circ. 10 (1.8) Mec Parts Metal Machining Oil Em. Slovakia 2002Heat Pump Forc. Circ. 20 (4) Automotive Metal Machining Oil Em. Oil Hungary 2003Heat Pump Forc. Circ. 5 (1) Mec Parts Parts Cleaning UF ED concentrate Malaysia 2003Heat Pump Forc. Circ. 3 (0.6) Mec Parts Metal Machining Oil Em. Slovakia 2005Heat Pump Forc. Circ. 8 (1.5) Mec Parts Metal Forging USA 2006Heat Pump Forc. Circ + Heat Pump Scraped 4 (0.7) Medical Device Die Casting Die Penetrants Ireland 2008MVR Forc. Circ. + Hot Water Scraped 20 (4) Mec Parts Precious Metals refining Precious met. India 2009MVR Forc. Circ. + Hot Water Scraped 35 (6.4) Automotive Metal Machining Oil Em. Spain 2009MVR Forc. Circ. 25 (4.6) Automotive Metal Machining Oil Em. Slovakia 2010MVR Forc. Circ. + Heat Pump Scraped 15 (2.7) Mec Parts Al tubes cleaning France 2010MVR Forc. Circ. + Heat Pump Scraped 15 (2.7) Furniture Die Casting Oil Italy 2010Heat Pump Forc. Circ. 4 (0.7) Automotive Metal Machining Oil Em. Oil France 2011Heat Pump Forc. Circ. 4 (0.7) Automotive Metal Machining Oil Em. Oil Poland 2011Heat Pump Forc. Circ + Heat Pump Scraped 6 (1.1) Mec Parts Metal Quenching Czech Rep. 2011MVR Forc. Circ. 10 (1.8) Automotive Metal Machining Oil Em. Korea 2012MVR Forc. Circ. + Hot Water Scraped 50 (9.2) Automotive RO concentrate (ZLD) Morocco 2012Heat Pump Forc. Circ. 1 (0.2) Automotive Metal Machining Oil Em. Japan 2012Heat Pump Forc. Circ. 4 (0.7) Automotive Metal Machining Oil Em. Oil UK 2013Heat Pump Forc. Circ. +Hot Water Scraped 5 (1) Aviation Metal Parts cleaning France 2013MVR Nat. Circ. 5 (1) Automotive Metal Machining Oil Em. Oil Russia 2014Heat Pump Forc. Circ. 12 (2.2) Aviation Metal Machining Oil Em. USA 2015
Surface Treatment Industry EVALED Reference
Mechanical & Surface treatments | December 2015 Case Studies in red
EVALEDTM Technology Flowrate (m3/day)
Segment Applications production wastewater
Product recovery
Nation Year
Heat Pump Scraped 0,1 (0.01) Mec Parts Surface treatment (Plating Ni Zn) Japan 1998Heat Pump Forc. Circ + Heat Pump Scraped 25 (4.6) Applaiance Surface treatment (Painting) Italy 2000Heat Pump Forc. Circ. 5 (1) Aluminium Plate Surface treatment (Al rolls pickling H3PO4) Norway 2001Heat Pump Forc. Circ. Dolble circuit 5 (1) Aluminium Plate Surface treatment (Al plate pickling AlCl3) AlCl3 Spain 2001Heat Pump Forc. Circ. 1,2 (0.2) Applaiance Nickel plating and degreasing Malaysia 2002Heat Pump Forc. Circ. 5 (1) Mec Parts Surface treatment (UF permeate ED) Malaysia 2003Heat Pump Forc. Circ. 4 (0.7) Applaiance Surface treatment (Valves IER eluates) USA 2004Heat Pump Forc. Circ. 8 (1.4) Mec Parts Surface treatment (Metal pickling) USA 2006Heat Pump Forc. Circ. Dolble circuit 5 (1) Automotive Surface treatment (Hard Plating Cr) Chrome Poland 2007MVR Forc. Circ. 12 (2.2) Aviation Plating WW France 2007Heat Pump Forc. Circ. 4 (0.7) Precious metals Surface treatment (Cyanide Au ) Au China 2008MVR Forc. Circ. 12 (2.2) Mec Parts Surface treatment (steel pipes phospating) Italy 2008MVR Forc. Circ. + Hot Water Scraped 16 (2.9) Precious metals Precious metals refining Au ,Pt , Pl India 2009Heat Pump Forc. Circ. Dolble circuit 5 (1) Automotive Surface treatment (Hard Plating Cr) Chrome China 2010MVR Forc. Circ. + Heat Pump Scraped 15 (2.7) Mec Parts Surface treatment (Al Tube ) France 2010MVR Forc. Circ. 50 (9.2) Applaiance Surface treatment (Zn, Plating, gas scrubber) Slovakia 2012Heat Pump Forc. Circ. 5 (1) Aviation Surface treatment (Engines Pickling, phosp., Russia 2012Heat Pump Forc. Circ. 5 (1) Aviation Surface treatment (Metal pickling) France 2012Heat Pump Forc. Circ. 6 (1.1) Automotive Surface treatment (Pickling Cu) Taiwan 2013MVR Forc. Circ. + Heat Pump Scraped 10 (1.9) Aviation Surface treatment (Plating Ni Zn Cd) Ni, Cd Russia 2013Heat Pump Forc. Circ. 4 (0.7) Rail Train Deiceing Gycol Glycol Turkey 2013Heat Pump Forc. Circ. 8 (1.4) Aviation Surface treatment (Plating Ni Zn Cd) Israel 2013MVR Forc. Circ. +Hot Water Scraped 60 (11) Aviation Surface treatment (Plating Ni Zn Cd) Russia 2014Hot Water Forc.Circ.. + Hot Water Scraped 25 (4.6) Automotive Surface treatment (Plating Ni Zn Cd) Germany 2015MVR Forc. Circ. 60 (11) Aviation Surface treatment (Plating Ni Zn Cd) Chzek Rep. 2015
EVALED competitors
Mechanical & Surface treatments | December 2015
1-200 ton/day (< 50 gpm) MVR Evaporators. Competitors can be local or International.
Typical suppliers: Encon, H2O, Loft-KMU, MKR
amount of waste to be treated 100 ton/day
< 10 ton/day (<2 gpm) Often via waste disposal
0.1-10 ton/day (< 2 gpm) Heat Pump Evaporators. Competitors can be local or International.
Typical suppliers: Eco-Techno (old Ecotecno), PF10, C&G,
Shell, Formeco, Saita
Packaged evaporators (0.1 - 500 ton/day - 100 gpm) is the EVALED territory
> 200 ton/day (>50gpm)
Tailor-made MVR Evaporators. The higher the capacity the less
competitive EVALED becomes. In the Chemical production
normally the flow are higher
Competitor Page in red
Loft - KMU
Mechanical & Surface treatments | December 2015
Location: Kirchentellinsfurt Germany Turnover: 2013 about 20 M € Employees : about 80 -90 Installations: about 1000 Branches: France, Italy, Poland Distributors: Austria, Spain, China, Turkey , Chek.Rep, USA
Web: http://www.loft-gmbh.de/
Products: MVR Package Size: 0.5-50 ton/day (0.02-10 gpm) Technology: Natural
Circulation (vertical tubes)Price: about the same for the large ones, 10% less for the small ones
For internal use only
C&G Evaporators
Mechanical & Surface treatments | December 2015
Location: Rignano sull’Arno (Fi) Italy Turnover: 2014 about 3 M € Employees : 13 Installations: about 600 (200 evap)
Distributors: USA, Japan, Malaysia Spain, UK, Brazil, Russia, China, India Web: http://www.cgdepur.it
Products: HP Package (Hot Water m-stage) Size: 0.5 -20 (5-45) ton/day (0.1-8 gpm) Technology: Coil heat exchanger
Price: about 10% lower
S.A.I.T.A. Evaporators
Mechanical & Surface treatments | December 2015
Location: Limena (Pd) Italy Turnover: 2014 about 3.7 M € (0.5 ev) Employees : 24 Installations: about 100 (D&B) (water treatment plants) Distributors: Europe, Brazil (export about 40%) Web: http://www.saitaimpianti.com
Products: HP Package (Hot Water m-stage) Size: 0.5 -9 (60) ton/day (0.1-8 gpm) Technology: Coil heat exchanger Scraper Price: about 10% lower
Website
Mechanical & Surface treatments | December 2015
applications
case studies
Industries
The scope of this webinar
Mechanical & Surface treatments | December 2015
Evaporators applied in …
Mechanical and Surface Treatments
AutomotiveAviationFurnitureApplianceOthers
Photovoltaic &Microelectronics
Treatment Challenges
New lubrorefrigerant case
Mechanical & Surface treatments | December 2015
Very high quality of the treated stream(COD<50 ppm) Lowest value of residue to dispose
Evaluate the feasibility of the treatment of a new lubrorefrigerant
Challenges
Trials on Evaporation with superconcentration for ZLDUF AC as polishing of the distillate
Goals
Solution
For internal use only
NL case
Mechanical & Surface treatments | December 2015 For internal use only
First evaporation stage Second evaporation stage
Final results
inside the pilot
Distillate, UF permeate and concentrate
NL case
Mechanical & Surface treatments | December 2015
Parameters M.U. Feed Distillate UF Permeate
COD mg/l 106200 836 <50
ZLD possible: TS on final conc > 70%
>> Very good quality : target on COD reached before AC
Exausted Emulsion Study
Mechanical & Surface treatments | December 2015
Facing problems of : • Bacteria and fungi• Quality of emulsions, composition and
surfactants• Quality of the distillate
Challenges
Distillate reuse for the production of fresh emulsions
Goals
Lab tests and data collection from 20 working plants
Solution
For internal use only
Oil emulsion
Mechanical & Surface treatments | December 2015
The main contaminants which reduce the effectiveness of the oil emulsions are, mainly:•Parasite oils from leaks of the hydraulic systems• Metallic solid particles• Micro-organisms (bacteria and fungus)• Other contaminants (different solids)
An oil emulsion can be considered exhausted when:•its microbiologic decomposition starts• the superficial quality of the metal piecesdecreases• the composition of additives lessens• the undesirable toxic substances such asgerms and heavy metals increase
COMPOSITION:BiocidesHumectants/stabilizersHeavy metalsEmulgents (anionic and non ionic)
Coolants (water)Lubricant (mineral, vegetal or synthetic oils)
Corrosion inhibitorsComplexants (EDTA)Dyes
Die lubricants
Mechanical & Surface treatments | December 2015
They are miscible in water and contain an active principle, the lubricant/releaser,which has the aim to create a compact layer on the mold surface to allow an easilyextraction of the part.
Particular importance assumes the water quality in terms of hardness,temperature and purity for the product efficiency
DEG diethylen glycolPEG polypropylen glycolDMBE diethylenglycol monobuthyletherSolid HC PolysiloxanesEmulsifying agents
Analysis: Propylen/ Ethylen glycol (5% PG/EG water)
Mechanical & Surface treatments | December 2015
Parameters (Propyl.Glyc.solution) Units Distillate Waste
pH 11.6 10.1conductivity µS/cm (20°C) 11.7 752COD mg/l 381 72200solid cont. (105°C) % 0.12propylen glycol mg/l 104 8900
Parameters (Ethyl.Glyc. solution) Units Distillate Waste
pH 8.5 9.9conductivity µS/cm (20°C) 2.6 504COD mg/l 4240 69700solid content (105°C) % 0.12ethylen glycol mg/l 833 19500
Analysis: bacteria and fungi test
Mechanical & Surface treatments | December 2015
Units Waste Distillate 1 Distillate 2
pseudomonasspp
UFC* /ml 500 0 100
mesophilebacteria
UFC* /ml 5.000.000 1 70.000
(*) UFC = Colony forming units
1= fresh distillate2= distillate after exposure to air (> 48 h)
Distillate quality
Mechanical & Surface treatments | December 2015
COD distribution in the distillate (22 measures)
5
78
2
0
5
10
0 - 150 150 - 500 500-1000 1000-1500COD [mg/l]
freq
uenc
y
14
43
2
0
5
10
15
0 - 0,3 0,3 - 0,5 0,5 - 1 1 - 2
freq
uen
cy
tenside concentration [mg/l]
tensides concentration distribution in the distillate (22 measures)
Very good separation of the surfactant agents
Good separation of COD
oil concentration distribution in the distillate(25 measures)
20
20
2 10
5
10
15
20
25
0 - 20 20 - 50 50 - 100 100 - 200 > 200
oil concentration [mg/l]
freq
uenc
yGood separation of oils
ZLD Automotive case
Mechanical & Surface treatments | December 2015
Treating RO concentrate after a complex process line (MBR+softening+RO)
Challenges
Achieving a ZLD configuration Goals
EVALED Evaporation (RV F 60 FF) crystallization (AC R 3 FF)
Solution
For internal use only
ZLD case
Mechanical & Surface treatments | December 2015
ZLD possible: TS on final conc > 70%Recovery > 98%
>>Parameters M.U. Feed Distil. Conc.
TS % 0.8 - >80
Conductivity µS/cm 9000 -100000
20 -30 >200000
For internal use only
Chromic Acid Reuse case
Mechanical & Surface treatments | December 2015
Replacing an existing evaporation unit from competitors having corrosion problems for a combination of a strong acid (Chromic Acid) and Fluorides
Challenges
Provide a unit suitable to handle chromic acid without corrosion issues
Reuse the Chromium Oxide back in the working bath
Goals
Installation of an Evaled Heat Pump PC F 6 KT unit in inert material.
Heat exchanger tubes: Silicon carbide and PVDF Evaporator: coated with fluoride polymer ECTFE
Solution
For internal use only
CAR: the plant solution
Mechanical & Surface treatments | December 2015
Chromium plating process• treatment of rinsing waters from the counter current washing tanks where the shock absorbers are immersed•Pre-treatment by strong cationic resin for removal of heavy metals (HM) to allow the reuse of the evaporator’s concentrated solution in the working bath.
Working bath
Cr 6+ Drag-out
Rinse RinseRinse
DistillateConcentrate EvapEvap
SC
IER SCHMsepar.15 g/l
Cr Cr 3+3+
Cr Cr 6+6+
IER
SA
CAR case
Mechanical & Surface treatments | December 2015
Parameters M.U. Feed Distillate
pH 1.4 3.6
Cr6+ mg/l 4400 <20
99% removal on Chromium in the distillate
For internal use only >
Parameters M.U. Feed Conc
pH 1.4 1,2
Cr6+ g/l 3-5 30
Reuse of Cr6+ in the working bath >
>
>
Turn
ing
was
tew
ater
into
a re
sour
ceMechanical & Surface treatments | December 2015
Case studies
MechanicalAutomotiveAviationFurnitureAppliance
1) Automotive 12) Automotive 23) Furniture 14) Appliance 15) Automotive 3
Automotive 1
Customer needs
New Automotive plant startup in early 2012 with twonew production lines and anannual output capacity of400,000 vehicles/year
Customer
To reduce the environmental impact ofthe plant, no industrial waste watercan be discharged (ZLD) into thenatural ecosystem andthe quantity of water consumed bymanufacturing processes must be cutby more than 50%. For internal use only
Mechanical & Surface treatments | December 2015
The plant
Analysis and Plant Process DiagramChemical Physical
plant
Dispose as solid waste
Distillate 109 ton/day
Concentrate 1 ton/day
Parameters u.m. Waste In
Distill.Out
Concent.Out
pH 8.3 7.7 -TS at 105 º C % 0.9 - >90Conductivity µS/cm 10000 <30 -COD ppm <100 <10Chloride ppm 700 <1 -Boron ppm <10 <0.1 -
Recycled to the RO system
RV
ACTechnology Type
Material Footprint(m2)
2 x RV F 60 FF UNS S 32750
85
2 x AC R 3 FF UNS S 32750
14
RO Conc. 110 ton/day (20gpm)
For internal use only
MBR Biological plant
RV
AC
RO Membrane Plant
Line 1 Line 2
Mechanical & Surface treatments | December 2015
Results
The solution achieved:heat recovery coming from cogeneration (CO2 footprint reduction)Water reuse 100%the target of water consumption cut at more than 70%
Water separated: ~ 99%Concentration factor: 40-100 times
For internal use onlyMechanical & Surface treatments | December 2015
For internal use only
These results will be achieved through innovative manufacturing processes, the use of renewable energy and the optimization of the water cycle.
The environmental impact of Renault’s Tangier plant will be reduced to levels that have never been reached :
o CO2 emissions cut by 98%, equivalent of about 135,000 tons of CO2 per year
o no industrial waste water discharged into the natural ecosystem (ZLD)
o quantity of water consumed cut by 70%.
From the website
Automotive 2
Customer needs
Customer
For internal use only
The plantis the only car manufacturer in Slovakia, manufacturing engines. At the Slovakian facility (300.000 vehicles capacity), the Company manufactures gasoline engines with five manufacturing lines: four metal cutting lines and one assembly line.
The customer aimed at reducing the oily waste water disposal costs.In their plans to improve environmental impact and to reduce their total amount of CO2, they needed to exploit the energy content of the oil fraction.
Mechanical & Surface treatments | December 2015
The plant
Analysis and Plant Process Diagram
Waste water inlet 30 ton/day (5.5 gpm)
Distillate27.9 ton/day
Concentrate2.1 ton/day
Parameters u.m. Waste In
Distill.Out
Concent.Out
COD ppm 6000 <200 -pH 5.8 9.7TS at 105 º C % 0.2-0.3 - 10Oils ppm 850 <30Conductivity µS/cm 1300 100 -TSS ppm <450 0 8000-
9000
Permeate discharged
RV
TechnologyType
Material Footprint(m2)
RV F 30 AA AISI 316 14
Outlet Quality
incineration
For internal use only UF Plant
Coalescent separator
CNC Working machine
Parts cleaning baths
Mechanical & Surface treatments | December 2015
Results
Water reused: ~ 95%Concentration factor: 20 times
For internal use only
The solution achieved:disposal cost reduction by
more than 15 timesrecovery of concentrate oil
reused as fuel (high calorific value) has reduced CO2 footprint
Mechanical & Surface treatments | December 2015
Furniture 1
Customer needs
Company specialized in different mechanical works and surface treatments as die-casting , deburring, grinding , sandblasting and die management operating as subcontractor for Furniture and Automotive (Moto cycles).
Reduce:o high disposal cost of about 15 m3/day of die-casting waste water.o increasing volumes of die lubricant used.
Customer
For internal use onlyMechanical & Surface treatments | December 2015
The plant
Analysis and Plant Process Diagram
Die casting waste water 15 ton/day (2.75 gpm)
Distillate14.6 ton/day
Concentrate0.4 ton/day
Parameters u.m. Waste In
Distill.Out
Concent.Out
pH 6.2 8.9 8.5Conductivity µS/cm <7600 <70 -
TS at 105 º C % 0.84 - < 50Total surfactants ppm 530 <2.5 -
COD ppm 8600 <1500 -
reused indie-casting process
PCTechnology Type
Material Footprint(m2)
PC R 1 FF UNS S 32750
3.3
RV F 15 FF UNS S 32750
10.5
For internal use only
Sent to oily collectors
RV
Tramp oil removal
Mechanical & Surface treatments | December 2015
Results
Water separated: ~ 97 % Concentration factor: ~ 33 times
The solution achieved:water rused in the production
processreduction of fresh die lubricants
consumptionImportant disposal cost reduction
For internal use onlyMechanical & Surface treatments | December 2015
Appliance 1
Customer needs
The Group is a global market leader for mechanical fastening systems and precision components. Based on a focused set of core technologies the company serve diversified end markets, including the automotive, construction/construction supply, electrical/electronics, aerospace and medical components industry.
A technology able to treat wastewater flow coming from a Cleaning Tunnel (EcocleanDürr) to reduce the waste disposal cost and the oily waste water management
Customer Italy
For internal use onlyMechanical & Surface treatments | December 2015
Analysis and Plant Process Diagram
The plant
Parameters u.m. Waste In
Distill.Out
Concent.Out
COD ppm 1000-4000
<50 < 50000
TS at 105 º C % 0.3 - 1 - <20Conductivity µS/cm 4000 <10 -Boron ppm 160 <2Surfactants ppm <600 <1 -Heavy Metals ppm 60 <0.01 <1500Tot Oils ppm 400-
1200<1 -
Technology Type
Material Footprint(m2)
PC F 8 AA AISI 316 7
Inlet Variability
The plant
Waste water inlet 8 ton/day (1.5 gpm)
Distillate>7.5 ton/day
Concentrate<0.5 ton/day
Reuse for cleaning
incineration
For internal use only
Coalescent separator
Fasteners Production
Parts cleaning Tunnels
Mechanical & Surface treatments | December 2015
PC
Results
Wastewater reduction: ~ 95 %Concentration factor: ~ 20 times
For internal use only
The solution achieved:water reuse for cleaningMore than 90 % waste disposal cost reduction
Coalescent oil separator
Mechanical & Surface treatments | December 2015
For internal use only
Customer
Customer needs
The company is a joint venture between the American car Manufacturer and a Russian one. The Elabuga Engine Plant is planned produce 100,000 units in 2015, with the possibility for further expansion.
Find a treatment solution able to reduce the disposal cost of the oily wastewater produced and reuse it within the manufacturing cycle.Create a solution to eliminate the controls on the discharge ww due to stringent discharge limits.
Russia
56
Automotive 3
Mechanical & Surface treatments | December 2015
Parameters u.m. Waste In QualityOutlet
Concent. Out
pH 6 - 9 7 - 8 -TS at 105 º C % 2 > 20COD ppm 25000 <500BOD 5 ppm 3000 <250Zinc ppm 100 <0.02 -Oil&Grease ppm 2000 <10 > 20000
For internal use only
Analysis and Plant Process Diagram
TechnologyType
Material Footprint(m2)
RV N 6 AA AISI 316 4.2
Distil. Quality
To dispose
Distillate 5.6 ton/day (1 gpm)
Concentrate 0.4 ton/day (0.1 gpm)
To reuse
Exausted oil emulsion6 ton/day (1.1 gpm)
Tramp Oil separation (storage tank oil removal )
UF Plant (oil polishing )
RV
Engine Parts Production
The plant
Mechanical & Surface treatments | December 2015
For internal use only
Water reused: > 90%Concentration factor: >10 times
The solution achieved:Disposal cost reductionReduction of the product water
impact, recycling the distillate in production
Energy saving using MVR technology (CO2 footprint reduction)
Water reuse
Pay-back: about 13 months
58
The results
Mechanical & Surface treatments | December 2015
For internal use only
Project Analysis and Plant Process Diagram
Future Option Crystallizer
Parameter u.m. Value WW Outlet ValuepH 6-9 6-9TSS mg/l 1000TS % 2Conductivity uS/cm 3000Chlorides mg/l 100Calcium mg/l 20BOD5 mg/l 3000 250COD mg/l 25000 500Oil&Grease mg/l 2000 50TKN mg/l 10 10Zinc (total) mg/l 100 0.02
59
The complete solution
Mechanical & Surface treatments | December 2015
For internal use only
Waste water: 6 ton/day ( 1.1 gpm) exhausted oil emulsion
Disposal cost calculation80 €/ton ( 0.36 $/gal) including transport and analysis Annual cost (300 working days) : about 144.000 €/y
Opex cost Available energy: EE 0.06 (€/kWh)Opex: about 7 €/ton (0.03 $/gal)Annual OPEX cost : about 11.340 €Separation: 5.4 tons/day water reuseConcentrate disposal cost: 80 €/ton ( 0.36 $/gal) Concentrate annual disposal cost: = about 14.400 €
Saving: 144.000 – 11.340 - 14.400 = 118.260 €/y
Pay-
back
: abo
ut13
mon
ths
60
Pay-back
Mechanical & Surface treatments | December 2015
Turn
ing
was
tew
ater
into
a re
sour
ceMechanical & Surface treatments | December 2015
Case studies
Surface Treatment
AutomotiveAviationFurnitureAppliance
1) Aluminum Plates2) Automotive Plating Line3) Automotive Chromium Line4) Furniture Pickling & Phosphating Line
Aluminum plates
Customer needs
Leading company in Aluminum Offset plate manufacturing since 1985, with production plants in Spain and China.
Customer
Treat the acid wastewater containing AlCl3 to obtain a by product to resell as flocculants at high concentration
For internal use only
Spain
Mechanical & Surface treatments | December 2015
The plant
Analysis and Plant Process Diagram
Distillate4.5 ton/day
IER Regeneration Diluted HCl
Reus
e in
pro
duct
ion
Concentrate1.5 ton/day
Parameters u.m.
Waste In
Distill.Out
Conc.Out
pH 1.7 2.7 4Conductivity µS/c
m120000 <1500 -
Al ppm 15000 <0.1 75000Chloride ppm 47000 <100 -AlCl3 % 7 - 10 - 35 (*)
Sold as flocculants For internal use only
Plate production
Pickling Acid Regen.
Al powder reaction
IE Resin Plant
PC
HCl + Al Diluted6 ton/day (1.1 gpm)
(*) selling quality request controlled by a densitymeter
Technology Type
Material Footprint(m2)
PC Forced Circ. E 6000 KT
Heat exchanger tubes: Silicon carbide and PVDFcoated with fluoride polymer ECTFE
8.2
Mechanical & Surface treatments | December 2015
Results
The solution achieved:ZLD plant with the water reuse for IER
regenerationVMR : AlCl3 sold as flocculant in the
WTP
Water reused: ~ 75% Valuable Material Recovery (VMR): AlCl3
For internal use onlydensitymeter
Mechanical & Surface treatments | December 2015
Pay-back
Waste water: 6 ton/day ( 1.1 gpm) acid IER regeneration (HCl + AlCl3)
Disposal cost calculation110 €/ton ( 0.6 $/gal) including transport and analysis Annual cost (300 working days) : about 200.000 €/y
Opex cost Available energy: EE 0.06 (€/kWh)Opex: about 13 €/ton (0.07 $/gal)Annual OPEX cost : about 24.000 €Separation: 4.5 tons/day water reuse (1.5 tons valuable product)Concentrate use: sold as Flocculant (35% AlCl3 conc.) :115 €/ton Concentrate annual selling profit: = about 50.000 €
Saving: 200.000 – 24.000 + 50.000 = 226.000 €/y
Pay-
back
: abo
ut14
mon
ths
For internal use onlyMechanical & Surface treatments | December 2015
Automotive Plating Line
Customer needs
The custumer is one of the largest Korean suppliers for the automotive industry. (assembly: four types of chassis modules. Production capacity of 300,000 u/y): in Slovakia produces parts of the braking system. These parts are subject to a passivation and zinc plating.
The plating line discharges about 60 ton/day of rinse water contaminated by heavy metals and acidic and alkaline streams. The customer request was to design a ZLD plant for the plating line to minimize the waste disposal cost and cut the water consumption.
CustomerSlovakia
For internal use onlyMechanical & Surface treatments | December 2015
The plant
Analysis and Plant Process Diagram
Filtration
Dispose as hazardous waste
Distillate56.2 ton/day
Concentrate1.8 ton/day
Parameters u.m.
Waste Mix In
Distill.Out
Concent.Out
pH 8-9 7 -TS at 105 º C % 0.6 - 20Conductivity µS/c
m<10000 <50 -
COD ppm 800 <50TDS ppm 4000-
6000- <160000
Boron ppm 50 <5 <1600
Recycled to the IER Plant
RV
Technology Type
Material Footprint(m2)
RV F 60 FF UNS S 32750
21
58 ton/day (11gpm)
For internal use only
Che -Phy Plant
Zn Plating Line
IER Plant
Rinsing Line
Mechanical & Surface treatments | December 2015
Results
Wastewater reduction: ~ 97% Concentration factor: ~ 30 times The solution achieved:
Zero Liquid Discharge92% disposal cost reductionWater reuse in the
manufacturing process
For internal use onlyMechanical & Surface treatments | December 2015
Automotive Chromium Line
Customer needs
Multinational company manufacturing automotive parts.
The polish facility makes shock absorbers for vehicles.
To reduce the high costs related to:
• waste water disposal of highly polluting and corrosive from hard chromium plating line
• operation of the galvanic line
Customer
Poland
For internal use onlyMechanical & Surface treatments | December 2015
The plant
Analysis and Plant Process Diagram Chromium plating waters6 ton/day (1.1 gpm)
Recycled to the chromium bath
Distillate5.4 ton/day
Recycled as rinse water
Concentrate0.6 ton/day
Parameters u.m. Waste In
Distill.Out
Concent.Out
Iron mg/l 150-200 <0.1 -Conductivity µS/cm <25000 <200 -TS at 105 º C % 1 -pH 1 - 2 3.6 1 - 1.5Density g/ml 1.006 - 1.5Cr6+ g/l 3.5- 5 <0.02 30
PC
Technology Type
Material Footprint(m2)
PC F 6 KT Heat exchanger tubes: Silicon carbide and PVDFcoated with fluoride polymer ECTFE
8.2
For internal use only
Fixed density controlled by density meter
Results
The solution achieved:complete ZLD, waste water reduction 100%Concentrate recycled to the chromium bath (adjustment of concentration by adding chromic anhydride and demineralised water)galvanic line OPEX reduction
Distillate recovered: ~ 90%Concentration factor: ~ 10 times
For internal use onlyMechanical & Surface treatments | December 2015
Furniture Phosphating & Pickling Line
Customer needs
Supplier of cold drawn alloyed and micro alloyed carbon steel tubes for applications in mechanical furniture, automotive and hydraulic pipes.
Find a solution to the ZLD wastewater generated from the tubes surface treatment: • phosphating line and sulfuric acid pickling line• wastewater treatment with a layout compatible with the limited space available
Customer
For internal use onlyMechanical & Surface treatments | December 2015
The plant (Pickling line)Analysis and Plant Process Diagram
Work. Bath Blow Down10 ton/day (1.8 gpm)
Distillate8 ton/day
Concentrate2 ton/day
Parameters u.m. Waste In
Distill.Out
Conc.Out
pH 1.5 -1.7 5.5 1.4
Conductivity µS/cm
8000 -15000 <20 -
TS at 105 º C % 0.6 -1 - 4
SO4 ppm 530 <5 -Heavy metals ppm 8600 <1 -
reused inthe washing line
Technology Type
Material Footprint(m2)
PC F 12 FF UNS S 32750
8.5
For internal use only
Send back to the Pickling bath
PC
Crystallizer
Washing
Tubes Pickling line (H2SO4)
Mechanical & Surface treatments | December 2015
The plant (Phosphating line)
Analysis and Plant Process Diagram
Parameters u.m. Waste In
Distill.Out
Conc.Out
pH 6 - 7 7 - 8 6 - 7
Conductivity µS/cm <3000 30 -TS at 105 º C % 0.5 - 5
Heavy metals ppm 200-
800 <0.5 2000-7000
Phosphor. ppm 100-200 <5 1000-
2000
Technology Type
Material Footprint(m2)
RV F 15 FF UNS S 32750
10.5
For internal use only
Blow Down15 ton/day (1.8 gpm)
Distillate13.5 ton/day Concentrate
Buffer solution1 ton/day reused in process
Disposed
Filter
Washing
Phosphatingline
Buffer Solution (1%)
RV Phos. Conc0.5 ton/day
Once a month
Mechanical & Surface treatments | December 2015
Results
Water reused: ~ 100 %Product Recovery : H2SO4 and Zinc Phosphate
The solution achieved:product recovered and reused
in the production processwater reuse in a real ZLD plantdisposal cost reduction
For internal use onlyMechanical & Surface treatments | December 2015
Turn
ing
was
tew
ater
into
a re
sour
ceMechanical & Surface treatments | December 2015
Case studies
Photo-Voltaic &Microelectronic
1) Case 12) Case 23) Case 34) Case 4
You will find all in….
Mechanical & Surface treatments | December 2015
• Industries Matrix Table
• Brochures
• digital catalogue
• Photos, Articles, Typical Analysis
• Videos (commercial, unit operation).
• Presentations (products, applications, case studies)
• Reference lists for each industry
• Technical reports (for each individual model)
www.evaled.com
The next step: Healthcare & Chemicals
Mechanical & Surface treatments | December 2015
You now need to know how to sell EVALED in each industry. And the rules differs by industry.
Join us for one or all of the future webinars dedicated to specific industries.
Mechanical & Surface Treatments
(Automotive, Aviation, Furniture, Appliances)
Photovoltaic & Microelectronic
Health Care (Pharma , Cosmetics)
Chemicals (Detergents, Explosives, Adhesives, Colorants)
Waste(Collectors, Landfill, Incinerators)
Biogas & Biof.
Food & Beverage Graph.A. - P&P
Textile
thank you
Q&A session
to cover any further doubts or opportunities