Tools and Techniques for Optimizing Metal Finishing Process/Environmental

MA Metal Finishing ForumMA Metal Finishing Forum

Tools and Techniques for Optimizing Metal Finishing Process/Environmental

MA Metal Finishing ForumMA Metal Finishing Forum

Kevin L. Klink, P.E.Kevin L. Klink, P.E.

2

OverviewOverview

Integrated Process/Environmental

Planning/Design Water and Chemical Recovery and Reuse Software Tools for Improved Decisionmaking

and Implementation Life Cycle Information Management Life Cycle Project Improvement Supply Chain Impacts

Integrated Process/Environmental

Planning/Design Water and Chemical Recovery and Reuse Software Tools for Improved Decisionmaking

and Implementation Life Cycle Information Management Life Cycle Project Improvement Supply Chain Impacts

3

PROCESS/ENVIRONMENTAL PROJECTSPROCESS/ENVIRONMENTAL PROJECTS

4

100%

0%

20%

40%

60%

80%

100%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Ab

ilit

y t

o I

nfl

uen

ce T

ota

l C

ap

ital

Co

st

AdvancedPlanning

ManufacturingOptimization

Preliminarydesign

Detailed design

Construction and EquipmentInstallation

ConceptualDesign

Maximum project cost control is gained through effective early planning and engineering

Opportunity to Influence Project Opportunity to Influence Project

Project Timeline

Total Capital Cost

5

Project Value is Maximized Through Systematic Planning and ImplementationProject Value is Maximized Through Systematic Planning and Implementation Plan for adequate and flexible systems that meet

current needs & can be easily modified to meet anticipated contingent/future scenarios

Design efficient systems that maximize product quality and yield and minimize waste

Implement useful information systems and documentation

Meet/exceed goals Avoid constraints

Plan for adequate and flexible systems that meet current needs & can be easily modified to meet anticipated contingent/future scenarios

Design efficient systems that maximize product quality and yield and minimize waste

Implement useful information systems and documentation

Meet/exceed goals Avoid constraints

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WATER AND CHEMICAL RECOVERY AND REUSE

WATER AND CHEMICAL RECOVERY AND REUSE

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Water and Chemical Recovery and ReuseWater and Chemical Recovery and Reuse

Drivers Reduce wastes Reduce solution contaminants and constituent

variations -- improve quality and performance of process solutions and rinse waters

Reduce chemical and water use

Constraints Buildup of undesirable contaminants Incremental systems that will not be properly operated

and maintained

Drivers Reduce wastes Reduce solution contaminants and constituent

variations -- improve quality and performance of process solutions and rinse waters

Reduce chemical and water use

Constraints Buildup of undesirable contaminants Incremental systems that will not be properly operated

and maintained

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Drag-outDrag-out

Process BathProcess Bath Rinse Tank Rinse Tank 11

Rinse Tank Rinse Tank 22

Drag-outDrag-outDrag-inDrag-in

Mak

e-u

p

Mak

e-u

p

Wat

erW

ater

Drag-outDrag-outB

atch

Dis

char

ge

to

Bat

ch D

isch

arg

e to

W

aste

Tre

atm

ent

Was

te T

rea

tmen

t

Mak

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p

Ch

emis

try

Mak

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p

Ch

emis

try

Co

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nu

ou

s D

isch

arg

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Co

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isch

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to W

aste

Tre

atm

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Was

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reat

me

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Mak

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Wat

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ater

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aste

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nt

Metal Finishing Process Water Flow Metal Finishing Process Water Flow SchematicSchematicMetal Finishing Process Water Flow Metal Finishing Process Water Flow SchematicSchematic

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PurificationPurificationMaintenanceMaintenance

Chemicals/Water Chemicals/Water Separation Separation

SystemSystem

Water RecycleWater RecycleSystemSystem

Drag-outDrag-out

Process Solution Maintenance and RinseWater Recycling

ImpuritiesImpurities

Process BathProcess Bath Rinse Tank Rinse Tank 11

Rinse Tank Rinse Tank 22

Purified Rinse Purified Rinse Water (Low TDS)Water (Low TDS)

Make-UpMake-UpWaterWater

Drag-outDrag-outDrag-inDrag-in

Pu

rifi

ed W

ate

rP

uri

fied

Wat

er

Purified ChemicalsPurified Chemicals

Drag-outDrag-out

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A Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle CostA Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle Cost

0 0.25 0.5 0.75 1

All pollution control

All pollution control

All pollution Prevention

All pollution Prevention

Incr

easi

ng

co

sts

Increasing pollution prevention

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SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT

SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT

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Navy Demonstrated Success with Off-the-Shelf Anodizing Process ControlsNavy Demonstrated Success with Off-the-Shelf Anodizing Process Controls

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Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing

Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing

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Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs

Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs

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Process Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual CostsProcess Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual Costs

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Process Cost Report Itemizes Nine Cost Categories for Each ProcessProcess Cost Report Itemizes Nine Cost Categories for Each Process

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Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual CostsModeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual Costs

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Process Model Data Can be Exported to Tankline SpreadsheetsProcess Model Data Can be Exported to Tankline Spreadsheets

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Chemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and InventoryChemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and Inventory

Initial Fill Monthly Usage AnnualChemical/Material Ordered Received Unit and Use Estimate Usage

Activated Carbon 500 500 lb 150 100 1200Ammonium Nitrate 2000 2000 lb 849 163 1957Anionic Polymer 110 110 gal 10 13 158Barrett Additive A 100 100 lb 0 11 127Barrett SN 2200 2200 gal 2200 NA NABarrett SNAC 200 200 lb 0 8 96Barrett SNAP AM 8 8 gal 0 8.7 104Barrett SNR-24 495 495 gal 0 177 2126Boric Acid 600 600 lb 344 171 2057Brush Plate 1 Lot brush plate brush plate brush plateCad. Concentrate brush plate brush plate brush plateCadmium Ball 2000 2013 lb 1000 16 193

Quantity Initial Fill Monthly Usage AnnualChemical/Material Ordered Received Unit and Use Estimate Usage

Activated Carbon 500 500 lb 150 100 1200Ammonium Nitrate 2000 2000 lb 849 163 1957Anionic Polymer 110 110 gal 10 13 158Barrett Additive A 100 100 lb 0 11 127Barrett SN 2200 2200 gal 2200 NA NABarrett SNAC 200 200 lb 0 8 96Barrett SNAP AM 8 8 gal 0 8.7 104Barrett SNR-24 495 495 gal 0 177 2126Boric Acid 600 600 lb 344 171 2057Brush Plate 1 Lot brush plate brush plate brush plateCad. Concentrate brush plate brush plate brush plateCadmium Ball 2000 2013 lb 1000 16 193

Quantity

Quantity After Months Order Contingent Minimum Months to MinInitial Fill Left Lead (mo) Quantity Inventory Inventory

350 3.5 3 50 350 0.001151 7.1 3 849 1338 (1.2)

100 7.6 3 0 39 4.6100 9.5 3 0 32 6.5

0 NA 3 1100 1100 0.00200 25 3 0 24 (22)

8 0.92 3 0 26 (2.1)495 2.8 3 0 532 (0.21)256 1.5 3 138 652 (2.3)

Chemical/MaterialActivated CarbonAmmonium NitrateAnionic PolymerBarrett Additive ABarrett SNBarrett SNACBarrett SNAP AMBarrett SNR-24Boric Acid

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Use of Data Management Software Provides Automatic Trend Plotting and Statistical CalculationsUse of Data Management Software Provides Automatic Trend Plotting and Statistical Calculations

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Linking Photos and Documents Into Data Software Enhances Value of InformationLinking Photos and Documents Into Data Software Enhances Value of Information

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Data Management System Software Implements Selected Automatic Responses to Data ResultsData Management System Software Implements Selected Automatic Responses to Data Results

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LIFE CYCLE INFORMATION MANAGEMENTLIFE CYCLE INFORMATION MANAGEMENT

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Planning1 year

Design18 months 2 years

Facility Management20 years

Construction

Planning Provides Awareness of Data Generation Over Project Life Cycle Planning Provides Awareness of Data Generation Over Project Life Cycle

DATA DATA DATA DATA

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A Data Warehouse Enhances Project Lifecycle Information Management and UseA Data Warehouse Enhances Project Lifecycle Information Management and Use

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Early Data Input Maximizes Data UtilityEarly Data Input Maximizes Data Utility

PlanningPlanning

Niklad 794Bright ElectrolessNickel Phosphorus ProcessProduct Code No. 78048

Technical Data SheetTable of Contents:1. Process description and advantages2. Deposit properties3. Process components4. Bath make-up5. Bath operation and control6. Solution analysis7. General guidelines8. Waste management9. Safety & handling guidelines10. Ordering informationMACDERMID INCORPORATED 245 FREIGHT ST. WATERBURY, CT USA 06702-9984 TEL (203) 575-5700 US FAX (203) 575-5630 INTERNATIONAL FAX (203) 575-7900

INCORPORATED

PlanningPlanning

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Data Warehouse Delivers Benefits Over the Entire LifecycleData Warehouse Delivers Benefits Over the Entire Lifecycle

DesignDesign

PlanningPlanning

Construction

Construction

Startup Commissioning O&M

Startup Commissioning O&M

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Access Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PCAccess Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PC

• IntranetO&M Manual

• O&M Logs, Notes

• IntranetO&M Manual

• O&M Logs, Notes

Design Files

Design Files

• Software Input/output

Load/Unload

Non

etch

Soa

k

Em

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Alk

alin

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CC

R 2

Des

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CC

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Type

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Type

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Type

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Type

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Type

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Type

3 A

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CC

R 1

CC

R 2

Bla

ck D

ye

Spr

ay R

inse

Dye

II

Dye

III

Type

1 A

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ze

CC

R 1

CC

R 2

Sea

l 1

Sea

l 2

Sea

l 3

CC

R 1

CC

R 2

HW

RLoad/Unload

Load/Unload

Wet

Shu

ttle

Em

pty

Em

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Em

pty

Em

pty

Dry

er

Dry

er

Dry

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Load/Unload

FogFog

Cr

Fog Fog Fog Fog Fog Fog

DD

DD

DD

DD

DD

DD

DD

DD

DD

DD

DD

DD

DD

Cr

Cr Collection Cr Treat

EqualizationPrimary pH

AdjustMF Recirc.

Acid NaOH

GAC

GAC

Final pH AdjustMicrofiltration

DRAFT

Integrated Pollution Prevention & Control Plan

SIZE FSCM NO DWG NO REV

C VisioDocumentVisioDocument

SCALE none SHEET 1 OF 2

Acid/Alkali

Process Water

Process Water

DD Feed

DD Bleed

Cr

Dye

Acid/Alkali Wastewater Discharge

Filter Press

Drum

Dialysate

Diffusate

Feed

2

3

2

4

1

1

4

2

3Water Treatment

Potable Water

Process Water

1

HW

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AtmosphericEvaporatorME

Wet

Shu

ttle

Legend:

Evaporation

Process Water

Conc. Wastewater

Dilute Wastewater

Sloped Bottom

CC

R 3

Em

pty

AtmosphericEvaporator

CleaningSkid

MF

Line 1 Washdown

Line 2 Washdown

UV Oxidation?

2

WetScrubber

WetScrubber

2

2

3

Dye

Spr

ay R

inse

Dye

Dye

Dye

Dye

Dye

Dye

Dye

Dye

Dye

Fog

Fog

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Fog

Dye

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Spr

ay R

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Dye

V

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l 4S

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Fog

Type 3AnodizingAdditive B

HoldingTank

Type 3AnodizingAdditive AHolding

Tank

Type 2AnodizingHolding

Tank

DyeHolding

Tank

DyeHolding

Tank

DyeHolding

Tank

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Benefits of State of the Art Project Data SystemsBenefits of State of the Art Project Data Systems

Data is more accessible and reliable

Accurate, reusable information for project lifecycle Improve project understanding and communications Reduces cost and accelerates project delivery time Lower risk for changes, conflicts, errors and

omissions Increased staff productivity due to easier access &

availability of data Improved record-keeping and cross-referencing

Data is more accessible and reliable

Accurate, reusable information for project lifecycle Improve project understanding and communications Reduces cost and accelerates project delivery time Lower risk for changes, conflicts, errors and

omissions Increased staff productivity due to easier access &

availability of data Improved record-keeping and cross-referencing

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Integrated Process Planning and Information Tools Produces Excellent BenefitsIntegrated Process Planning and Information Tools Produces Excellent Benefits

Establish requirements, goals, constraints Understand impacts of production ranges on process

systems and support systems Plan efficient life cycle information management systems Maximize opportunity to incorporate productive, efficient,

lean, profitable systems Initiate effective life cycle implementation and

mechanisms for continuous improvement Improve project delivery approach, information sharing,

efficiency, ability to control project, and ability to integrate beneficial technique and technology

Establish requirements, goals, constraints Understand impacts of production ranges on process

systems and support systems Plan efficient life cycle information management systems Maximize opportunity to incorporate productive, efficient,

lean, profitable systems Initiate effective life cycle implementation and

mechanisms for continuous improvement Improve project delivery approach, information sharing,

efficiency, ability to control project, and ability to integrate beneficial technique and technology

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Supply Chain ConsiderationsSupply Chain Considerations

Motivation Respond to Requirements Opportunity for Improvement

Impacts Efficiency Quality Profitability

Motivation Respond to Requirements Opportunity for Improvement

Impacts Efficiency Quality Profitability