rinse water recovery system-metapure for recovery and reuse of electroplating rinse water. pure tech...
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Rinse water Recovery System-METAPurefor recovery and reuse of electroplating rinse water.
Pure Tech India,A-5, Trec step, Thuvakudi, Trichy -620 015Telephone:00 91-431 320 6753; Telefax: 00 91-431 250 1100E-Mail: [email protected]; website: www.puretechindia.com
Electroplating processes and various chemicals used:
S. No Plating process Major chemicals used
1 Cadmium plating Cadmium Oxide, Sodium Cyanide, Sodium Hydroxide
2 Zinc plating Zinc Oxide, Sodium Cyanide, Sodium Hydroxide
3 Copper plating Copper Cyanide, Sodium Cyanide, Sodium Hydroxide
4 Nickel plating Nickel Sulphate, Nickel Chloride, Boric Acid
5 Chromium plating High speed self regulating salt (Chromium sulphate, Chromic Acid)
Important Contributors in a Electroplating Effluent Generation:
Component Function Effluent Contribution/Remarks
Plating Bath Main component primarily responsible for plating. Contains bath chemicals.
Bath is not drained at all except for some unavoidable circumstances generally not seen.
Plating Rinse Removes excess coating material.
Major contributor of effluent. Contains primarily bath chemicals with some environmental contaminants.
Acid Bath and Rinse
To clean materials of rust. Bath and rinse becomes unusable after a particular period of operation. Main contaminants include rust material with some dust particles.
Alkali Bath and Rinse
To clean materials of rust preventive solutions, oil and grease for better plating efficiency.
Bath and rinse becomes unusable after a particular period of operation. Main contaminants include oil and grease, rust preventive solution.
Floor Washings
Spillovers from plating, rinse, acid and alkali tanks.
All effluents listed above in small quantities with water used for floor washing.
Treatment processes available:
• Chemical treatment using – Sulphuric Acid (pH reduction for chromium conversion)
– Sodium Bisulphite (used for converting hexavalent to trivalent Chromium)
– Sodium Hypo (Cyanide Oxidation)
– Lime/ Caustic (neutralization)
– Polyelectrolyte (flocculation)
– Clarification (solid- liquid separation) and– Solid sludge separation.
• Membrane based physical/physiochemical processes.
Conventional Treatment:
Electroplating Effluent
Oxidation/ Reduction/ Neutralization *
Neutralization
Precipitation
Flocculation (Polyelectrolyte)
Clarification
Sludge Storage
Dewatering
Disposal
Waste water discharge
* : NOTE
Cyanide waste: Oxidation
Chromium Waste: Reduction
Acid/Alkali Waste: Neutralization
Membrane Systems
An Overview
Filtration: Types and Comparison
Normal Filtration Cross- flow Filtration
• Normal Filtration: Water with contaminants pass in direction perpendicular to filter media. The contaminants will choke the pores of the filter media.
• Cross- flow Filtration: Water with contaminants pass in direction parallel to the filter media. The Outlet from this filtration will have two streams coming out. The concentrate stream will carry along with it the contaminants. The filtered water will come out of a separate outlet. The frequency of filter media getting choked is very low when compared to normal filtration.
Cross- flow Membrane Processes:
SS
Macromolecules
Sugar, DV Salts, DA
MV Salts, UA
MF
UF
NF
RO
Water
KEY:SS - Suspended solidsDV Salts - Divalent saltsDA - Dissociated acidsMV Salts - Monovalent saltsUA - Undissociated acids
Reject portion
Permeate portion
MF – Micro filtrationUF - Ultra filtration NF – Nano FiltrationRO – Reverse Osmosis
Specific advantages of membrane based treatment systems:
• Compact and less space occupying.• Marginal chemical consumption (needed in case of pH
correction).• Skid mounted systems.• Very low sludge generation.• Very low electricity consumption.• Requires little/ no civil construction.• Separated water is ideally suitable for high quality rinse
and bath top up.
Reverse Osmosis:
Finest form of filtration
Osmosis - Reverse Osmosis Illustration:
Concentrate Dilute DiluteConcentrate
Semi- Permeable Membrane
Semi- Permeable membrane is one which will allow only water molecules to pass and not salts.
In the Left diagram, under normal circumstances, water molecules from dilute solution side will permeate towards concentrate side to form an equilibrium.This is Osmosis and the pressure present is Osmostic pressure.
In the right diagram, when a pressure P is applied in excess to the normal pressure , water alone is squeezed into the dilute solution side from the concentrate solution side. This is Reverse- Osmosis.
Pressure P
Typical Reverse Osmosis Membranes:
Reverse Osmosis Process flow diagram:
RO membrane structure:
Separated components applications:
• Permeate flow (usable/product water flow) – Rinse– Bath top up
• Concentrate flow (Reject flow):-
– Bath (if the concentrate contains only salts used in the electroplating bath with permissible contaminants)
Reverse Osmosis Membranes Rejection Rates:
Solute Symbol Molecular weight Rejection (%)
Sodium Fluoride NaF 42 99
Sodium Cyanide NaCN (pH 11) 49 97
Sodium Chloride NaCl 58 99
Silica SiO2 (50 ppm) 60 98
Sodium Bi- Carbonate NaHCo3 84 99
Sodium Nitrate NaNo3 85 97
Magnesium Chloride MgCl2 95 99
Calcium Chloride CaCl2 111 99
Magnesium Sulphate MgSo4 120 >99
Nickel Sulphate NiSo4 155 >99
Copper Sulphate CuSo4 160 >99
Membrane based Rinse water recovery systems
Major contaminants and their removal:
S .No Contaminant Removal Process
1. pH Correction • Acid/ Alkali addition
2. Suspended Solids
• Stainless Steel Filter Strainer• Stainless Steel Bag Filter
3. Microscopic oil particles • Activated Carbon Filter
4. Coating Materials• IONICS unit using Reverse Osmosis membranes
Process Flow Diagram
Effluent from electroplating
process
Acid/ Alkali addition
Filtration System
High pressurepump
RO based IONICSUnit
Permeate tank to process
Pump
Reject back to bath/ treatment
Prep Tank
Low flow membrane systems:
High flow membrane systems:
A Typical application in electroplating process:Flow of parts
Stage 1 Stage 2 Stage 3 Stage 4
High Pressure Rinse
Chemical Cleaner
Spray-Dip-Spray
City Water RinsePhosphate Dip
Flow of parts
Stage 5 Stage 6 Stage 7 Stage 8 Stage 9 DI water Spray-Dip-Spray
City Water Rinse Chromate Dip Spray Rinse
Spray-Dip-Spray
Water Rinse
Spray Water Rinse
RO
TO WASTE TREATMENT
RO Process in Nickel Plating
feed
PLATE RINSE # 1 RINSE # 2
parts parts
RO
95%
recovery
concentrate permeate
Make-up
(Pure water)
evaporation
Benefits:• 70% of rinse water can be recovered and reused for Bath Top up
and as Rinse water.• Pollution Problem solved• The cost of treatment is got back to by way of water which can be
reused for rinsing process.
Customers:• Silver Crown Electroplaters: 100 and 200 LPH• Divya Engineering : 10 LPH• Sundaram Fasteners Limited, Chennai: 200 LPH
Other Electroplating Process related Products:
• Desorber: Oil water separator for Degreasing Baths.
• OleoSepa: Desorber, Ultrafiltration System for complete oil removal and reuse of Degreasing solutions.
• Bag Filtration System: For filtering suspended solids upto 1 microns for your plating baths. Filter media can be offered in Stainless Steel, Polypropylene and HDPE wire cloths. Complete unit can be fabricated in the above materials.
• RO Plant: For removing Total Dissolved Solids in water used for bath and rinse for better efficiency of plating.
Thank You
For Queries, Please contact:E- Mail:
[email protected](Photographs shown are taken from our supplied equipments
and there are feature additions taking place in each new equipment manufactured)