viviana nedel reckziegel -...
TRANSCRIPT
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R.F.Thiesen,E.Osrio,I.A.H.Schneider
LTMDEMIN PPGE3M,LASIDDEMET PPGE3M,UniversidadeFederaldoRioGrandedoSul
Av.BentoGonalves,9500 CEP:91501970,PortoAlegre,RS,Brazil
VivianaNedel Reckziegel
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Summary
Introduction
Materials and Methods
Results and Discussion
Conclusions
Acknowledgments
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Introduction
Forging is a manufacturing process involving the shaping ofmetal using localized compressive forces.
Lubrificant:1) Reduce the metalmetalfriction,2) Aimingatenablingtheremovaloftheforgedpartfrom
insidethematrix,3) Coolandprotect ,4) Extendtheusefullifeofthematrices.
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Types of Lubricants
TYPEOFLUBRICANT ADVANTAGES DISADVANTAGES
Graphite OilbasedIncreaseslifetime
Applicableinawiderangeofforgingoperations.Resistance.
Generationofhighlypollutinganddifficulttotreateffluents
Emissionofsmallamountofsmoke
GraphiteWaterbased
IncreasesarraylifeDoesnotgeneratesmoke
LessenvironmentallyaggressiveEasydilutioninwater
Graphiteparticlesmaybeemitted,possiblydamagingelectricalsystemsoraccumulatingontheshopfloor.
SyntheticAppliedinforgesthatworkwithspecificalloysandincutting
edgeindustriesHighcost
Solidbased Replaces 100%of lubricants
Highcost,limitedtoplaceswhereconventionaltypescannotbeused.Lowcomplexityparts.
Generalcharacteristicsoflubricantsusedintheforgingprocess.
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Introduction
Forging Press
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Change inProcess
Waterbased lubricant
Oilbased graphite lubricant
Purpose of this article is: studying the sludge generated from the treatment ofthe effluent using waterbased lubricant. The sludge characteristics, its handlingand final destination or reuse possibilities were assessed.
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Materials andMethodsPhysicalchemicalcharacteristicsofthewaterbasedgraphitelubricants
Parameter Waterbased lubricant
Color Dark gray
Appearance Homogeneous fluid
Graphite content >=10%
pH of the emulsion >=10
Density at 20 C 1.1 g/cm
Viscosity cSt at 40 C. 1500 mPa.s
Average particle size 4 m
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Materials andMethods
Schematicrepresentationofthestepsofthetreatmentstation.
Samples collected
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SludgeCharacterization
SettledvolumeASTMD3977; SpecificmassaccordingtoASTMD854, MoisturecontentASTMD221610; Ash,volatilematterandfixedcarboncontent(ASTMD317207); Calorificvalue(ASTMD201500); ElementalanalysisUSEPA3051,USEPA3050BandASTMD537302; CharacterizationregardinghazardsaccordingtotheStandardNBR10004.
Xray diffraction inaSiemensdiffractometer model Kristalloflex D500; Electronic scanning microscopy and (EDS) Granulometric analysis with laserbeam diffraction; Thermogravimetric analysis inaThermobalance Netzsch STA.
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Results and Discussion
Parameter Effluent OLStandard Efficiency(%)Raw Treated
DBO(mg/L) 6120 610
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SludgeCharacterization
SettledsludgeaftertreatmentintheImhoff Cone(a);afterfiltration(b),afterdryingat60oCandclodbreaking(c);aftercompactionat100MPa(d).
Sedimentation(1hour)=450mLofsludgeperliterofeffluent(55%ofthevolume)(24hours)=400mL(60%ofthevolumeofeffluentintheclarifiedform).
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SludgeElementalAnalysis
CLASSIIAWASTE NONINERT
Carbon70,7%
Aluminiun1,6%
Iron4,8%
Oxygen21%
Min.Elem*1,9%
SlugdeCompositionPAC
Carbon
Aluminum
Iron
Oxygen
MinorityElements
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SludgeCharacterization
Diffractogram referringtotheDRXanalysisofthesludgegenerated.
WaterbasedsludgeCalorificvalue(cal/g) 5850Ashes(%) 21.4Volatilematter(%) 9.0Fixedcarbon(%) 69.6
Immediateanalysis
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Thermogravimetric Analysis
Thermogravimetric analysis
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Alternatives forsludge recycling
Thechangeinlubricantsfromoilbaseddowaterbasedsimplifiedthewatertreatmentprocess,andgeneratedasludgethatcanbefiltered,driedandcompacted,reducingstorage,transportationanddisposalcosts.Thecharacteristicsofoilfreesludgeallowedsendingtocementkilns,reducingpartiallythecostsofdestination.
Aftersludgecharacterization,otherusescouldbeconsidered,includingascofiredcombustibletocoalthermalpowerplants.
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Conclusion
Forging industries generate considerable amount of emissions, effluents and waste,requiring investments to prevent pollution and environmental damage. The treatment ofeffluents is a required operation. The use of waterbased lubricants, replacing oilbasedlubricants, improves the environmental performance. The change of lubricant enabled asludge that can be easily filtered and handled. It presents a carbon content of 70% mainlyin the form of graphite, with certain level of oxidation. In a regional context, it may besurely employed for power generating purposes in thermoelectric plants or cement kilns.However, other application alternatives are being investigated, including its cleansing andreturn to the lubrication process.
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Acknowledgments
TheauthorsaregratefulforthefinancialsupportextendedbyGKN,CAPESandCNPq forthisresearch.
Thanks/OBRIGADA