Tools and Techniques for Optimizing Metal Finishing Process/Environmental

MA Metal Finishing Forum

Kevin L. Klink, P.E.

2

Overview

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

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PROCESS/ENVIRONMENTAL PROJECTS

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0%

20%

40%

60%

80%

100%

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

Abili

ty to

Influ

ence

Tot

al C

apita

l Cos

t Advanced Planning

Manufacturing Optimization

Preliminary design

Detailed design

Construction and Equipment Installation

Conceptual Design

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

Opportunity to Influence Project

Project Timeline

Total Capital Cost

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Project 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

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WATER AND CHEMICAL RECOVERY AND REUSE

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Water 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

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Drag-out

Process Bath Rinse Tank 1

Rinse Tank 2

Drag-out Drag-in

Mak

e-up

Wat

er

Drag-out B

atch

Dis

char

ge to

W

aste

Tre

atm

ent

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e-up

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mis

try

Con

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us D

isch

arge

to

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te T

reat

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t

Mak

e-up

Wat

er

Con

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us D

isch

arge

to

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te T

reat

men

t

Metal Finishing Process Water Flow Schematic

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Purification Maintenance

Chemicals/Water Separation

System

Water Recycle System

Drag-out

Process Solution Maintenance and RinseWater Recycling

Impurities

Process Bath Rinse Tank 1

Rinse Tank 2

Purified Rinse Water (Low TDS)

Make-Up Water

Drag-out Drag-in

Purif

ied

Wat

er

Purified Chemicals

Drag-out

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A 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 Prevention

Incr

easi

ng c

osts

Increasing pollution prevention

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SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT

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

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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

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Process 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 Process

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

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Process Model Data Can be Exported to Tankline Spreadsheets

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Chemical 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

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 Calculations

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Linking Photos and Documents Into Data Software Enhances Value of Information

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Data Management System Software Implements Selected Automatic Responses to Data Results

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LIFE CYCLE INFORMATION MANAGEMENT

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Planning 1 year

Design 18 months 2 years

Facility Management 20 years

Construction

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 Use

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Early Data Input Maximizes Data Utility

Planning

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) 575-7900INCORPORATED

Planning

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Data Warehouse Delivers Benefits Over the Entire Lifecycle

Design

Planning

Construction

Startup Commissioning O&M

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

• Intranet O&M Manual

• O&M Logs, Notes

Design Files

• Software Input/output

Load/Unload

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CCR

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Type

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2

CCR

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Type

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Type

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Type

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CCR

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HWRLoad/

UnloadLoad/

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ttle

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Load/Unload

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Cr Collection Cr Treat

Equalization Primary pHAdjust MF Recirc.

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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

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Acid/Alkali Wastewater Discharge

Filter Press

Drum

Dialysate

Diffusate

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24

1

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4

2

3Water Treatment

Potable Water

Process Water

1

HWR

AtmosphericEvaporatorME

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Legend:

Evaporation

Process Water

Conc. Wastewater

Dilute Wastewater

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AtmosphericEvaporator

CleaningSkid

MF

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Line 2 Washdown

UV Oxidation?

2

WetScrubber

WetScrubber

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Type 3AnodizingAdditive B

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Type 3AnodizingAdditive A

HoldingTank

Type 2AnodizingHolding

Tank

DyeHolding

Tank

DyeHolding

Tank

DyeHolding

Tank

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Benefits 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

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Integrated 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

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Supply Chain Considerations

Motivation Respond to Requirements Opportunity for Improvement

Impacts Efficiency Quality Profitability