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October 2007 SERFILCO® Europe Ltd
FILTRATION AND PURIFICATION SYSTEMS TO MINIMISE
OCCUPATIONAL EXPOSURE TO NICKEL SALTS
IMF/NIDI CONFERENCE OCTOBER 4TH 2007
Huw Williams – SERFILCO® Europe Ltd
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October 2007 SERFILCO® Europe Ltd
• Prevents roughness• Extends life of solutions• As a pre-treatment to reverse osmosis,
coalescing and carbon
FILTRATION
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October 2007 SERFILCO® Europe Ltd
PURIFICATION
• Removes organic impurities
• Provides for uniform ductility
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October 2007 SERFILCO® Europe Ltd
FACTORS WHICH EFFECT THE CHOICE OF A FILTRATION SYSTEM
• Size of tanks• Type of solution• Degree of clarity
required• Initial cost• Cost to operate• Flow rate
• Compatibility to temperature and concentrations
• In-tank vs. Out-of-tank• Type and amount of solids to
be removed between servicing• Versatility to meet changing
requirements
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October 2007 SERFILCO® Europe Ltd
TYPE OF SOLIDS
Gritty• Sand-like usually
found in an acid solution will build up a cake or thickness which can remain porous to allow for additional flow through.
Slimey• Usually found in an
alkaline bath. String-like gels tend to blind a surface media prematurely.
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October 2007 SERFILCO® Europe Ltd
WHERE DO TROUBLESOME SOLIDS COME FROM?
• Drag in
• Anodes
• Water
• Airborne Sources
• Chemical Break-down
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October 2007 SERFILCO® Europe Ltd
FILTER SYSTEMS
• Pressurised Filtration
• Suction Filtration
• Gravity Filtration
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October 2007 SERFILCO® Europe Ltd
FILTER SYSTEMS FOR NICKEL
• Cartridge – Wound, Spun, Pleated
• Paper Disc
• Bag
• Permanent Media
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October 2007 SERFILCO® Europe Ltd
TYPICAL CARTRIDGE SYTEMS
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October 2007 SERFILCO® Europe Ltd
AUTOMATIC BACKWASH PERMANENT MEDIAFILTRATION SYSTEMS
AUTOMATIC BACKWASH PERMANENT MEDIAFILTRATION SYSTEMS
11 - 16m3/hr
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October 2007 SERFILCO® Europe Ltd
AUTOMATIC BACKWASH PERMANENT MEDIAFILTRATION SYSTEMS
AUTOMATIC BACKWASH PERMANENT MEDIAFILTRATION SYSTEMS
34 - 72m3/hr
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October 2007 SERFILCO® Europe Ltd
FILTER VESSEL
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October 2007 SERFILCO® Europe Ltd
FILTER VESSEL
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October 2007 SERFILCO® Europe Ltd
SEQUENCE OF OPERATION
• FILTRATION
• Blowdown #1 - air purge solution back to tank
• Backwash
• Blowdown #2 - air purge water to effluent
• FILTRATION
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October 2007 SERFILCO® Europe Ltd
NORMAL OPERATIONNORMAL OPERATION
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October 2007 SERFILCO® Europe Ltd
PRE-BACKWASH BLOWDOWNPRE-BACKWASH BLOWDOWN
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October 2007 SERFILCO® Europe Ltd
BACKWASH TO WASTE TREATMENT
BACKWASH TO WASTE TREATMENT
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October 2007 SERFILCO® Europe Ltd
POST BACKWASH BLOWDOWNPOST BACKWASH BLOWDOWN
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October 2007 SERFILCO® Europe Ltd
FLOW RATE PERFORMANCE OF DIFFERENT TYPES OF FILTER
SYSTEMS
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October 2007 SERFILCO® Europe Ltd
AUTOMATIC BACKWASH PERMANENT MEDIA
AUTOMATIC BACKWASH PERMANENT MEDIA
Possible Disadvantages• Higher Initial Cost than Most
Advantages• Zero Media costs - Buying/Disposal• Zero Labour Cost for Servicing• Low Sludge Formation• No Separate Drummed Waste• Zero solution loss• Application Specific Media• Optional Carbon Chamber
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October 2007 SERFILCO® Europe Ltd
COST JUSTIFICATION FOR AUTOMATIC PERMANENT MEDIA FILTER SYSTEM VS CARTRIDGES
Application - Filtration of 10000 litre Barrel Acid Zinc solution @ 25-35ºC. Plant has 6 x 48 inch barrels. Plant operating 8 hours per day x 5 days per week Cartridges - 24 x 30 inch 10 micron Cartridges are changed every 2 weeks
Cartridges used per year……………………………………………624 Average Cost of buying and disposing of 1 cartridge……………£15.00 Annual cost of filter media and disposal……………………………………£9360
Labour per change…………………………………………………..2 hours Labour per year………………………………………………………52hours Hourly rate……………………………………………………………£10.00
Annual Labour costs to maintain Filter…………………………………….£520
Solution loss per change………………………………………...28 litres Solution loss per year…………………………………………….728 litres Solution cost per litre……………………………………………...£3.90
Annual cost of solution loss…………………………………………………£2839.20
TOTAL COST INVOLVED WITH CARTRIDGE FILTRATION……………£12719.20 Cost of Automatic Permanent Filter system …………………………..£22500
THEREFORE PAYBACK PERIOD IS……………………………1.76 YEARS
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October 2007 SERFILCO® Europe Ltd
COST JUSTIFICATION FOR AUTOMATIC PERMANENT MEDIA FILTER SYSTEM VS
USING A PAPER DISC FILTRATION SYSTEM Application: - Typical Barrel Acid Zinc Plating Plant Note: - Filter Media is changed twice per week
Labour per week ……………………………………………2.5 hours Labour per year……………………………………………..130 hours Hourly rate ………………………………………………….. £10.00
Annual Labour costs to maintain Filter……………………………………£1300
Filter Media per week ………………………………………10kG Filter Media per year…………………………………………520kG Cost per kG…………………………………………………...£2.92
Annual cost of Filter Media…………………………………………………. £1518
Filter Papers per week………………………………………..30 Filter Papers per year…………………………………………1560 Cost per paper………………………………………………….£0.54
Annual cost of Filter Paper…………………………………………………..£842.40
Solution loss per week………………………………………...28 litres Solution loss per year………………………………………….1456 Solution cost per litre…………………………………………..£3.90
Annual cost of solution loss…………………………………………………£5678.40
Disposal per year……………………………………………….3.05m3 Disposal Cost per cubic metre………………………………..£348.80
Annual cost of disposal……………………………………………………….£1063.84
TOTAL COST INVOLVED WITH PAPER/DISC FILTRATION……………………£10402.64 COST OF NEW AUTOMATIC PERMANENT MEDIA FILTER SYSTEM………...£17534 THEREFORE PAYBACK PERIOD IS……………………………1.68 YEARS
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October 2007 SERFILCO® Europe Ltd
MEDIA
• The chemical and physical properties are important.
• The media must be hard, not smooth, and free of soluble particles.
• Chemical content is less than 0.0001% of the following:- Arsenic, Cadmium, Chromium, Cyanide, Copper, Nickel, Lead, Zinc and Mercury.
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October 2007 SERFILCO® Europe Ltd
MEDIA
DESCRIPTION U.S. MESH APPROVALS
Sand – 45 - .55 mm
40-30 AWWA 100-89 SPECS
Gravel – 1/4" x 1/8" (#3)
6-3 medium
AWWA 100-89 SPECS
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October 2007 SERFILCO® Europe Ltd
MEDIA
• Acid Solubility (AWWA B100-89) - 5% max• Specific Gravity (AWWA B100-89)- 2.62% min• Porosity (ASTM C30/37)- 38.35%• Loss of Ignition (AFC Handbook) 0.69%• Hour Absorption 0.48%• Dry Unit Weight (PFC) 100.00 lbs/of
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October 2007 SERFILCO® Europe Ltd
BY-PASS CARBON PURIFICATION
• More adsorptive surface area than powdered carbon.
• Chambers are separate to the filter system and permit intermittent or continuous, controllable carbon purification.
• Only Filtered solution is treated.
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October 2007 SERFILCO® Europe Ltd
BY-PASS CARBON PURIFICATION
• Reduces brightener and solution costs when compared to continuous or batch powdered carbon slurry treatments.
• Large savings compared to Carbon cartridges.
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October 2007 SERFILCO® Europe Ltd
• CARBON CHAMBER
• 1, 3 OR 7 CANISTERS
• 3 MICRON TRAP FILTER
• CLEAN AND EASY
• UP TO 21 Kg IN 1 CHAMBER
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October 2007 SERFILCO® Europe Ltd
Schematic of Automatic Filter with Mobile By-pass Carbon chamber installed
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October 2007 SERFILCO® Europe Ltd
IN CONCLUSION
USING AN AUTOMATIC, PERMANENT MEDIA FILTRATION SYSTEM COUPLED WITH A MOBILE CARBON CHAMBER ON NICKEL PLATING SOLUTIONS:-
• Reduces operator exposure to nickel salts• Reduces down time and filtration costs• Produces crystal clear electrolytes by maintaining a high average
flow rate• Reduces roughness and improves quality• Provides for uniform Ductility• Provides for the most cost effective and user friendly organic
removal