forschungszentrum karlsruhe in der helmholtz-gemeinschaft stand: 29.04.2015 folie: 1 seattle,...

Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft

Stand: 04/18/23 Folie: 1

Seattle, 24.9.2003

LCA

for Optimization

of electroplating SME’s



Seattle, 24.9.2003

Outline of the presentation

1. Methodology of ecological plant optimization -

(EPO)

2. Participants of the project

3. Results

4. Benefit of the projects



Seattle, 24.9.2003

Methodology of ecological plant optimization - (EPO)

Iteration

question

definition of systemand data collectionof the actual state

-

modelling ofSystem of actual

state

-

Definition of thetargets of theoptimisation

-

ecological analysis

recommondation ofactivities

ecological plant optimisation- EPO -

Iterative procedure through

systematical Material - and energy -

flow modelling to:

• technological analysis

• economic analysis

• ecological analysis

of plant optimisation.

modelling of Systemof target state

ecological extensionof the system

economic analysis

ecologicalresult economical

result



Seattle, 24.9.2003

Production plant

production plants

for auxiliary material and operating supply item production

Recycling and disposal- plants

peripheral system

Substrate production

(Educt)

Substrate-

processing(product)

Core system

Optional extension

System boundary

peripheral system

System boundary

Core system

System view of the

EPO

Separation of

core system

and peripheral

system




Seattle, 24.9.2003

c

x

Assessment ofmaterial andenergy flows

Process-based costaccounting

Ecologicalassessment

Modelling ofprocesses and plants

Resources EmissionsV

VI

VII

VIII

IX

IVI

II

III

Overall system (core and peripheral system)

Processes

actual state2 31

6

-target state

2 31 4

5 6

core systemcore systemVI




Seattle, 24.9.2003

Resources Em issionsV

VI

VII

VIII

IX

IVI

II

III

Core systems

Overall system (core & peripheral system)

actual state

2 31

6

-target state

2 31 4

5 6

core systemcore systemVI

Difference of Mass balances

Changing elementary flows




Seattle, 24.9.2003

Impact categories• Resources• Air acidification• Depletion of ozone layer• Eutrophication• Aquatic ecotoxicity• Human toxicity• Green house effect• Photochemical oxidants




Seattle, 24.9.2003

Assessment methodbased on German UBA

method

Discussion of results in the society needs to have an assessment method

accepted by the society




Seattle, 24.9.2003

Participants of the project

KME Rösler

Nachtmann

Feuerverzinkung Genthin Lufthansa

Technik

FSB

Siemens

Friedric

h

Grohe

Closed loop material flows

for surface

treatment processes

Conversion of existing

electroplating plants using

optimized material flow techniques

Feuerverzinkung Hannover

Liebherr

About 40 companiesinvolved

e.g.hmp

Institute forEnvironm ental Engineering

Departm ent of W asteMinim ization

Institute forEnvironm ental Engineering

Departm ent of W asteMinim ization



Seattle, 24.9.2003

• repairing- resp. Component electroplating in aircraft ind.• electroplating for decorative surfaces• electroplated deplating• acid polishing of glass• producing of printed circuit boards• anodisation of aluminia• electroplating of plastics• hot dip galvanizing• vibratory finishing

analysed plantsPCB etching-inner layerMatt nickle platingSodiumpersulfate etching with NaPS-RegenerationNeutralisation/ precipitationquality rinsingNitric acid etching of copperHydrochloric acid etchingAcid rinsingAcid polishingSulphuric acid etching of copperSealing and nickle sealingrinsingRinsing water cascadeThermal conzentrationdryingReverse osmoseChromium platingCopper platingNickle platingelectrosilveringZinc platingTin platingFull desalination of waterInside rinsing

Waste water traetmentAnodisation of aluminia incl. nanofiltration, vaporization and recyclingalkaline rinsingetching (pickling)

AccelerateCadmium-recyclingElectroless nickel platingChromate-detoxificationAlodineChromium sulphuric acid etchingCyanide- detoxificationpicklingE0-pickle; E6-pickleElectrolytical degreasingElectrolytical metal- extraction (Cu, Ni, Ag, Zn)degreasing

Softend water processDemetalizationDemetalization with sulfate sludge separationEpal-pickleExternal Recycling of Al- etching wasteDyeing of aluminiaHot dip galvanzingFluxingGlinting conventional and with vaporation and recyclingGlinting nickle platingVibratory finishingHard chrome platingIon exchanger circuit installation Circuit rinsingPCB-slightly etching with exchange, process heating and regeneration

processes



Seattle, 24.9.2003

All optimised production plants have decreasing

environmental impacts and

Cost savings

but

Not every target and actual state are comparable

Results



Seattle, 24.9.2003

Benefit of the project

• Pool of Excel-Models (about 900)

of electroplating processes

• Central Excel-Workbook

supporting the modelling of

core systems

Switch

Process dataspreading rates

consumption of chemicalsrinsing water volume

Materials data

Modeling of a process:EXCEL workbook

PretreatmentInputConcentrationschem. reactionsOutput

Main processInputConcentrationschem. reactionsOutput

rinsingrinser 1rinser 2circulating rinser

RegeneratorInputConcentrationschem. reactionsOutput

Waterpro-cessing1

Waterpro-cessing2

IO-costsMaterial flows,prices, plantcosts



Seattle, 24.9.2003

Benefit of the project

Knowledge database with the

qualitative results of the

research projects „Optimizing of

electroplating SME’s“

providing information for all

analysed, modeled and

optimized processes and

process-chains

structure of the database for one SME

SME

technologies

variants processes

states of processes



Seattle, 24.9.2003

Summary

• The development of the EPO-Method was successful

• The plants were successfully optimised (environmentally and economical)

• Several Excel-Models are ready for use• For new users there is a Database for the first

steps of an EPO



Seattle, 24.9.2003

Contact

Forschungszentrum Karlsruhe GmbH

Institute for technical chemistry

Department of Technology-Induced Material flow

(ITC-ZTS)

Dr.-Ing. Robert Ackermann

P.O.box 3640

D-76021 Karlsruhe

Phone: +49 7247 82 2712

Fax: +49 7247 82 6715

e-mail: [email protected]

forschungszentrum karlsruhe in der helmholtz-gemeinschaft stand: 29.04.2015 folie: 1 seattle,...

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forschungszentrum karlsruhe

helmholtzgemeinschaft

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