Surface Engineering
A chemical-free descaling process for cold hot-rolled sheet metal
In the mechanic-hydraulic cleaning process developed under the project, the scale to be removed (iron oxide) is used as the cleaning agent at the same time. The process is based on a patented high-pressure vacuum technology and reduces water consumption by 90%.
A new preparation process for the extension of the holding time of acidic zinc electrolyte and hydrochloric acid cleaning as well as process water circulation management in electroplating
© OFTECH Oberflächentechnik GmbH
An electroplating company built a mobile treatment unit in which any impurities are eliminated from the solutions at an early stage in the process using special ion exchangers. This saves large quantities of hydrochloric acid and sodium hydroxide solution. All of the rinse water is treated in a reverse osmosis filter system and then reintroduced into the water cycle.
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© DBU
The anticorrosion coating developed under the project contains very few organic solvents and is particularly suitable for coating metal surfaces in automotive manufacturing. It is applied in a single layer and hardens at low temperatures.
An analysis of energy and material flows showed that exploiting the energy content of the solvents can reduce the energy needed for the coating process and the waste generated in the paint shops.
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An analysis of energy and material flows was used as a basis for the implementation of measures to reduce the consumption of water, waste water and chemicals in the pretreatment of metal components.
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An analysis of energy and material flows identified measures to reduce the consumption of electricity and paint in the manufacture of lawn mower spindles, and to use the environmentally friendly resource of natural gas instead of fuel oil.
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An analysis of energy and material flows showed that a technical optimisation of the powder coating process and an improved use of energy from waste can considerably improve energy efficiency when coating wood composites.
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An energy analysis identified measures to increase energy efficiency in the paint shop.
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In four selected electroplating enterprises waste concepts were compiled for the five most common metal-applying process stages (copper, zinc, chrome, nickel galvanically and auto-catalytically). First the adjustment of the rinsing criteria to the actual need and the decrease of the drag out were examined by an optimization of the dripping off procedure. Depending on the operational conditions up to 40 % of the mud accumulation of the process stages could be avoided. It was found out that the savings of raw materials (feed) connected with the waste concepts usually make a larger contribution to the cost reduction than the avoided disposal costs.
Change of existing Electroplating plants to a process technique of minimised material losses and reduced costs: comparison of different biodegradation procedures implemented in order to regenerate degreasing solutions (Part 1)
The degreasing effect of the regenerated solution is satisfactory, both for the Bioclean and for the membrane bioreactor variants. A limiting factor of the two method variants is the poor emulsification of the tenside mixture used, which did not allow consistent emulsification of the oils introduced.
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