Galvanotechnics

Changing existing galvanization plants to materials loss minimized techniques at simultaneous costs reduction: economic feasibility studies

Using a production-integrated optimisation system for process technology, potential for ecological and economic improvements in existing (long-established) installations has been realised. Prerequisites for this purpose are professional process management and the application of precisely defined reference quantities.

Summary

Expenditure on downstream clean-up and disposal measures can be significantly reduced by the application of production-integrated processes for the economisation of raw materials and waste avoidance.  In the electroplating sector, however, integrated concepts which can be applied regardless of the manufacturer concerned have continued to be subject to substantial reservations.

Using a production-integrated optimisation system, the object of this research project was to demonstrate by example that, where process technology is optimised for the reduction of material losses, potential for both ecological and economic improvements can be realised in existing (long-established) installations.  In selected electroplating undertakings, optimisation measures based upon a step-by-step and integrated approach have also been introduced and documented.

The object of the present subproject was the documentation of optimisation measures introduced in the various plants considered, for the purposes of operational analysis.

Results:

  • Chemical costs incurred by the partners involved in this project have been substantially reduced – in specific cases by up to 90%.  Significant reductions in waste disposal costs have also been recorded.  For other operating costs, only minor reductions have been achieved.
  • The payback period for the system units used in this project was no more than 36 months.
  • Professional process management is a major prerequisite for the success of integrated environmental protection measures.  For the purposes of process control and the identification of weak points, the application of precisely defined reference quantities is essential.

More Project Informations

Project title: Changing existing galvanization plants to materials loss minimized techniques at simultaneous costs reduction: economic feasibility studies

Project number: 01RK9732/6

Project period: 1997 - 2002

Project region:  Germany (Berlin)

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Source: German National Library of Science and Technology Hannover (TIB)