Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft. LCA for Optimization of electroplating SME s

Transcription

1 LCA for Optimization of electroplating SME s Stand: Folie: 1

2 Outline of the presentation 1. Methodology of ecological plant optimization - (EPO) 2. Participants of the project 3. Results 4. Benefit of the projects Stand: Folie: 2

3 Methodology of ecological plant optimization - (EPO) question definition of system and data collection - of the actual state ecological plant optimisation -EPO- ecological extension of the system modelling - of System of actual state Definition of the targets of the- optimisation modelling of System of target state Iteration Iterative procedure through systematical Material - and energy - flow modelling to: technological analysis economic analysis ecological analysis economic analysis ecological analysis of plant optimisation. ecological result economical result recommondation of activities Stand: Folie: 3

4 Methodology of ecological plant optimization - (EPO) production plants for auxiliary material and operating supply item production Substrate production (Educt) System boundary peripheral system System view of the EPO peripheral system Core system Production plant System boundary Core system Separation of Optional extension Substrateprocessing (product) Recycling and disposal- plants core system and peripheral system Stand: Folie: 4

5 Methodology of ecological plant optimization - (EPO) Overall system (core and peripheral system) Ecological assessment Assessment of material and energy flows Process-based cost accounting Modelling of processes and plants Resources VI III II I V IV target state core system VI - IX Processes VIII VII c Emissions actual state core system 6 x Stand: Folie: 5

6 Methodology of ecological plant optimization - (EPO) Changing elementary flows Overall system (core & peripheral system) I VII IV Resources II VI VIII Emissions V III IX Core systems Difference of Mass balances VI target state core system - actual state core system 6 Stand: Folie: 6

7 Methodology of ecological plant optimization - (EPO) Impact categories Resources Air acidification Depletion of ozone layer Eutrophication Aquatic ecotoxicity Human toxicity Green house effect Photochemical oxidants Stand: Folie: 7

8 Methodology of ecological plant optimization - (EPO) Assessment method based on German UBA method Discussion of results in the society needs to have an assessment method accepted by the society Stand: Folie: 8

9 Participants of the project Closed loop material flows for surface treatment processes About 40 companies involved Conversion of existing electroplating plants using optimized material flow techniques Feuerverzinkung Genthin Siemens Feuerverzinkung Hannover Friedrich Grohe FSB e.g. KME Lufthansa Technik Nachtmann Rösler Liebherr hmp Institute for Environmental Engineering Department of Waste Minimization Institute for Environmental Engineering Department of Waste Minimization Stand: Folie: 9

10 analysed plants 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 Waste water traetment Anodisation of aluminia incl. nanofiltration, vaporization and recycling alkaline rinsing etching (pickling) Accelerate Cadmium-recycling Electroless nickel plating Chromate-detoxification Alodine Chromium sulphuric acid etching Cyanide- detoxification pickling E0-pickle; E6-pickle Electrolytical degreasing Electrolytical metalextraction (Cu, Ni, Ag, Zn) degreasing PCB etching-inner layer Matt nickle plating Sodiumpersulfate etching with NaPS-Regeneration Neutralisation/ precipitation quality rinsing Nitric acid etching of copper Hydrochloric acid etching Acid rinsing Acid polishing Sulphuric acid etching of copper Sealing and nickle sealing rinsing Rinsing water cascade Thermal conzentration drying Reverse osmose Chromium plating Copper plating Nickle plating electrosilvering Zinc plating Tin plating Full desalination of water Inside rinsing processes Softend water process Demetalization Demetalization with sulfate sludge separation Epal-pickle External Recycling of Aletching waste Dyeing of aluminia Hot dip galvanzing Fluxing Glinting conventional and with vaporation and recycling Glinting nickle plating Vibratory finishing Hard chrome plating Ion exchanger circuit installation Circuit rinsing PCB-slightly etching with exchange, process heating and regeneration Stand: Folie: 10

11 Results All optimised production plants have decreasing environmental impacts and Cost savings but Not every target and actual state are comparable Stand: Folie: 11

12 Benefit of the project Modeling of a process: EXCEL workbook Pool of Excel-Models (about 900) of electroplating processes Switch Materials data Process data spreading rates consumption of chemicals rinsing water volume Central Excel-Workbook supporting the modelling of core systems Pretreatment Input Concentrations chem. reactions Output Regenerator Input Concentrations chem. reactions Output Main process Input Concentrations chem. reactions Output Water processing 1 rinsing rinser 1 rinser 2 circulating rinser Water processing 2 IO-costs Material flows, prices, plant costs Stand: Folie: 12

13 Benefit of the project Knowledge database with the qualitative results of the research projects Optimizing of electroplating SME s SME technologies! providing information for all variants processes analysed, modeled and optimized processes and process-chains states of processes structure of the database for one SME Stand: Folie: 13

14 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 Stand: Folie: 14

15 Contact GmbH Institute for technical chemistry Department of Technology-Induced Material flow (ITC-ZTS) Dr.-Ing. Robert Ackermann P.O.box 3640 D Karlsruhe Phone: Fax: Stand: Folie: 15