Overview PROCESS/ENVIRONMENTAL PROJECTS. Project Value is Maximized Through Systematic Planning and Implementation

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1 Overview Tools and Techniques for Optimizing Metal Finishing Process/Environmental MA Metal Finishing Forum Kevin L. Klink, P.E. Integrated Process/Environmental /Design Water and Chemical Recovery and Reuse Software Tools for Improved Decisionmaking and Implementation Life Cycle Information Management Life Cycle Project Improvement Supply Chain Impacts 2 Opportunity to Influence Project 100% Advanced PROCESS/ENVIRONMENTAL PROJECTS Ability to Influence Total Capital Cost 80% 60% 40% 20% Manufacturing Optimization Conceptual Design Preliminary design Detailed design 100% Total Capital Cost Construction and Equipment Installation Maximum project cost control is gained through effective early planning and engineering 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Project Timeline 3 4 Project Value is Maximized Through Systematic and Implementation Plan for adequate and flexible systems that meet current needs & can be easily modified to meet anticipated contingent/future scenarios Design efficient systems that maximize product quality and yield and minimize waste Implement useful information systems and documentation Meet/exceed goals Avoid constraints WATER AND CHEMICAL RECOVERY AND REUSE 5 6

2 Water and Chemical Recovery and Reuse Metal Finishing Process Water Flow Schematic Drivers Reduce wastes Reduce solution contaminants and constituent variations -- improve quality and performance of process solutions and rinse waters Reduce chemical and water use Constraints Buildup of undesirable contaminants Incremental systems that will not be properly operated and maintained Make-up Chemistry Drag-in Process Bath Batch Discharge to Waste Treatment Make-up Water 1 Continuous Discharge to Waste Treatment Make-up Water 2 Continuous Discharge to Waste Treatment 7 8 Process Solution Maintenance and RinseWater Recycling A Balance of Integrated Pollution Prevention and Pollution Contr ol Provides Lowest Life Cycle Cost Drag-in Process Bath Maintenance 1 Purification Purified Water 2 Water Recycle System Purified Rinse Water (Low TDS) Increasing costs All pollution control All pollution Prevention Impurities Purified Chemicals Chemicals/Water Separation System Make-Up Water Increasing pollution prevention 10 Navy Demonstrated Success with Off-the-Shelf Anodizing Process Controls SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT 11 12

3 Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs Process Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual Costs Process Cost Report Itemizes Nine Cost Categories for Each Process Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual Costs Process Model Data Can be Exported to Tankline Spreadsheets 17 18

4 Chemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and Inventory Use of Data Management Software Provides Automatic Trend Plotting and Statistical Calculations Quantity Initial Fill Monthly Usage Annual Chemical/Material Ordered Received Unit and Use Estimate Usage Activated Carbon lb Ammonium Nitrate lb Anionic Polymer gal Barrett Additive A lb Barrett SN gal 2200 NA NA Barrett SNAC lb Barrett SNAP AM 8 8 gal Barrett SNR gal Boric Acid lb Brush Plate 1 Lot brush brush plate plate brush plate Cad. Concentrate brush plate brush plate brush plate Cadmium Ball 2000 lb Chemical/Material Activated Carbon Ammonium Nitrate Anionic Polymer Barrett Additive A Barrett SN Barrett SNAC Barrett SNAP AM Barrett SNR-24 Boric Acid Quantity After Months Order Contingent Minimum Months to Min Initial Fill Left Lead (mo) Quantity Inventory Inventory (1.2) NA (22) (2.1) (0.21) (2.3) Linking Photos and Documents Into Data Software Enhances Value of Information Data Management System Software Implements Selected Automatic Responses to Data Results Provides Awareness of Data Generation Over Project Life Cycle LIFE CYCLE INFORMATION MANAGEMENT 1 year Design Construction 18 months 2 years Facility Management 20 years DATA DATA DATA DATA 23 24

5 MACDERMIDINCORPORATED 245 FREIGHT ST. WATERBURY, CT USA TEL (203) US FAX (203) INCORPORATED INTERNATIONAL FAX (203) A Data Warehouse Enhances Project Lifecycle Information Management and Use Early Data Input Maximizes Data Utility Niklad 794 Bright Electroless Nickel Phosphorus Process Product Code No Technical Data Sheet Table of Contents: 1. Process description and advantages 2. Deposit properties 3. Process components 4. Bath make-up 5. Bath operation and control 6. Solution analysis 7. General guidelines 8. Waste management 9. Safety & handling guidelines 10. Ordering information Data Warehouse Delivers Benefits Over the Entire Lifecycle Access Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PC Startup Commissioning O&M Design Files Software Input/output Intranet O&M Manual O&M Logs, Notes Construction Design Benefits of State of the Art Project Data Systems Data is more accessible and reliable Accurate, reusable information for project lifecycle Improve project understanding and communications Reduces cost and accelerates project delivery time Lower risk for changes, conflicts, errors and omissions Increased staff productivity due to easier access & availability of data Improved record-keeping and cross-referencing 29 Integrated Process and Information Tools Produces Excellent Benefits Establish requirements, goals, constraints Understand impacts of production ranges on process systems and support systems Plan efficient life cycle information management systems Maximize opportunity to incorporate productive, efficient, lean, profitable systems Initiate effective life cycle implementation and mechanisms for continuous improvement Improve project delivery approach, information sharing, efficiency, ability to control project, and ability to integrate beneficial technique and technology 30

6 Supply Chain Considerations Motivation Respond to Requirements Opportunity for Improvement Impacts Efficiency Quality Profitability 31