Tools and Techniques for Optimizing Metal Finishing Process/Environmental MA Metal Finishing Forum Kevin L. Klink, P.E.
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Tools and Techniques for Optimizing Metal Finishing Process/Environmental
MA Metal Finishing Forum
Kevin L. Klink, P.E.
2
Overview
Integrated Process/Environmental Planning/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
3
PROCESS/ENVIRONMENTAL PROJECTS
4
0%
20%
40%
60%
80%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Abili
ty to
Influ
ence
Tot
al C
apita
l Cos
t Advanced Planning
Manufacturing Optimization
Preliminary design
Detailed design
Construction and Equipment Installation
Conceptual Design
Maximum project cost control is gained through effective early planning and engineering
Opportunity to Influence Project
Project Timeline
Total Capital Cost
5
Project Value is Maximized Through Systematic Planning 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
6
WATER AND CHEMICAL RECOVERY AND REUSE
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Water and Chemical Recovery and Reuse
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
8
Drag-out
Process Bath Rinse Tank 1
Rinse Tank 2
Drag-out Drag-in
Mak
e-up
Wat
er
Drag-out B
atch
Dis
char
ge to
W
aste
Tre
atm
ent
Mak
e-up
Che
mis
try
Con
tinuo
us D
isch
arge
to
Was
te T
reat
men
t
Mak
e-up
Wat
er
Con
tinuo
us D
isch
arge
to
Was
te T
reat
men
t
Metal Finishing Process Water Flow Schematic
9
Purification Maintenance
Chemicals/Water Separation
System
Water Recycle System
Drag-out
Process Solution Maintenance and RinseWater Recycling
Impurities
Process Bath Rinse Tank 1
Rinse Tank 2
Purified Rinse Water (Low TDS)
Make-Up Water
Drag-out Drag-in
Purif
ied
Wat
er
Purified Chemicals
Drag-out
10
A Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle Cost
0 0.25 0.5 0.75 1
All pollution control
All pollution Prevention
Incr
easi
ng c
osts
Increasing pollution prevention
11
SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT
12
Navy Demonstrated Success with Off-the-Shelf Anodizing Process Controls
13
Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing
14
Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs
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Process Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual Costs
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Process Cost Report Itemizes Nine Cost Categories for Each Process
17
Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual Costs
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Process Model Data Can be Exported to Tankline Spreadsheets
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Chemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and Inventory
Initial Fill Monthly Usage AnnualChemical/Material Ordered Received Unit and Use Estimate Usage
Activated Carbon 500 500 lb 150 100 1200Ammonium Nitrate 2000 2000 lb 849 163 1957Anionic Polymer 110 110 gal 10 13 158Barrett Additive A 100 100 lb 0 11 127Barrett SN 2200 2200 gal 2200 NA NABarrett SNAC 200 200 lb 0 8 96Barrett SNAP AM 8 8 gal 0 8.7 104Barrett SNR-24 495 495 gal 0 177 2126Boric Acid 600 600 lb 344 171 2057Brush Plate 1 Lot brush plate brush plate brush plateCad. Concentrate brush plate brush plate brush plateCadmium Ball 2000 2013 lb 1000 16 193
Quantity
Quantity After Months Order Contingent Minimum Months to MinInitial Fill Left Lead (mo) Quantity Inventory Inventory
350 3.5 3 50 350 0.001151 7.1 3 849 1338 (1.2)100 7.6 3 0 39 4.6100 9.5 3 0 32 6.5
0 NA 3 1100 1100 0.00200 25 3 0 24 (22)
8 0.92 3 0 26 (2.1)495 2.8 3 0 532 (0.21)256 1.5 3 138 652 (2.3)
Chemical/MaterialActivated CarbonAmmonium NitrateAnionic PolymerBarrett Additive ABarrett SNBarrett SNACBarrett SNAP AMBarrett SNR-24Boric Acid
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Use of Data Management Software Provides Automatic Trend Plotting and Statistical Calculations
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Linking Photos and Documents Into Data Software Enhances Value of Information
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Data Management System Software Implements Selected Automatic Responses to Data Results
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LIFE CYCLE INFORMATION MANAGEMENT
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Planning 1 year
Design 18 months 2 years
Facility Management 20 years
Construction
Planning Provides Awareness of Data Generation Over Project Life Cycle
DATA DATA DATA DATA
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A Data Warehouse Enhances Project Lifecycle Information Management and Use
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Early Data Input Maximizes Data Utility
Planning
Niklad 794Bright ElectrolessNickel Phosphorus ProcessProduct Code No. 78048
Technical Data SheetTable of Contents:1. Process description and advantages2. Deposit properties3. Process components4. Bath make-up5. Bath operation and control6. Solution analysis7. General guidelines8. Waste management9. Safety & handling guidelines10. Ordering informationMACDERMID INCORPORATED 245 FREIGHT ST. WATERBURY, CT USA 06702-9984 TEL (203) 575-5700 US FAX (203) 575-5630 INTERNATIONAL FAX (203) 575-7900INCORPORATED
Planning
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Data Warehouse Delivers Benefits Over the Entire Lifecycle
Design
Planning
Construction
Startup Commissioning O&M
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Access Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PC
• Intranet O&M Manual
• O&M Logs, Notes
Design Files
• Software Input/output
Load/Unload
None
tch S
oak
Empt
y
Alka
line
Etch
CCR
1
CCR
2
Desm
ut
Spra
y Rins
e
Acid
Etch
Tri A
cid
CCR
1
CCR
2
Chem
Film
CCR
1
CCR
2
Type
2 A
nodiz
e
CCR
1
CCR
2
CCR
3
Type
2 A
nodiz
e
Type
3 A
nodiz
eAd
ditive
A
Type
3 A
nodiz
eAd
ditive
B
Type
3 A
nodiz
eAd
ditive
B
Type
3 A
nodiz
eAd
ditive
B
CCR
1
CCR
2
Blac
k Dye
Spra
y Rins
e
Dye
II
Dye
III
Type
1 A
nodiz
e
CCR
1
CCR
2
Seal
1
Seal
2
Seal
3
CCR
1
CCR
2
HWRLoad/
UnloadLoad/
Unload
Wet
Shu
ttle
Empt
y
Empt
y
Empt
y
Empt
y
Drye
r
Drye
r
Drye
r
Load/Unload
FogFog
Cr
Fog Fog Fog Fog Fog Fog
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
Cr
Cr Collection Cr Treat
Equalization Primary pHAdjust MF Recirc.
Acid NaOH
GAC
GAC
Final pH AdjustMicrofiltration
DRAFT
Integrated Pollution Prevention & Control Plan
SIZE FSCM NO DWG NO REV
C VisioDocumentVisioDocument
SCALE none SHEET 1 OF 2
Acid/Alkali
Process Water
Process Water
DD Feed
DD Bleed
Cr
Dye
Acid/Alkali Wastewater Discharge
Filter Press
Drum
Dialysate
Diffusate
Feed
23
24
1
1
4
2
3Water Treatment
Potable Water
Process Water
1
HWR
AtmosphericEvaporatorME
Wet
Shu
ttle
Legend:
Evaporation
Process Water
Conc. Wastewater
Dilute Wastewater
Sloped Bottom
CCR
3
Empt
y
AtmosphericEvaporator
CleaningSkid
MF
Line 1 Washdown
Line 2 Washdown
UV Oxidation?
2
WetScrubber
WetScrubber
2
2
3
Dye
Spra
y Rins
e Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Fog
Fog
Fog
Fog
Fog
Dye
IV
Spra
y Rins
e
Dye
V
Seal
4Se
al 5
3
3
Fog
Fog
Type 3AnodizingAdditive B
HoldingTank
Type 3AnodizingAdditive A
HoldingTank
Type 2AnodizingHolding
Tank
DyeHolding
Tank
DyeHolding
Tank
DyeHolding
Tank
29
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
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Integrated Process Planning 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
31
Supply Chain Considerations
Motivation Respond to Requirements Opportunity for Improvement
Impacts Efficiency Quality Profitability
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