Viviana Nedel Reckziegel - uest.ntua.gruest.ntua.gr/athens2017/proceedings/presentations/ppt_athens... · • Characterization regarding hazards according to the Standard NBR 10004.

R.F.Thiesen,E.Osrio,I.A.H.Schneider

LTMDEMIN PPGE3M,LASIDDEMET PPGE3M,UniversidadeFederaldoRioGrandedoSul

Av.BentoGonalves,9500 CEP:91501970,PortoAlegre,RS,Brazil

VivianaNedel Reckziegel

Summary

Introduction

Materials and Methods

Results and Discussion

Conclusions

Acknowledgments

Introduction

Forging is a manufacturing process involving the shaping ofmetal using localized compressive forces.

Lubrificant:1) Reduce the metalmetalfriction,2) Aimingatenablingtheremovaloftheforgedpartfrom

insidethematrix,3) Coolandprotect ,4) Extendtheusefullifeofthematrices.

Types of Lubricants

TYPEOFLUBRICANT ADVANTAGES DISADVANTAGES

Graphite OilbasedIncreaseslifetime

Applicableinawiderangeofforgingoperations.Resistance.

Generationofhighlypollutinganddifficulttotreateffluents

Emissionofsmallamountofsmoke

GraphiteWaterbased

IncreasesarraylifeDoesnotgeneratesmoke

LessenvironmentallyaggressiveEasydilutioninwater

Graphiteparticlesmaybeemitted,possiblydamagingelectricalsystemsoraccumulatingontheshopfloor.

SyntheticAppliedinforgesthatworkwithspecificalloysandincutting

edgeindustriesHighcost

Solidbased Replaces 100%of lubricants

Highcost,limitedtoplaceswhereconventionaltypescannotbeused.Lowcomplexityparts.

Generalcharacteristicsoflubricantsusedintheforgingprocess.

Introduction

Forging Press

Change inProcess

Waterbased lubricant

Oilbased graphite lubricant

Purpose of this article is: studying the sludge generated from the treatment ofthe effluent using waterbased lubricant. The sludge characteristics, its handlingand final destination or reuse possibilities were assessed.

Materials andMethodsPhysicalchemicalcharacteristicsofthewaterbasedgraphitelubricants

Parameter Waterbased lubricant

Color Dark gray

Appearance Homogeneous fluid

Graphite content >=10%

pH of the emulsion >=10

Density at 20 C 1.1 g/cm

Viscosity cSt at 40 C. 1500 mPa.s

Average particle size 4 m

Materials andMethods

Schematicrepresentationofthestepsofthetreatmentstation.

Samples collected

SludgeCharacterization

SettledvolumeASTMD3977; SpecificmassaccordingtoASTMD854, MoisturecontentASTMD221610; Ash,volatilematterandfixedcarboncontent(ASTMD317207); Calorificvalue(ASTMD201500); ElementalanalysisUSEPA3051,USEPA3050BandASTMD537302; CharacterizationregardinghazardsaccordingtotheStandardNBR10004.

Xray diffraction inaSiemensdiffractometer model Kristalloflex D500; Electronic scanning microscopy and (EDS) Granulometric analysis with laserbeam diffraction; Thermogravimetric analysis inaThermobalance Netzsch STA.

Results and Discussion

Parameter Effluent OLStandard Efficiency(%)Raw Treated

DBO(mg/L) 6120 610

SludgeCharacterization

SettledsludgeaftertreatmentintheImhoff Cone(a);afterfiltration(b),afterdryingat60oCandclodbreaking(c);aftercompactionat100MPa(d).

Sedimentation(1hour)=450mLofsludgeperliterofeffluent(55%ofthevolume)(24hours)=400mL(60%ofthevolumeofeffluentintheclarifiedform).

SludgeElementalAnalysis

CLASSIIAWASTE NONINERT

Carbon70,7%

Aluminiun1,6%

Iron4,8%

Oxygen21%

Min.Elem*1,9%

SlugdeCompositionPAC

Carbon

Aluminum

Iron

Oxygen

MinorityElements

SludgeCharacterization

Diffractogram referringtotheDRXanalysisofthesludgegenerated.

WaterbasedsludgeCalorificvalue(cal/g) 5850Ashes(%) 21.4Volatilematter(%) 9.0Fixedcarbon(%) 69.6

Immediateanalysis

Thermogravimetric Analysis

Thermogravimetric analysis

Alternatives forsludge recycling

Thechangeinlubricantsfromoilbaseddowaterbasedsimplifiedthewatertreatmentprocess,andgeneratedasludgethatcanbefiltered,driedandcompacted,reducingstorage,transportationanddisposalcosts.Thecharacteristicsofoilfreesludgeallowedsendingtocementkilns,reducingpartiallythecostsofdestination.

Aftersludgecharacterization,otherusescouldbeconsidered,includingascofiredcombustibletocoalthermalpowerplants.

Conclusion

Forging industries generate considerable amount of emissions, effluents and waste,requiring investments to prevent pollution and environmental damage. The treatment ofeffluents is a required operation. The use of waterbased lubricants, replacing oilbasedlubricants, improves the environmental performance. The change of lubricant enabled asludge that can be easily filtered and handled. It presents a carbon content of 70% mainlyin the form of graphite, with certain level of oxidation. In a regional context, it may besurely employed for power generating purposes in thermoelectric plants or cement kilns.However, other application alternatives are being investigated, including its cleansing andreturn to the lubrication process.

Acknowledgments

TheauthorsaregratefulforthefinancialsupportextendedbyGKN,CAPESandCNPq forthisresearch.

Thanks/OBRIGADA