EVALED EVAPORATORS

WATER TECHNOLOGIES

Turn

ing

was

tew

ater

into

a re

sour

ceDionisio Visintin

New opportunities within the industrial wastewater market :

• Mechanical &

Surface Treatment(Automotive, Aviation, Furniture, Appliances)

• Photovoltaic & Microelectronic

EVALEDTM

EVAPORATORS

Marketing Departement

Today’s presenter & Housekeeping

Mechanical & Surface treatments | December 2015

o Attendees lines are muted. o Questions are handled by typing in the box as shown below. o Webinar is being recorded and will be made availableo Following the webinar, a short 5 question survey will be sent to

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Type your questions here at anytime during the webinar and we will see them and adress them at the end

Pamela Spada Product Manager

Cristina Del Piccolo R&D Process Director

Dionisio Visintin Marketing & Com. Director

Index


Scope

1. OpportunitiesIndustries : waste water focusMatrix table of ApplicationsReferences list Competitors

2. Challenges

3. Case studiesEVALED installation (materials, size , Pre and Post treatments)

The scope of this webinar


Evaporators applied in …

Mechanical and Surface Treatments

AutomotiveAviationFurnitureApplianceOthers

Photovoltaic &Microelectronics

Market Drivers & Main Issues


Process analysis (Mech &ST)


Big GroupsAutomotive, Aviation, Furniture, Appliance, Medical Devices

1. Main Components (motors , engines, compressors, transmission, gearboxes)

2. Assembly

Suppliers Sub suppliers (Tier 1-5)1. Body parts

2. Motor parts (body, valves, pistons, impellers, springs)

3. Pumps, Compressors

4. Starters and ignitions

5. Brakes, suspensions

6. Transmission-gear parts (gear boxes)

7. Frictions, steering systems

8. Exhaust pipes and silencers

9. Air conditioning, hating systems

10. Safety systems (air-bags)

11. Electrical components

The production process is divided into three phases:

The actors of this phases are:

1. Manufacturing Mechanical Treatments

2. Manufacturing SurfaceTreatments

3. Assembly

Manufacturing Process


Mechanical TreatmentCutting, Buckling, Drilling, Milling CastingForgingPressing TumblingQuality controls

Surface TreatmentCleaning, Degreasing

PicklingChemical hardening:Phosphate, NitrogenElectro chemical (galvanic):Al AnodizationNi, Cr, Zn, Cu, Ag, Cd plating PaintingCataphoresis

STEP 1 STEP 2 STEP 3AssemblyFinal cleaningProtections

Manufacturing Process (Mechanical Treatment)


Mechanical treatment

Water and Waste Water

Cutting, Buckling, Drilling, Milling

Process waterRO ConcentratesIER EluatesLubro refrigerating liquids (recycling)Exhausted oil emulsions

Casting Die lubricants

Forging Forging oily waterPressing Mould releaseTumbling Process cleaning water

Tumbling waterCleaning and degreasing

Degreasing BathsCleaning water (tunnels)

Quality controls Die penetrants rinsing and concentrate baths

Manufacturing Process (Surface Treatment)


Surface Treatment Water and Waste WaterCleaning, Degreasing Process water

RO Concentr., IER EluatesCleaning process (baths, tunnels)

Degreasing bathsPickling Acid/alkaline pickling bathsChemical hardening:Phosphate, Nitrogen

Process water Rinsing and working baths

Electrochemical process (Electroplating,Galvanic)

Al AnodizationPlating: Ni, Cr, Cd, Cu, Zn

Process water Rinsing and working bathsRecycling water and ZLDMetal recovery Cr

Painting Rinsing and water wallsCataphoresis Rinsing and working baths

The Matrix


For each of these industries we have created a matrix which lists:

• Segments;• Applications;• Parameters to control;• Average flowrate• Technology

In details, we analyse where and how EVALED is applied, discussing:

• Challenges• References • Case Studies

Mechanical and Surface Treatment Industry (Mec&ST) Segments


1. Automotive

2. Aviation

3. Furniture4. Appliance 5. Medical Device 6. Micromechanics7. Others Mechanical

Parts Manuf.

Surface Treatment

Mechanical Treatments

Matrix: Mechanical Treatment


Segments ApplicationsWaste Water

Parameters to Control (pH, Conductivity, DM 105°C, COD)

Average Flowrate (tons/day)

PCAC RV

Reference in red

MechanicalTreatment

Exhausted oil emulsions Oils, HM, Surfactants 1-50 x xMoulds release liquids baths (die casting)

Oils, HM, Surfactants 10-50 x x x

Quenching baths Oils, HM, Surfactants 1-10 x xTumbling baths Oils, HM, Surfactants, SS 1-10 xCleaning and Degreasing Oils, HM, Surfactants, SS 1-50 x x xParts rinsing waters(Dye penetrant, Deicing fluids)

Gycols, BOD, Solvents 1-50 x x

Precious metals ww streams (laundry &washings)

Precious Metals , NOx, Surfactants

1-5 x

IE regeneration (ZLD) Cl, SO4, TH, TDS, HM 10-100 x xRO concentrates (ZLD) Cl, SO4, TH, TDS, HM 10-100 x x

Matrix: Surface Treatment


Segments ApplicationsWaste Water

Parameters to Control (pH, Conductivity, DM 105°C, COD)

Average Flowrate (tons/day)

PC AC RV

Reference in red

SurfaceTreatment

Pre-treatment baths Alkalinity, NH3, TH, TDS, Oils 1-10 x xCleaning and Degreasing baths Alkalinity, TH, TDS, Oils 1-50 x x xPhosphate coating baths NH3, TH, TDS, Oils, PO4, HM 1-10 x xPickling baths (H2SO4 , HCl, HF, HNO3)

TDS, SO4 , Cl, F, NO3, HM 1-10 x

Cyanide rinsing baths Alkalinity, TH, CN, NH3 1-10 x xCopper, Zinc, Nickel rinsing baths Cu, Zn, Ni, Fe, TDS 1-10 x xCobalt, Cadmium rinsing baths Co, Cd, Fe, TDS 1-10 x xChromium rinsing baths Cr3, Cr6, Fe, HM, TDS 1-10 x xAluminium anodizing rinsing baths Alkalinity, TH, Al, NH3 5-50 x xSilver, Gold (precious metals) baths Precious Met. Alkalinity, TH, TDS 1-2 xGas Scrubber Blow-down NH3, TH, TDS, Oils 10-100 x xRO concentrate (ZLD) Cl, SO4, TH, TDS, HM 10-100 x xIE regeneration (ZLD) Cl, SO4, TH, TDS, HM 10-100 x xNew or Revamping WW Plants (Mixed streams)

NH3, TH, TDS, Oils, HM 10-100 x x

Mechanical Industry EVALED Reference

Mechanical & Surface treatments | December 2015 Case Studies in red

EVALEDTM Technology Flowrate m3/day (gpm)

Segment Applications production wastewater

Product recovery

Nation Year

Heat Pump Forc. Circ. 30 (5.5) Appliance Die Casting (Al) Italy 1998Heat Pump Forc. Circ. 4 (0.7) Aviation Metal Machining Oil Em. UK 1998Heat Pump Forc. Circ. 5 (1) Mec Parts Metal Machining Oil Em. Oil UK 2000Heat Pump Forc. Circ. 8 (1.4) Applaiance Parts Cleaning (tunnel) Italy 2000Heat Pump Forc. Circ. 10 (1.8) Mec Parts Metal Machining Oil Em. Slovakia 2002Heat Pump Forc. Circ. 20 (4) Automotive Metal Machining Oil Em. Oil Hungary 2003Heat Pump Forc. Circ. 5 (1) Mec Parts Parts Cleaning UF ED concentrate Malaysia 2003Heat Pump Forc. Circ. 3 (0.6) Mec Parts Metal Machining Oil Em. Slovakia 2005Heat Pump Forc. Circ. 8 (1.5) Mec Parts Metal Forging USA 2006Heat Pump Forc. Circ + Heat Pump Scraped 4 (0.7) Medical Device Die Casting Die Penetrants Ireland 2008MVR Forc. Circ. + Hot Water Scraped 20 (4) Mec Parts Precious Metals refining Precious met. India 2009MVR Forc. Circ. + Hot Water Scraped 35 (6.4) Automotive Metal Machining Oil Em. Spain 2009MVR Forc. Circ. 25 (4.6) Automotive Metal Machining Oil Em. Slovakia 2010MVR Forc. Circ. + Heat Pump Scraped 15 (2.7) Mec Parts Al tubes cleaning France 2010MVR Forc. Circ. + Heat Pump Scraped 15 (2.7) Furniture Die Casting Oil Italy 2010Heat Pump Forc. Circ. 4 (0.7) Automotive Metal Machining Oil Em. Oil France 2011Heat Pump Forc. Circ. 4 (0.7) Automotive Metal Machining Oil Em. Oil Poland 2011Heat Pump Forc. Circ + Heat Pump Scraped 6 (1.1) Mec Parts Metal Quenching Czech Rep. 2011MVR Forc. Circ. 10 (1.8) Automotive Metal Machining Oil Em. Korea 2012MVR Forc. Circ. + Hot Water Scraped 50 (9.2) Automotive RO concentrate (ZLD) Morocco 2012Heat Pump Forc. Circ. 1 (0.2) Automotive Metal Machining Oil Em. Japan 2012Heat Pump Forc. Circ. 4 (0.7) Automotive Metal Machining Oil Em. Oil UK 2013Heat Pump Forc. Circ. +Hot Water Scraped 5 (1) Aviation Metal Parts cleaning France 2013MVR Nat. Circ. 5 (1) Automotive Metal Machining Oil Em. Oil Russia 2014Heat Pump Forc. Circ. 12 (2.2) Aviation Metal Machining Oil Em. USA 2015

Surface Treatment Industry EVALED Reference

Mechanical & Surface treatments | December 2015 Case Studies in red

EVALEDTM Technology Flowrate (m3/day)

Segment Applications production wastewater

Product recovery

Nation Year

Heat Pump Scraped 0,1 (0.01) Mec Parts Surface treatment (Plating Ni Zn) Japan 1998Heat Pump Forc. Circ + Heat Pump Scraped 25 (4.6) Applaiance Surface treatment (Painting) Italy 2000Heat Pump Forc. Circ. 5 (1) Aluminium Plate Surface treatment (Al rolls pickling H3PO4) Norway 2001Heat Pump Forc. Circ. Dolble circuit 5 (1) Aluminium Plate Surface treatment (Al plate pickling AlCl3) AlCl3 Spain 2001Heat Pump Forc. Circ. 1,2 (0.2) Applaiance Nickel plating and degreasing Malaysia 2002Heat Pump Forc. Circ. 5 (1) Mec Parts Surface treatment (UF permeate ED) Malaysia 2003Heat Pump Forc. Circ. 4 (0.7) Applaiance Surface treatment (Valves IER eluates) USA 2004Heat Pump Forc. Circ. 8 (1.4) Mec Parts Surface treatment (Metal pickling) USA 2006Heat Pump Forc. Circ. Dolble circuit 5 (1) Automotive Surface treatment (Hard Plating Cr) Chrome Poland 2007MVR Forc. Circ. 12 (2.2) Aviation Plating WW France 2007Heat Pump Forc. Circ. 4 (0.7) Precious metals Surface treatment (Cyanide Au ) Au China 2008MVR Forc. Circ. 12 (2.2) Mec Parts Surface treatment (steel pipes phospating) Italy 2008MVR Forc. Circ. + Hot Water Scraped 16 (2.9) Precious metals Precious metals refining Au ,Pt , Pl India 2009Heat Pump Forc. Circ. Dolble circuit 5 (1) Automotive Surface treatment (Hard Plating Cr) Chrome China 2010MVR Forc. Circ. + Heat Pump Scraped 15 (2.7) Mec Parts Surface treatment (Al Tube ) France 2010MVR Forc. Circ. 50 (9.2) Applaiance Surface treatment (Zn, Plating, gas scrubber) Slovakia 2012Heat Pump Forc. Circ. 5 (1) Aviation Surface treatment (Engines Pickling, phosp., Russia 2012Heat Pump Forc. Circ. 5 (1) Aviation Surface treatment (Metal pickling) France 2012Heat Pump Forc. Circ. 6 (1.1) Automotive Surface treatment (Pickling Cu) Taiwan 2013MVR Forc. Circ. + Heat Pump Scraped 10 (1.9) Aviation Surface treatment (Plating Ni Zn Cd) Ni, Cd Russia 2013Heat Pump Forc. Circ. 4 (0.7) Rail Train Deiceing Gycol Glycol Turkey 2013Heat Pump Forc. Circ. 8 (1.4) Aviation Surface treatment (Plating Ni Zn Cd) Israel 2013MVR Forc. Circ. +Hot Water Scraped 60 (11) Aviation Surface treatment (Plating Ni Zn Cd) Russia 2014Hot Water Forc.Circ.. + Hot Water Scraped 25 (4.6) Automotive Surface treatment (Plating Ni Zn Cd) Germany 2015MVR Forc. Circ. 60 (11) Aviation Surface treatment (Plating Ni Zn Cd) Chzek Rep. 2015

EVALED competitors


1-200 ton/day (< 50 gpm) MVR Evaporators. Competitors can be local or International.

Typical suppliers: Encon, H2O, Loft-KMU, MKR

amount of waste to be treated 100 ton/day

< 10 ton/day (<2 gpm) Often via waste disposal

0.1-10 ton/day (< 2 gpm) Heat Pump Evaporators. Competitors can be local or International.

Typical suppliers: Eco-Techno (old Ecotecno), PF10, C&G,

Shell, Formeco, Saita

Packaged evaporators (0.1 - 500 ton/day - 100 gpm) is the EVALED territory

> 200 ton/day (>50gpm)

Tailor-made MVR Evaporators. The higher the capacity the less

competitive EVALED becomes. In the Chemical production

normally the flow are higher

Competitor Page in red

Loft - KMU


Location: Kirchentellinsfurt Germany Turnover: 2013 about 20 M € Employees : about 80 -90 Installations: about 1000 Branches: France, Italy, Poland Distributors: Austria, Spain, China, Turkey , Chek.Rep, USA

Web: http://www.loft-gmbh.de/

Products: MVR Package Size: 0.5-50 ton/day (0.02-10 gpm) Technology: Natural

Circulation (vertical tubes)Price: about the same for the large ones, 10% less for the small ones

For internal use only

C&G Evaporators


Location: Rignano sull’Arno (Fi) Italy Turnover: 2014 about 3 M € Employees : 13 Installations: about 600 (200 evap)

Distributors: USA, Japan, Malaysia Spain, UK, Brazil, Russia, China, India Web: http://www.cgdepur.it

Products: HP Package (Hot Water m-stage) Size: 0.5 -20 (5-45) ton/day (0.1-8 gpm) Technology: Coil heat exchanger

Price: about 10% lower

S.A.I.T.A. Evaporators


Location: Limena (Pd) Italy Turnover: 2014 about 3.7 M € (0.5 ev) Employees : 24 Installations: about 100 (D&B) (water treatment plants) Distributors: Europe, Brazil (export about 40%) Web: http://www.saitaimpianti.com

Products: HP Package (Hot Water m-stage) Size: 0.5 -9 (60) ton/day (0.1-8 gpm) Technology: Coil heat exchanger Scraper Price: about 10% lower

Website


applications

case studies

Industries

The scope of this webinar


Evaporators applied in …

Mechanical and Surface Treatments

AutomotiveAviationFurnitureApplianceOthers

Photovoltaic &Microelectronics

Treatment Challenges

New lubrorefrigerant case


Very high quality of the treated stream(COD<50 ppm) Lowest value of residue to dispose

Evaluate the feasibility of the treatment of a new lubrorefrigerant

Challenges

Trials on Evaporation with superconcentration for ZLDUF AC as polishing of the distillate

Goals

Solution


NL case

Mechanical & Surface treatments | December 2015 For internal use only

First evaporation stage Second evaporation stage

Final results

inside the pilot

Distillate, UF permeate and concentrate

NL case


Parameters M.U. Feed Distillate UF Permeate

COD mg/l 106200 836 <50

ZLD possible: TS on final conc > 70%

>> Very good quality : target on COD reached before AC

Exausted Emulsion Study


Facing problems of : • Bacteria and fungi• Quality of emulsions, composition and

surfactants• Quality of the distillate

Challenges

Distillate reuse for the production of fresh emulsions

Goals

Lab tests and data collection from 20 working plants

Solution


Oil emulsion


The main contaminants which reduce the effectiveness of the oil emulsions are, mainly:•Parasite oils from leaks of the hydraulic systems• Metallic solid particles• Micro-organisms (bacteria and fungus)• Other contaminants (different solids)

An oil emulsion can be considered exhausted when:•its microbiologic decomposition starts• the superficial quality of the metal piecesdecreases• the composition of additives lessens• the undesirable toxic substances such asgerms and heavy metals increase

COMPOSITION:BiocidesHumectants/stabilizersHeavy metalsEmulgents (anionic and non ionic)

Coolants (water)Lubricant (mineral, vegetal or synthetic oils)

Corrosion inhibitorsComplexants (EDTA)Dyes

Die lubricants


They are miscible in water and contain an active principle, the lubricant/releaser,which has the aim to create a compact layer on the mold surface to allow an easilyextraction of the part.

Particular importance assumes the water quality in terms of hardness,temperature and purity for the product efficiency

DEG diethylen glycolPEG polypropylen glycolDMBE diethylenglycol monobuthyletherSolid HC PolysiloxanesEmulsifying agents

Analysis: Propylen/ Ethylen glycol (5% PG/EG water)


Parameters (Propyl.Glyc.solution) Units Distillate Waste

pH 11.6 10.1conductivity µS/cm (20°C) 11.7 752COD mg/l 381 72200solid cont. (105°C) % 0.12propylen glycol mg/l 104 8900

Parameters (Ethyl.Glyc. solution) Units Distillate Waste

pH 8.5 9.9conductivity µS/cm (20°C) 2.6 504COD mg/l 4240 69700solid content (105°C) % 0.12ethylen glycol mg/l 833 19500

Analysis: bacteria and fungi test


Units Waste Distillate 1 Distillate 2

pseudomonasspp

UFC* /ml 500 0 100

mesophilebacteria

UFC* /ml 5.000.000 1 70.000

(*) UFC = Colony forming units

1= fresh distillate2= distillate after exposure to air (> 48 h)

Distillate quality


COD distribution in the distillate (22 measures)

5

78

2

0

5

10

0 - 150 150 - 500 500-1000 1000-1500COD [mg/l]

freq

uenc

y

14

43

2

0

5

10

15

0 - 0,3 0,3 - 0,5 0,5 - 1 1 - 2

freq

uen

cy

tenside concentration [mg/l]

tensides concentration distribution in the distillate (22 measures)

Very good separation of the surfactant agents

Good separation of COD

oil concentration distribution in the distillate(25 measures)

20

20

2 10

5

10

15

20

25

0 - 20 20 - 50 50 - 100 100 - 200 > 200

oil concentration [mg/l]

freq

uenc

yGood separation of oils

ZLD Automotive case


Treating RO concentrate after a complex process line (MBR+softening+RO)

Challenges

Achieving a ZLD configuration Goals

EVALED Evaporation (RV F 60 FF) crystallization (AC R 3 FF)

Solution


ZLD case


ZLD possible: TS on final conc > 70%Recovery > 98%

>>Parameters M.U. Feed Distil. Conc.

TS % 0.8 - >80

Conductivity µS/cm 9000 -100000

20 -30 >200000


Chromic Acid Reuse case


Replacing an existing evaporation unit from competitors having corrosion problems for a combination of a strong acid (Chromic Acid) and Fluorides

Challenges

Provide a unit suitable to handle chromic acid without corrosion issues

Reuse the Chromium Oxide back in the working bath

Goals

Installation of an Evaled Heat Pump PC F 6 KT unit in inert material.

Heat exchanger tubes: Silicon carbide and PVDF Evaporator: coated with fluoride polymer ECTFE

Solution


CAR: the plant solution


Chromium plating process• treatment of rinsing waters from the counter current washing tanks where the shock absorbers are immersed•Pre-treatment by strong cationic resin for removal of heavy metals (HM) to allow the reuse of the evaporator’s concentrated solution in the working bath.

Working bath

Cr 6+ Drag-out

Rinse RinseRinse

DistillateConcentrate EvapEvap

SC

IER SCHMsepar.15 g/l

Cr Cr 3+3+

Cr Cr 6+6+

IER

SA

CAR case


Parameters M.U. Feed Distillate

pH 1.4 3.6

Cr6+ mg/l 4400 <20

99% removal on Chromium in the distillate

For internal use only >

Parameters M.U. Feed Conc

pH 1.4 1,2

Cr6+ g/l 3-5 30

Reuse of Cr6+ in the working bath >

>

>

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ceMechanical & Surface treatments | December 2015

Case studies

MechanicalAutomotiveAviationFurnitureAppliance

1) Automotive 12) Automotive 23) Furniture 14) Appliance 15) Automotive 3

Automotive 1

Customer needs

New Automotive plant startup in early 2012 with twonew production lines and anannual output capacity of400,000 vehicles/year

Customer

To reduce the environmental impact ofthe plant, no industrial waste watercan be discharged (ZLD) into thenatural ecosystem andthe quantity of water consumed bymanufacturing processes must be cutby more than 50%. For internal use only


The plant

Analysis and Plant Process DiagramChemical Physical

plant

Dispose as solid waste

Distillate 109 ton/day

Concentrate 1 ton/day

Parameters u.m. Waste In

Distill.Out

Concent.Out

pH 8.3 7.7 -TS at 105 º C % 0.9 - >90Conductivity µS/cm 10000 <30 -COD ppm <100 <10Chloride ppm 700 <1 -Boron ppm <10 <0.1 -

Recycled to the RO system

RV

ACTechnology Type

Material Footprint(m2)

2 x RV F 60 FF UNS S 32750

85

2 x AC R 3 FF UNS S 32750

14

RO Conc. 110 ton/day (20gpm)


MBR Biological plant

RV

AC

RO Membrane Plant

Line 1 Line 2


Results

The solution achieved:heat recovery coming from cogeneration (CO2 footprint reduction)Water reuse 100%the target of water consumption cut at more than 70%

Water separated: ~ 99%Concentration factor: 40-100 times

For internal use onlyMechanical & Surface treatments | December 2015


These results will be achieved through innovative manufacturing processes, the use of renewable energy and the optimization of the water cycle.

The environmental impact of Renault’s Tangier plant will be reduced to levels that have never been reached :

o CO2 emissions cut by 98%, equivalent of about 135,000 tons of CO2 per year

o no industrial waste water discharged into the natural ecosystem (ZLD)

o quantity of water consumed cut by 70%.

From the website

Automotive 2

Customer needs

Customer


The plantis the only car manufacturer in Slovakia, manufacturing engines. At the Slovakian facility (300.000 vehicles capacity), the Company manufactures gasoline engines with five manufacturing lines: four metal cutting lines and one assembly line.

The customer aimed at reducing the oily waste water disposal costs.In their plans to improve environmental impact and to reduce their total amount of CO2, they needed to exploit the energy content of the oil fraction.


The plant

Analysis and Plant Process Diagram

Waste water inlet 30 ton/day (5.5 gpm)

Distillate27.9 ton/day

Concentrate2.1 ton/day


Distill.Out

Concent.Out

COD ppm 6000 <200 -pH 5.8 9.7TS at 105 º C % 0.2-0.3 - 10Oils ppm 850 <30Conductivity µS/cm 1300 100 -TSS ppm <450 0 8000-

9000

Permeate discharged

RV

TechnologyType


RV F 30 AA AISI 316 14

Outlet Quality

incineration

For internal use only UF Plant

Coalescent separator

CNC Working machine

Parts cleaning baths


Results

Water reused: ~ 95%Concentration factor: 20 times


The solution achieved:disposal cost reduction by

more than 15 timesrecovery of concentrate oil

reused as fuel (high calorific value) has reduced CO2 footprint


Furniture 1

Customer needs

Company specialized in different mechanical works and surface treatments as die-casting , deburring, grinding , sandblasting and die management operating as subcontractor for Furniture and Automotive (Moto cycles).

Reduce:o high disposal cost of about 15 m3/day of die-casting waste water.o increasing volumes of die lubricant used.

Customer


The plant


Die casting waste water 15 ton/day (2.75 gpm)




Distill.Out

Concent.Out

pH 6.2 8.9 8.5Conductivity µS/cm <7600 <70 -

TS at 105 º C % 0.84 - < 50Total surfactants ppm 530 <2.5 -

COD ppm 8600 <1500 -

reused indie-casting process

PCTechnology Type


PC R 1 FF UNS S 32750

3.3

RV F 15 FF UNS S 32750

10.5


Sent to oily collectors

RV

Tramp oil removal


Results

Water separated: ~ 97 % Concentration factor: ~ 33 times

The solution achieved:water rused in the production

processreduction of fresh die lubricants

consumptionImportant disposal cost reduction


Appliance 1

Customer needs

The Group is a global market leader for mechanical fastening systems and precision components. Based on a focused set of core technologies the company serve diversified end markets, including the automotive, construction/construction supply, electrical/electronics, aerospace and medical components industry.

A technology able to treat wastewater flow coming from a Cleaning Tunnel (EcocleanDürr) to reduce the waste disposal cost and the oily waste water management

Customer Italy



The plant


Distill.Out

Concent.Out

COD ppm 1000-4000

<50 < 50000

TS at 105 º C % 0.3 - 1 - <20Conductivity µS/cm 4000 <10 -Boron ppm 160 <2Surfactants ppm <600 <1 -Heavy Metals ppm 60 <0.01 <1500Tot Oils ppm 400-

1200<1 -

Technology Type


PC F 8 AA AISI 316 7

Inlet Variability

The plant

Waste water inlet 8 ton/day (1.5 gpm)

Distillate>7.5 ton/day

Concentrate<0.5 ton/day

Reuse for cleaning

incineration


Coalescent separator

Fasteners Production

Parts cleaning Tunnels


PC

Results

Wastewater reduction: ~ 95 %Concentration factor: ~ 20 times


The solution achieved:water reuse for cleaningMore than 90 % waste disposal cost reduction

Coalescent oil separator



Customer

Customer needs

The company is a joint venture between the American car Manufacturer and a Russian one. The Elabuga Engine Plant is planned produce 100,000 units in 2015, with the possibility for further expansion.

Find a treatment solution able to reduce the disposal cost of the oily wastewater produced and reuse it within the manufacturing cycle.Create a solution to eliminate the controls on the discharge ww due to stringent discharge limits.

Russia

56

Automotive 3


Parameters u.m. Waste In QualityOutlet

Concent. Out

pH 6 - 9 7 - 8 -TS at 105 º C % 2 > 20COD ppm 25000 <500BOD 5 ppm 3000 <250Zinc ppm 100 <0.02 -Oil&Grease ppm 2000 <10 > 20000



TechnologyType


RV N 6 AA AISI 316 4.2

Distil. Quality

To dispose

Distillate 5.6 ton/day (1 gpm)

Concentrate 0.4 ton/day (0.1 gpm)

To reuse

Exausted oil emulsion6 ton/day (1.1 gpm)

Tramp Oil separation (storage tank oil removal )

UF Plant (oil polishing )

RV

Engine Parts Production

The plant



Water reused: > 90%Concentration factor: >10 times

The solution achieved:Disposal cost reductionReduction of the product water

impact, recycling the distillate in production

Energy saving using MVR technology (CO2 footprint reduction)

Water reuse

Pay-back: about 13 months

58

The results



Project Analysis and Plant Process Diagram

Future Option Crystallizer

Parameter u.m. Value WW Outlet ValuepH 6-9 6-9TSS mg/l 1000TS % 2Conductivity uS/cm 3000Chlorides mg/l 100Calcium mg/l 20BOD5 mg/l 3000 250COD mg/l 25000 500Oil&Grease mg/l 2000 50TKN mg/l 10 10Zinc (total) mg/l 100 0.02

59

The complete solution



Waste water: 6 ton/day ( 1.1 gpm) exhausted oil emulsion

Disposal cost calculation80 €/ton ( 0.36 $/gal) including transport and analysis Annual cost (300 working days) : about 144.000 €/y

Opex cost Available energy: EE 0.06 (€/kWh)Opex: about 7 €/ton (0.03 $/gal)Annual OPEX cost : about 11.340 €Separation: 5.4 tons/day water reuseConcentrate disposal cost: 80 €/ton ( 0.36 $/gal) Concentrate annual disposal cost: = about 14.400 €

Saving: 144.000 – 11.340 - 14.400 = 118.260 €/y

Pay-

back

: abo

ut13

mon

ths

60

Pay-back


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Case studies

Surface Treatment

AutomotiveAviationFurnitureAppliance

1) Aluminum Plates2) Automotive Plating Line3) Automotive Chromium Line4) Furniture Pickling & Phosphating Line

Aluminum plates

Customer needs

Leading company in Aluminum Offset plate manufacturing since 1985, with production plants in Spain and China.

Customer

Treat the acid wastewater containing AlCl3 to obtain a by product to resell as flocculants at high concentration


Spain


The plant



IER Regeneration Diluted HCl

Reus

e in

pro

duct

ion


Parameters u.m.

Waste In

Distill.Out

Conc.Out

pH 1.7 2.7 4Conductivity µS/c

m120000 <1500 -

Al ppm 15000 <0.1 75000Chloride ppm 47000 <100 -AlCl3 % 7 - 10 - 35 (*)

Sold as flocculants For internal use only

Plate production

Pickling Acid Regen.

Al powder reaction

IE Resin Plant

PC

HCl + Al Diluted6 ton/day (1.1 gpm)

(*) selling quality request controlled by a densitymeter

Technology Type


PC Forced Circ. E 6000 KT

Heat exchanger tubes: Silicon carbide and PVDFcoated with fluoride polymer ECTFE

8.2


Results

The solution achieved:ZLD plant with the water reuse for IER

regenerationVMR : AlCl3 sold as flocculant in the

WTP

Water reused: ~ 75% Valuable Material Recovery (VMR): AlCl3

For internal use onlydensitymeter


Pay-back

Waste water: 6 ton/day ( 1.1 gpm) acid IER regeneration (HCl + AlCl3)

Disposal cost calculation110 €/ton ( 0.6 $/gal) including transport and analysis Annual cost (300 working days) : about 200.000 €/y

Opex cost Available energy: EE 0.06 (€/kWh)Opex: about 13 €/ton (0.07 $/gal)Annual OPEX cost : about 24.000 €Separation: 4.5 tons/day water reuse (1.5 tons valuable product)Concentrate use: sold as Flocculant (35% AlCl3 conc.) :115 €/ton Concentrate annual selling profit: = about 50.000 €

Saving: 200.000 – 24.000 + 50.000 = 226.000 €/y

Pay-

back

: abo

ut14

mon

ths


Automotive Plating Line

Customer needs

The custumer is one of the largest Korean suppliers for the automotive industry. (assembly: four types of chassis modules. Production capacity of 300,000 u/y): in Slovakia produces parts of the braking system. These parts are subject to a passivation and zinc plating.

The plating line discharges about 60 ton/day of rinse water contaminated by heavy metals and acidic and alkaline streams. The customer request was to design a ZLD plant for the plating line to minimize the waste disposal cost and cut the water consumption.

CustomerSlovakia


The plant


Filtration

Dispose as hazardous waste



Parameters u.m.

Waste Mix In

Distill.Out

Concent.Out

pH 8-9 7 -TS at 105 º C % 0.6 - 20Conductivity µS/c

m<10000 <50 -

COD ppm 800 <50TDS ppm 4000-

6000- <160000

Boron ppm 50 <5 <1600

Recycled to the IER Plant

RV

Technology Type



21

58 ton/day (11gpm)


Che -Phy Plant

Zn Plating Line

IER Plant

Rinsing Line


Results

Wastewater reduction: ~ 97% Concentration factor: ~ 30 times The solution achieved:

Zero Liquid Discharge92% disposal cost reductionWater reuse in the

manufacturing process


Automotive Chromium Line

Customer needs

Multinational company manufacturing automotive parts.

The polish facility makes shock absorbers for vehicles.

To reduce the high costs related to:

• waste water disposal of highly polluting and corrosive from hard chromium plating line

• operation of the galvanic line

Customer

Poland


The plant

Analysis and Plant Process Diagram Chromium plating waters6 ton/day (1.1 gpm)

Recycled to the chromium bath


Recycled as rinse water



Distill.Out

Concent.Out

Iron mg/l 150-200 <0.1 -Conductivity µS/cm <25000 <200 -TS at 105 º C % 1 -pH 1 - 2 3.6 1 - 1.5Density g/ml 1.006 - 1.5Cr6+ g/l 3.5- 5 <0.02 30

PC

Technology Type


PC F 6 KT Heat exchanger tubes: Silicon carbide and PVDFcoated with fluoride polymer ECTFE

8.2


Fixed density controlled by density meter

Results

The solution achieved:complete ZLD, waste water reduction 100%Concentrate recycled to the chromium bath (adjustment of concentration by adding chromic anhydride and demineralised water)galvanic line OPEX reduction

Distillate recovered: ~ 90%Concentration factor: ~ 10 times


Furniture Phosphating & Pickling Line

Customer needs

Supplier of cold drawn alloyed and micro alloyed carbon steel tubes for applications in mechanical furniture, automotive and hydraulic pipes.

Find a solution to the ZLD wastewater generated from the tubes surface treatment: • phosphating line and sulfuric acid pickling line• wastewater treatment with a layout compatible with the limited space available

Customer


The plant (Pickling line)Analysis and Plant Process Diagram

Work. Bath Blow Down10 ton/day (1.8 gpm)

Distillate8 ton/day

Concentrate2 ton/day


Distill.Out

Conc.Out

pH 1.5 -1.7 5.5 1.4

Conductivity µS/cm

8000 -15000 <20 -

TS at 105 º C % 0.6 -1 - 4

SO4 ppm 530 <5 -Heavy metals ppm 8600 <1 -

reused inthe washing line

Technology Type


PC F 12 FF UNS S 32750

8.5


Send back to the Pickling bath

PC

Crystallizer

Washing

Tubes Pickling line (H2SO4)


The plant (Phosphating line)



Distill.Out

Conc.Out

pH 6 - 7 7 - 8 6 - 7

Conductivity µS/cm <3000 30 -TS at 105 º C % 0.5 - 5

Heavy metals ppm 200-

800 <0.5 2000-7000

Phosphor. ppm 100-200 <5 1000-

2000

Technology Type



10.5


Blow Down15 ton/day (1.8 gpm)

Distillate13.5 ton/day Concentrate

Buffer solution1 ton/day reused in process

Disposed

Filter

Washing

Phosphatingline

Buffer Solution (1%)

RV Phos. Conc0.5 ton/day

Once a month


Results

Water reused: ~ 100 %Product Recovery : H2SO4 and Zinc Phosphate

The solution achieved:product recovered and reused

in the production processwater reuse in a real ZLD plantdisposal cost reduction


Turn

ing

was

tew

ater

into

a re

sour


Case studies

Photo-Voltaic &Microelectronic

1) Case 12) Case 23) Case 34) Case 4

You will find all in….


• Industries Matrix Table

• Brochures

• digital catalogue

• Photos, Articles, Typical Analysis

• Videos (commercial, unit operation).

• Presentations (products, applications, case studies)

• Reference lists for each industry

• Technical reports (for each individual model)

www.evaled.com

The next step: Healthcare & Chemicals


You now need to know how to sell EVALED in each industry. And the rules differs by industry.

Join us for one or all of the future webinars dedicated to specific industries.

Mechanical & Surface Treatments

(Automotive, Aviation, Furniture, Appliances)

Photovoltaic & Microelectronic

Health Care (Pharma , Cosmetics)

Chemicals (Detergents, Explosives, Adhesives, Colorants)

Waste(Collectors, Landfill, Incinerators)

Biogas & Biof.

Food & Beverage Graph.A. - P&P

Textile

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Q&A session

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