Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 1
Seattle, 24.9.2003
LCA
for Optimization
of electroplating SME’s
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 2
Seattle, 24.9.2003
Outline of the presentation
1. Methodology of ecological plant optimization -
(EPO)
2. Participants of the project
3. Results
4. Benefit of the projects
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 3
Seattle, 24.9.2003
Methodology of ecological plant optimization - (EPO)
Iteration
question
definition of systemand data collectionof the actual state
-
modelling ofSystem of actual
state
-
Definition of thetargets of theoptimisation
-
ecological analysis
recommondation ofactivities
ecological plant optimisation- EPO -
Iterative procedure through
systematical Material - and energy -
flow modelling to:
• technological analysis
• economic analysis
• ecological analysis
of plant optimisation.
modelling of Systemof target state
ecological extensionof the system
economic analysis
ecologicalresult economical
result
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 4
Seattle, 24.9.2003
Production plant
production plants
for auxiliary material and operating supply item production
Recycling and disposal- plants
peripheral system
Substrate production
(Educt)
Substrate-
processing(product)
Core system
Optional extension
System boundary
peripheral system
System boundary
Core system
System view of the
EPO
Separation of
core system
and peripheral
system
Methodology of ecological plant optimization - (EPO)
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 5
Seattle, 24.9.2003
c
x
Assessment ofmaterial andenergy flows
Process-based costaccounting
Ecologicalassessment
Modelling ofprocesses and plants
Resources EmissionsV
VI
VII
VIII
IX
IVI
II
III
Overall system (core and peripheral system)
Processes
actual state2 31
6
-target state
2 31 4
5 6
core systemcore systemVI
Methodology of ecological plant optimization - (EPO)
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 6
Seattle, 24.9.2003
Resources Em issionsV
VI
VII
VIII
IX
IVI
II
III
Core systems
Overall system (core & peripheral system)
actual state
2 31
6
-target state
2 31 4
5 6
core systemcore systemVI
Difference of Mass balances
Changing elementary flows
Methodology of ecological plant optimization - (EPO)
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 7
Seattle, 24.9.2003
Impact categories• Resources• Air acidification• Depletion of ozone layer• Eutrophication• Aquatic ecotoxicity• Human toxicity• Green house effect• Photochemical oxidants
Methodology of ecological plant optimization - (EPO)
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 8
Seattle, 24.9.2003
Assessment methodbased on German UBA
method
Discussion of results in the society needs to have an assessment method
accepted by the society
Methodology of ecological plant optimization - (EPO)
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 9
Seattle, 24.9.2003
Participants of the project
KME Rösler
Nachtmann
Feuerverzinkung Genthin Lufthansa
Technik
FSB
Siemens
Friedric
h
Grohe
Closed loop material flows
for surface
treatment processes
Conversion of existing
electroplating plants using
optimized material flow techniques
Feuerverzinkung Hannover
Liebherr
About 40 companiesinvolved
e.g.hmp
Institute forEnvironm ental Engineering
Departm ent of W asteMinim ization
Institute forEnvironm ental Engineering
Departm ent of W asteMinim ization
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 10
Seattle, 24.9.2003
• 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
analysed plantsPCB etching-inner layerMatt nickle platingSodiumpersulfate etching with NaPS-RegenerationNeutralisation/ precipitationquality rinsingNitric acid etching of copperHydrochloric acid etchingAcid rinsingAcid polishingSulphuric acid etching of copperSealing and nickle sealingrinsingRinsing water cascadeThermal conzentrationdryingReverse osmoseChromium platingCopper platingNickle platingelectrosilveringZinc platingTin platingFull desalination of waterInside rinsing
Waste water traetmentAnodisation of aluminia incl. nanofiltration, vaporization and recyclingalkaline rinsingetching (pickling)
AccelerateCadmium-recyclingElectroless nickel platingChromate-detoxificationAlodineChromium sulphuric acid etchingCyanide- detoxificationpicklingE0-pickle; E6-pickleElectrolytical degreasingElectrolytical metal- extraction (Cu, Ni, Ag, Zn)degreasing
Softend water processDemetalizationDemetalization with sulfate sludge separationEpal-pickleExternal Recycling of Al- etching wasteDyeing of aluminiaHot dip galvanzingFluxingGlinting conventional and with vaporation and recyclingGlinting nickle platingVibratory finishingHard chrome platingIon exchanger circuit installation Circuit rinsingPCB-slightly etching with exchange, process heating and regeneration
processes
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 11
Seattle, 24.9.2003
All optimised production plants have decreasing
environmental impacts and
Cost savings
but
Not every target and actual state are comparable
Results
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 12
Seattle, 24.9.2003
Benefit of the project
• Pool of Excel-Models (about 900)
of electroplating processes
• Central Excel-Workbook
supporting the modelling of
core systems
Switch
Process dataspreading rates
consumption of chemicalsrinsing water volume
Materials data
Modeling of a process:EXCEL workbook
PretreatmentInputConcentrationschem. reactionsOutput
Main processInputConcentrationschem. reactionsOutput
rinsingrinser 1rinser 2circulating rinser
RegeneratorInputConcentrationschem. reactionsOutput
Waterpro-cessing1
Waterpro-cessing2
IO-costsMaterial flows,prices, plantcosts
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 13
Seattle, 24.9.2003
Benefit of the project
Knowledge database with the
qualitative results of the
research projects „Optimizing of
electroplating SME’s“
providing information for all
analysed, modeled and
optimized processes and
process-chains
structure of the database for one SME
SME
technologies
variants processes
states of processes
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 14
Seattle, 24.9.2003
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
Forschungszentrum Karlsruhein der Helmholtz-Gemeinschaft
Stand: 04/18/23 Folie: 15
Seattle, 24.9.2003
Contact
Forschungszentrum Karlsruhe GmbH
Institute for technical chemistry
Department of Technology-Induced Material flow
(ITC-ZTS)
Dr.-Ing. Robert Ackermann
P.O.box 3640
D-76021 Karlsruhe
Phone: +49 7247 82 2712
Fax: +49 7247 82 6715
e-mail: [email protected]