Transcript ELECTROLYTIC CELL FIELD EXPERIENCE — THE ROLE OF …

ELECTROLYTIC CELL FIELD
EXPERIENCE — THE ROLE OF FIELD
OPERATIONS AND FEEDBACK IN THE
COMMERCIALIZATION OF THE
RENOCELL®
NOVEMBER 1999
VRII-9028-0/Slide 1
Renovare International, Inc.
VRII-9028-0/Slide 2
Renovare International, Inc.
TECHNOLOGY FOR THE
NEW MILLENNIUM
“RenoCell®” embodies a revolutionary electrodeposition technology that Renovare International,
Inc. is commercializing and bringing to the market at a
time when the demand for more robust, efficient and
cost-effective water treatment equipment and systems
is growing worldwide.
VRII-9028-0/Slide 3
Renovare International, Inc.
RENOCELL’S
DEMONSTRATED CAPABILITIES
• Achieves metal recovery or effluent discharge
limits with sub-mg/L performance
• Collects most metals as elements ready for sale
or reuse
• Uses removable cathode cartridges for ease of
operations and maintenance
• Improves cost effectiveness and reduces life
cycle costs
VRII-9028-0/Slide 4
Renovare International, Inc.
TECHNOLOGY
OVERVIEW
VRII-9028-0/Slide 5
Renovare International, Inc.
RENOCELL BACKGROUND
• Nine years in development by a world-class R&D
organization
• Advanced electrochemical R&D focused on:
– Current distribution – Potential distribution
– Hydrodynamics
– Cell geometry
– Cell components
– Cell performance
• Patented by EA Technology, Ltd. (EATL),
Capenhurst UK
VRII-9028-0/Slide 6
Renovare International, Inc.
EATL’S ELECTROCHEMICAL
CELL DEVELOPMENT
1970
1980
1990
DEM CELL
• General Purpose
• Synthesis, Waste
Treatment
• Product (Licensee)
• 1984
1997
Manufacture by
EA Technology
(active, 1996)
ANODIC CORROSION
• Synthesis of Metal Salts
• Manufacture by
EA Technology
• 1989
CHEMELEC CELL
• Metal Recovery
• Effluent Streams
• Product (Licensee)
• 1981
POROCELL
• Metal Recovery
• Effluent Streams
• Custom Product,
Manufacture by
EA Technology
(active, 1996)
RENOCELL®
1997 LICENSE
TO RENOVARE
CEER CELL
• Circuit Boards
• Recovery of Cu
and Etchant
• Product (Licensee)
• 1981
DEVELOPMENTS
• Divided Tank Cell
• Rotating Cathode
Cell
• DEM Cell MK II
VRII-9028-0/Slide 7
Renovare International, Inc.
ELECTRODEPOSITION OF METALS
• Recent developments involve improved, high surface
area cathodes and metal oxide anodes where the cell
performance depends on three mass transport
processes:
• Convection in the bulk solution; mixing of the solution
can increase the bulk transfer
– Diffusion from the bulk solution to the electrode surface
– Conversion of the adsorbed ion into metal which is restricted by the
limiting current for a particular metal and solution chemistry and
cannot be overcome by mixing or increasing the potential
VRII-9028-0/Slide 8
Renovare International, Inc.
3-D ELECTRODEPOSITION
OF METALS
• Improvements in applied electrolytical cells have
focused on:
– Obtaining high active cathode areas which allows compact
design and efficient conversions even at low concentrations
– High current efficiency to minimize energy usage
– High current density to effect rapid metal removal
– Intimate contact between electrolyte and electrodes to provide
high mass transport
– Ease of product removal
– Safety and ease of control
– Lower operating and capital costs
VRII-9028-0/Slide 9
Renovare International, Inc.
3-D ELECTRODEPOSITION
OF METALS
• Commonly-used 2-D cells, such as tank cells, do not
achieve stringent treatment standards.
• Considerable effort directed towards using 3-D cells with
packed, fluidized, and porous electrodes. Fluidization of
carbon or glass particles increased mass transfer but loss of
electrical contact and abrasion of particles during
fluidization reduces the performance of these types of cells.
• Considerable efforts have been directed towards finding
high surface area, stationary electrode materials. Testing
indicates that low concentrations of metals can only be
achieved with reasonable current efficiencies by using
porous electrodes.
VRII-9028-0/Slide 10
Renovare International, Inc.
RENOCELL’S R&D
• Objectives in the early 1990’s were:
– Enhancement in metal recovery performance over conventional cells
by using porous cathode cells
– Develop a “user friendly” product suitable for industrial applications
• Resulted in a high cathode surface utilization and
excellent metal removal rates due to:
– Even electrolyte flow through the entire area of the cathode
– Electrical potential feed (and current flow) to the entire length and
circumference of the cathode cylinder
– Removal of the metals by incorporating the carbon cathode and
support as a replaceable cartridge
– Recovery of the metal by chemical or anodic redissolution
or smelting
VRII-9028-0/Slide 11
Renovare International, Inc.
RENOCELL’S PATENTED
ELECTROLYTIC CELL TECHNOLOGY
P ost Electrode
Connector
Cathode
Current Feeder
Anode
Plastic
Outer Support
Carbon Fiber
Plating Element
Anode
DIN: DRII-6002-1
Porous dif f user core
Electroly te Flow Path
VRII-9028-0/Slide 12
Renovare International, Inc.
RESEARCH LEADS TO A
CHANGING PARADIGM ...
• For the first time, an electrolytic cell attains high metal
removal rates with sub-mg/L performance.
• This performance is achieved through effective use of
3-D porous carbon cathodes. The 3-D cathode greatly
enhances performance because the porous cathode
has >500 times greater effective surface area than 2-D
cathode of the same nominal size. This high surface
area allows metal deposition at higher current
efficiencies, lower current densities and higher
deposition rates and thereby achieves lower final metal
ion concentrations.
VRII-9028-0/Slide 13
Renovare International, Inc.
TECHNOLOGY
PERFORMANCE
VRII-9028-0/Slide 14
Renovare International, Inc.
3-D CATHODE USE ALLOWS ...
• State of the art performance for treatment of process
and wastewater containing heavy and precious metals
• Electrochemical deposition of many metals directly from
aqueous solutions without the addition of reagents.
• Performance advantages based upon:
–
–
–
–
Porous high surface area cathode
Improved current and potential control enhance metal removal
Compact robust design
Technology evolution including divided cell
VRII-9028-0/Slide 15
Renovare International, Inc.
SUCCESSFULLY DEMONSTRATED
METALS
•
•
•
•
•
•
•
•
VRII-9028-0/Slide 16
Cadmium
Copper
Mercury
Platinum
Iron
Osmium
Ruthenium
Tin
•
•
•
•
•
•
•
•
Nickel
Cobalt
Rhodium
Gold
Lead
Palladium
Silver
Zinc
Renovare International, Inc.
RENOCELL TESTING AND
OPERATING PERFORMANCE*
Application
Metal
Initial
(PPM)
Final
(PPM)
Current
Efficiency
(%)
Cu
910
0.02
41
Cu
98.2
0.22
20.7
Cyanide plating rinse
Cu
105
0.34
2
Fluoborate plating rinse
Cu
115
0.3
38.7
Electroless Cu rinse
Cu
82
0.8
14.2
Micro etch bath rinse
Cu
44
0.11
20
Cyanide plating rinse
Ag
740
0.34
7.5
Cyanide static dragout
Cd
107
0.34
2
Acid sulfate rinse
Cd
978
0.37
22
Acid sulfate rinse
*All tests on 2.5 liter volumes using a 0.015m2 laboratory RenoCell
VRII-9028-0/Slide 17
Renovare International, Inc.
RENOCELL TESTING AND
OPERATING PERFORMANCE*
(Continued)
Current
Application
Metal
Initial
(PPM)
Final
(PPM)
Efficiency
%
Acid sulfate rinse
Zn
77.5
0.23
2
Acid sulfate rinse
Sn
93.2
0.5
7
Fluoborate plating rinse
Pb
85
0.32
6
Watt’s bath rinse
Ni
105
0.5
4
Acid sulfate rinse
Cr(III)
124
1
1.6
Cyanide liquor
Au
380
<0.1
-
Acidic liquors
Pt/Pd
24/110
1/0.01
4
Pt
2000
0.5
-
Pd
500
<0.5
-
Hg
6.3
0.036
-
Groundwater (acidic)
*All tests on 2.5 liter volumes using a 0.015m2 laboratory RenoCell
VRII-9028-0/Slide 18
Renovare International, Inc.
COPPER RECOVERY FROM
DILUTE PLATING BATH
Time
(minutes)
Average
Current
Efficiency
0
4440
30
3360
76
67
2440
63
92
2010
56
120
1380
54
144
820
53
170
256
52
240
0.02
39
Solution:
Flow rate:
Current density :
VRII-9028-0/Slide 19
Concentration
mg/l
2.5 liters
2 lpm
400 A/m 2
Renovare International, Inc.
ELECTROLYTIC CELL
TREATMENT COMPARISON
Electrolytic Cells
Tank Cell
Reciprocating Anode
Cell
Fluidized Bed Cell
Rotating Cathode Cell
Patented 3-D Cathode
10000
1000
100
10
1
0.01
0.1
Effective Operating Range for Copper Removal (PPM)
XRII-7028/ED#1
VRII-9028-0/Slide 20
Renovare International, Inc.
ELECTROLYTIC CELL
OPERATING RANGES
EFFLUENT & WATER TREATMENT
xx
xx
xx
METAL RECOVERY
100
10 5
10
1
10 4
10
3
0.1
0.01
10 2
10
T ank Cells
Air Sparged T ank Cells
Enhanced Flow Plate Cells
Rotating Cylinder Cells
Patented 3-D Cathode
VRII-9028-0/Slide 21
0.001
xx
xx
xx 1
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
0.0001
0.1
g/l
PPM
Renovare International, Inc.
TECHNOLOGY
COMMERCIALIZATION
VRII-9028-0/Slide 22
Renovare International, Inc.
RENOCELL
COMMERCIALIZATION STRATEGY
• Since the principles of electrodeposition are the same
for all electrochemical cells, Renovare’s strategy is to
“engineer and apply” RenoCell’s patented, 3-D
technology to take advantage of its substantially
enhanced performance.
• This will allow Renovare to meet its goals of
establishing RenoCell as the new standard of
performance and economics in heavy and precious
metal recovery and effluent treatment applications.
VRII-9028-0/Slide 23
Renovare International, Inc.
PRODUCT DEVELOPMENT
• Products are market-driven and reflect the need for
world-class design,“user-friendliness” and ease of
implementation across a wide range of industrial
applications.
• Renovare uses a seamless outsourcing approach or
product design and manufacturing, resulting in rapid
development, quicker time-to-market, and lower cost
with reduced risks.
VRII-9028-0/Slide 24
Renovare International, Inc.
RENOCELL
PRODUCT DEVELOPMENT
• Cell Design
• Working Electrode Designs
• Counter Electrode Design
• “Divided” Cell Operations
VRII-9028-0/Slide 25
Renovare International, Inc.
MAJOR FEATURES AND CAPABILITIES
• Porous carbon element cathode
–
–
–
–
Greatly increased deposition surface area
High metal extraction rates
Three to ten times more energy efficient
Effective at concentrations down to 1 mg/L and below
• Metal deposits plated on carbon element
• Replaceable cathode cartridges
– Easy metal removal
– Quick and easy cathode replacement
– Low operating and manpower requirements
VRII-9028-0/Slide 26
Renovare International, Inc.
MAJOR FEATURES AND CAPABILITIES
(Continued)
• Compact, robust design
– Increased reliability in industrial environments
– Very small footprint
– Capable of being wall mounted
• Industry-standard components
• Optional divided cell operations
– Allows treatment of anodically-sensitive solutions
VRII-9028-0/Slide 27
Renovare International, Inc.
PRE-PRODUCTION APPLICATIONS
AND INSTALLATIONS
Industry
VRII-9028-0/Slide 28
Application
Metal(s)
Electroplating
Dragout tank recovery
Cd
Photographic
Photographic wastes
Ag
Chemical
Process effluent
Precious metals
Remediation
Ground water
Various
Electroplating
Rinse baths
Ag
Chemical
Ion exchange regenerants
Various
PCB/Electronics
Manufacturer
Process wastes
Cu
Renovare International, Inc.
PRE-PRODUCTION APPLICATIONS
AND INSTALLATIONS
(Continued)
Industry
VRII-9028-0/Slide 29
Application
Metal(s)
Metal Finishing
Etchant solutions
Cu
Chemical Industry
Effluent
Various
Metal Finishing
Process effluent
Cd
Metal Finishing
Process treatment
Cd
Scotch Whisky
Water treatment
Cu
Remediation
Leachate
Various
Nuclear
Effluent
Various
Electric Utility
Various
Various
Renovare International, Inc.
BASIS FOR CELL DESIGN CHANGES
• Improve Performance
• Improve Cell Reliability
• Reduce Maintenance Costs
• Reflect Lessons Learned in the Field
• Reduce Production Cost
VRII-9028-0/Slide 30
Renovare International, Inc.
HOUSING DESIGN CHANGES
• Hinged Swing Bolts and Handles
• Larger Diameter
• Tapped Pipe Holes for Fluid Flow
CATHODE DESIGN CHANGES
•
•
•
•
VRII-9028-0/Slide 31
Dual Cathode Posts
Cathode Post to Feeder Jam Nut Connection
Straight Cathode Feeder Strips
Removable Base Plate
Renovare International, Inc.
ANODE DESIGN CHANGES
• Feeder Posts through Either Lid
DIVIDER MEMBRANE
DESIGN CHANGES
• Tapered Membrane Flanges With O-rings
• Dual Wall Membrane Divide
VRII-9028-0/Slide 32
Renovare International, Inc.
NEW PRODUCT DESIGN
FEATURES FOR RENOCELL
• Top lid easily removable
• All electrical and fluid transfer connections now confined to
top and bottom lids
• Current feeder post seals now use O-ring
• Dual current feeder posts for both cathode and anode
• Anode can be mounted with current feeder posts exiting
either the top or bottom lids
• Catholyte inlet and outlet connections are now both US 3/4
inch (ISO 25mm) female pipe thread connections
• Anolyte inlet and outlet connections are now both US 1/2 inch
(ISO 20mm) female pipe thread connections
• Bottom lid insert is easily removable FOR CELL CLEANING
• Divider assembly allows membrane replacement
VRII-9028-0/Slide 33
Renovare International, Inc.
RENOCELL SUPPORTS WASTE
MINIMIZATION
• RenoCell technology focuses on waste minimization
and metal recovery in the complex and diverse world
of metal finishing operations. Major considerations
include:
– Different types and concentrations of metals, concentrates and
rinses
– Variations in waste water volumes
– Increasing life cycle costs of treatment
– More stringent effluent discharge limits
VRII-9028-0/Slide 34
Renovare International, Inc.
PRINTED WIRING BOARD (PWB)
OPERATIONS
• PWB manufacturing are complex operations with over
50 different process steps
• Utilizes variety of metal conductors including:
– Copper
– Silver
– Tin/Lead
– Nickel
– Tin
– Gold
• Six to ten major PWB process lines including:
– Pattern Plate Acid Copper and Tin/Lead Plating
– Nickel/Gold Tab Plating
VRII-9028-0/Slide 35
Renovare International, Inc.
PWB PATTERN PLATE ACID Cu
AND TIN/LEAD PLATING LINE
VRII-9028-0/Slide 36
Renovare International, Inc.
PWB Pattern Plate Acid Cu
and Tin/Lead Plating Line
Plating Line Assumptions:
• 100 panels/hour
• 6 L water/rinse with 12 rinses/hour
Waste Generated
Rinse Water Used
Metal Removed
Conventional Technology
9,000,000 L
1,200 kg Cu in 30,000 kg sludge
430 kg Sn in 8,600 kg sludge
38,600
kg sludge
to test, handle and dispose
VRII-9028-0/Slide 37
RenoCell
180,000 L
1,200 kg Cu on 150 cartridges
430 kg Sn on 60 cartridges
210
cartridges
with recoverable metal
Renovare International, Inc.
•
•
Typical Cost Comparison for Cu
Removal from PWB Shop Rinse Waters
Based on:
•
•
•
40 PPM copper removal to 1 PPM copper
Sludge management (including dewatering, transportation and treatment) is
$350/ton
Ion exchange spent resin is assumed to be treated on site
Ion Exchange Treatment
VRII-9028-0/Slide 38
RenoCell
Renovare International, Inc.
RENOCELL BENEFITS
TO PWB APPLICATIONS
• RenoCell provides PWB manufacturers with several
major benefits:
– Virtual elimination of all metal-bearing hazardous sludges, saving over
40% in overall treatment costs
– Total operational cost savings of 70% over conventional treatment
methods
– Lower initial capital costs with faster pay back periods (less than 2 years)
– Reduced wastewater loading on existing waste treatment facilities
– Conformance with national and local discharge compliance standards
VRII-9028-0/Slide 39
Renovare International, Inc.
IN SUMMARY
• RenoCell is the next generation of process and waste
water metal ion removal and metal reclamation
treatment equipment.
• Renovare’s RenoCell product delivers advanced,
patented three-dimensional electrodeposition
technology incorporated in a compact, robust cell
design.
• The principles of electrodeposition is the same for all
electrochemical cells. However, simply put .…
“RenoCell® technology works substantially better.”
VRII-9028-0/Slide 40
Renovare International, Inc.