Transcript Tools and Techniques for Optimizing Metal Finishing Process/Environmental MA Metal Finishing Forum Kevin L.

Tools and Techniques for Optimizing Metal
Finishing Process/Environmental
MA Metal Finishing Forum
Kevin L. Klink, P.E.
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
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


2
PROCESS/ENVIRONMENTAL PROJECTS
3
Opportunity to Influence Project
Ability to Influence Total Capital Cost
100%
Advanced
Planning
Manufacturing
Optimization
80%
Maximum project
cost control is
gained through
effective early
planning and
engineering
Conceptual
Design
Preliminary
design
Total Capital Cost
60%
40%
Detailed design
Construction and Equipment
Installation
20%
0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Project Timeline
4
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
5
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
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Rinse Tank
1
Continuous Discharge
to Waste Treatment
Drag-out
Make-up Water
Process Bath
Continuous Discharge
to Waste Treatment
Drag-in
Make-up Water
Batch Discharge to
Waste Treatment
Make-up Chemistry
Metal Finishing Process Water Flow
Schematic
Drag-out
Drag-out
Rinse Tank
2
8
Process Solution Maintenance and
RinseWater Recycling
Process Bath
Maintenance
Impurities
Purified Chemicals
Drag-out
Drag-out
Rinse Tank
1
Purification
Chemicals/Water
Separation
System
Drag-out
Rinse Tank
2
Purified Water
Drag-in
Purified Rinse
Water (Low TDS)
Water Recycle
System
Make-Up
Water
9
Increasing costs
A Balance of Integrated Pollution Prevention and Pollution Control
Provides Lowest Life Cycle Cost
All pollution
control
0
0.25
All pollution
Prevention
0.5
0.75
1
Increasing pollution
prevention
10
SOFTWARE TOOLS FOR
PROCESS/ENVIRONMENTAL IMPROVEMENT
11
Navy Demonstrated Success with Off-the-Shelf
Anodizing Process Controls
12
Computerized Process Recipes, Monitoring, Control,
and Verification Reports Improve Processing
13
Process Modeling Provides Estimates of Facility Flow Balance,
Energy, Material Use, and Annual Costs
14
Process Modeling Provides Estimates of Process Flow
Balance, Energy, Material Use, and Annual Costs
15
Process Cost Report Itemizes Nine Cost
Categories for Each Process
16
Modeling Production Ranges Produces Ranges for
Flows, Energy, Material Use, and Annual Costs
17
Process Model Data Can be Exported to Tankline
Spreadsheets
18
Chemical Usage Export to MS EXCEL Provides
Basis for Chemical Consumption and Inventory
Chemical/Material
Activated Carbon
Ammonium Nitrate
Anionic Polymer
Barrett Additive A
Barrett SN
Barrett SNAC
Barrett SNAP AM
Barrett SNR-24
Boric Acid
Brush Plate
Cad. Concentrate
Cadmium Ball
Chemical/Material
Activated Carbon
Ammonium Nitrate
Anionic Polymer
Barrett Additive A
Barrett SN
Barrett SNAC
Barrett SNAP AM
Barrett SNR-24
Boric Acid
Ordered
500
2000
110
100
2200
200
8
495
600
1
2000
Quantity After
Initial Fill
350
1151
100
100
0 NA
200
8
495
256
Quantity
Received
500
2000
110
100
2200
200
8
495
600
2013
Months
Left
Initial Fill
and Use
Unit
lb
lb
gal
lb
gal
lb
gal
gal
lb
Lot
150
849
10
0
2200
0
0
0
344
brush plate
brush plate
lb
1000
Order
Lead (mo)
3.5
7.1
7.6
9.5
25
0.92
2.8
1.5
Contingent
Quantity
3
3
3
3
3
3
3
3
3
50
849
0
0
1100
0
0
0
138
Monthly Usage
Annual
Estimate
Usage
100
163
13
11
NA
NA
8
8.7
177
171
brush plate
brush plate
brush plate
brush plate
16
Minimum
Inventory
350
1338
39
32
1100
24
26
532
652
1200
1957
158
127
96
104
2126
2057
193
Months to Min
Inventory
0.00
(1.2)
4.6
6.5
0.00
(22)
(2.1)
(0.21)
(2.3)
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Use of Data Management Software Provides Automatic
Trend Plotting and Statistical Calculations
20
Linking Photos and Documents Into Data Software
Enhances Value of Information
21
Data Management System Software Implements
Selected Automatic Responses to Data Results
22
LIFE CYCLE INFORMATION MANAGEMENT
23
Planning Provides Awareness of Data
Generation Over Project Life Cycle
Planning
1 year
Design
18 months
Construction
2 years
Facility Management
20 years
DATA
DATA
DATA
DATA
24
A Data Warehouse Enhances Project Lifecycle
Information Management and Use
25
Early Data Input Maximizes Data
Utility
Planning
Niklad 794
Bright Electroless
Nickel Phosphorus Process
Product Code No. 78048
Technical Data Sheet
Table of Contents:
1. Process description and advantages
2. Deposit properties
3. Process components
4. Bath make-up
5. Bath operation and control
6. Solution analysis
7. General guidelines
8. Waste management
9. Safety & handling guidelines
10. Ordering information
Planning
MACDERMID INCORPORATED 245 FREIGHT ST. WATERBURY, CT USA 06702-9984 TEL (203) 575-5700 US FAX (203) 575-5630
INTERNATIONAL FAX (203) 575-7900
INCORPORATED
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Data Warehouse Delivers Benefits
Over the Entire Lifecycle
Startup
Commissioning
O&M
Planning
Construction
Design
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Access Vast Range of Data On Fixed PC or Laptop,
Tablet or Pocket PC
MF
Process Water
Cr
2
3
Empty
Empty
Empty
Empty
Empty
Wet Shuttle
CCR 3
CCR 2
CCR 1
CCR 2
CCR 1
Type 1 Anodize
CCR 2
CCR 1
Chem Film
Tri Acid
Acid Etch
CCR 2
Spray Rinse
CCR 1
Desmut
Alkaline Etch
HWR
Load/
Unload
Empty
Dryer
Load/
Unload
3
Line 1
Washdown
Fog
Nonetch Soak
Fog
Cr
Acid/Alkali
Atmospheric
Evaporator
1
Process Water
Fog
Fog
Fog
Fog
Fog
Fog
Fog
DD
2
4
3
DD
DD
DD
DD
DD
DD
DD
DD
Spray Rinse
Wet Shuttle
Type 2 Anodize
Type 2 Anodize
Type 3 Anodize
Additive A
Type 3 Anodize
Additive B
Type 3 Anodize
Additive B
CCR 1
Type 3 Anodize
Additive B
CCR 2
CCR 3
Black Dye
Dye II
Dye III
Spray Rinse
Dye V
Spray Rinse
Seal 1
CCR 1
CCR 2
Seal 2
Seal 3
Seal 5
HWR
CCR 1
Load/
Unload
Dryer
Load/
Unload
CCR 2
Seal 4
Dye IV
Fog
Dryer
Design
Files
Atmospheric
Evaporator
ME
1
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Fog
Fog
Fog
Fog
Fog
DD
DD
DD
DD Bleed
DD Feed
Line 2
Washdown
Type 3
Anodizing
Additive B
Holding
Tank
3
Type 3
Anodizing
Additive A
Holding
Tank
Type 2
Anodizing
Holding
Tank
Dye
Holding
Tank
Dye
Holding
Tank
Dye
Holding
Tank
Diffusate
Feed
DD
Potable Water
Dialysate
Water Treatment
2
3
Cr
Cr Collection
2
Cr Treat
Acid/Alkali
Equalization
Primary pH
Adjust
MF Recirc.
Microfiltration
Final pH Adjust
Wastewater Discharge
UV Oxidation?
GAC
Process Water
4
Dye
Filter Press
1
Acid
Cleaning
Skid
Drum
GAC
NaOH
Legend:
Wet
Scrubber
2
Wet
Scrubber
2
Evaporation
Process Water
Integrated Pollution Prevention & Control Plan
Conc. Wastewater
SIZE
Dilute Wastewater
Sloped Bottom
DRAFT
FSCM NO
C
DWG NO
REV
VisioDocumentVisioDocument
SCALE
none
• Software
Input/output
• Intranet
O&M Manual
• O&M Logs, Notes
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SHEET
1 OF 2
Benefits of State of the Art Project Data Systems
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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

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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
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Supply Chain Considerations
Motivation
 Respond to Requirements
 Opportunity for Improvement
Impacts
 Efficiency
 Quality
 Profitability
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