THE ENVIRONMENTAL IMPACT OF ANODIZING

The process of anodizing with a sulfuric acid bath produces two byproducts: degraded sulfuric acid and aluminum hydroxide. Aluminum hydroxide is a compound of aluminum from the anodized part, and hydrogen and oxygen from the acid. Classified by the EPA as hazardous, aluminum hydroxide wastewater cannot simply be dumped into a municipal wastewater system. The EPA has strict standards for the highest allowable aluminum concentration level upon disposal; degraded sulfuric acid must also be neutralized before disposal to a ph of between six and eight. Through give and take between the industry and the EPA, the EPA sets up guidelines and standards called Best Available Technology Economically Achievable (BAT). BAT standards are then mandated for waste disposal. Some very innovative solutions to waste management have since been introduced that not only reduce the waste that needs disposal, but also reclamation and recycling of the aluminum metal itself. Wastewater The first step in dealing with wastewater is to produce less of it; this is the idea behind electrodialysis. Electrodialysis is a process of extending the life of the anodizing electrolyte by removing the aluminum ions from the bath. Electricity charges the ions that are then driven through an ionic sensitive membrane on their way to an oppositely charged electrode. The membrane picks up the aluminum and allows the acid electrolyte to pass through and continue on back to the bath. The collected aluminum hydroxide is sludge, and the acid bath is then cleaned of it. In another process called acid sorption, the exact opposite takes place. In acid sorption, ion exchange resins absorb the sulfuric acid while the metals pass by. The resins then release the acids in a water wash, and the metals are collected for disposal. In another method, flocculating agents separate the aluminum from the electrolyte. These polymer additives combine with the aluminum hydroxide and congeal, creating a wooly mass that is skimmed away. The only equipment

needed is the agents themselvesthis makes it an attractive process to both large and small businesses. Aluminum Hydroxide Sludge In all of the above processes, heavy aluminum hydroxide sludge is left. Presses can squeeze out water, and sludge dryers further concentrate the sludge making it up to 75 percent solid. Small producers (less than 100 kilograms per month) are exempt from EPA guidelines in the disposal of hazardous waste and may take it to a general municipal landfill. Larger producers, though, must adhere to EPA regulations in the storage, transportation, and disposal of their waste. Similar in size to the U.S. Tax Code, there are literally thousands and thousands of pages on rules and regulations pertaining to hazardous waste in the U.S. Code Title 40, Protection of Environment. Section 261.31 of U.S. Code Title 40, titled Hazardous Wastes from Nonspecific Sources calls wastewater treatment sludge from the chemical conversion coating of aluminum by the name Industry and EPA Hazardous Waste No. F019. This simply means that if an anodizer is not an exempt small producer as described above, the anodizer must comply with EPA hazardous waste regulations in the disposal of aluminum sludge. Other Pollutants Air pollution is a concern in the anodizing shop. In the anodizing bath, sulfuric acid fumes are released that can be hazardous not only to the air, but to employees in the plant. Local exhaust ventilation removes the fumes at the source point and a scrubber provides additional cleaning before release into the atmosphere. The concentration in the electrolyte bath may be only 10 to 20 percent, but long-term exposure causes permanent health problems if precautions are not taken. In the atmosphere, released sulfuric acid subsequently falls back to the ground as acid rain, which adversely affects flora, fauna, soils and surface waters. Besides the electrolyte bearing sludge, other wastes are generated in the anodizing process. The solvents and cleaners used in the pre-treating process, as well as the materials removed from the aluminum, must be collected and properly disposed of. After anodizing, there are also dyes and sealants that need additional disposal.

Hazardous Waste Services Hazardous waste contractors are an expensive way to deal with disposal, but save the anodizer from compliance errors that can be even more costly. Hazardous disposal contractors services range from simple consulting to complete handling of the waste . Once in hand, the waste is recycled , incinerated, or taken to a landfill . If sludge contains high enough levels of aluminum, it can be removed from sludge and sent off for use in the manufacturing of bricks and clays, cosmetics, and paper products. This process often proves unfeasible due either to the contaminants in the sludge or its low metal content per volume. Incineration is another option for sludge disposal. It has the advantages of reducing both the volume and toxicity of the sludge, but is an expensive process. Aluminum sludge is often taken for disposal to a Resource Conservation and Recovery Act (RCRA) landfill. RCRA landfills are lined with six inches of synthetic membranes that sit on top of at least five feet of solid clay. Monitors at different levels detect leaching and all collected leachate is processed and treated.
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Environmental impact
Anodizing is one of the more environmentally friendly metal finishing processes. With the exception of organic (aka integral color) anodizing, the by-products do not contain heavy metals, halogens, or volatile organic compounds. The most common anodizing effluents, aluminium hydroxide and aluminium sulfate, are recycled for the manufacturing of alum, baking powder, cosmetics, newsprint and fertilizer or used by industrial wastewater treatment systems.[15]

Environmental Impact Anodizing is one of the most environmentally-friendly metal finishing processes; anodizing by-products do not contain heavy metals, halogens and volatiles. The most common anodizing effluents, aluminum hydroxide and aluminum sulfate, are recycled for the manufacturing of alum, baking powder, cosmetics, newsprint and fertilizer or used by industrial wastewater treatment systems. Anodizings environmental friendliness and relative safety are amongst its best properties, in the age of increasing concern for human protection and quality of our land, water and air.

Superior Anodizing creates no hazardous waste in our anodizing operation and holds all necessary permits.

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Anodizing and the Environment

Aluminum Life Cycle Enhancement with Anodizing The environmental advantages of aluminum are widely acknowledged. Aluminum is one of the most durable and versatile of metals, offering improved mileage in automobiles by virtue of its lightweight and tremendous recyclability. According to the Aluminum Association, about one-third of all aluminum produced in the U.S. today is from recycled sources, saving some 95 percent of the energy required to produce aluminum from raw materials. Anodizing enhances aluminum and its environmental virtues. Anodizing uses the base metal - the aluminum alloy - to create a thin, extremely strong and corrosion-resistant finish. The anodized surface is very hard and thus preserves and extends the life of the aluminum product. In contrast to anodizing, coatings - paint for example - can dramatically reduce the ability to recycle the aluminum and can increase costs. Paints, plastics, and plating rely on problematic materials in their production that can compromise green objectives. Anodizing, on the other hand, is "recycle-neutral" with minimal use of such materials as volatile organic compounds (VOCs) and heavy metals.

The corrosion resistance of anodized aluminum is well established for industrial applications. Transportation components, building elements, storage containers, and process equipment utilize anodizing to extend the life and expand the utility of aluminum structures. Anodized aluminum is safe for cookware and provides durable work surfaces for applications that require superior abrasionresistance. Anodizing also reduces friction and increases lubricity, an advantage with fitted components and for moving parts. Increased wear resistance means a longer life cycle. Hardcoat anodizing further improves wear resistance and general coating durability to physical forces. Aluminum Saves Energy and Materials Aluminum metal is a good conductor of electricity; the anodic coating is an insulator. Combinations of the two properties can be incorporated into systems that save energy and materials. The metal can serve both a structural and conductive purpose, while the anodic coating insulates the

In light of environmental impacts, anodized aluminum is the "naturally green" material. Anodizing accentuates the environmental benefits of aluminum without compromising them, and the process is relatively benign when compared to other materials and processes.

circuit and preserves the structure. This simplifies physical design for electric circuits and saves space and wiring. All of the aforementioned properties of anodizing contribute substantially to a product's life cycle and reduce energy demands. Environmental Aspects of the Anodizing Process Anodizing is a water-based process and uses no VOCs. There are no vehicle solvents, no carrier resins, and any pigmentation used in anodizing is created by extremely small amounts of metals or dye securely locked within the hard surface. No halogenated hydrocarbons or similar toxic organics are used in anodizing. Similar neutralization reduces most anodizing chemicals to common dissolved minerals. Most anodizing is performed without generation of hazardous waste, and in many cases aluminum-rich anodizing wastes are environmentally valuable in removing pollutants and settling solids in domestic sewage treatment processes. Anodizing is not metal plating. The two are sometimes confused, but in fact, are completely different processes. The anodic coating is generated from the base metal and, thus, has essentially the same constituents as the aluminum. The surface builds Anodizing provides aesthetic from the metals as an ultra-thin, nontoxic aluminum oxide. Added appeal, as well as stability materials constitute a minute amount of mass to a product; and durability. Material Safety Data Sheets for anodized aluminum are identical to those for the metal. Under EPA rules, conventional anodizing generates no hazardous waste; it does not use VOCs or EPA-listed toxic organics. The involvement of heavy metals is dramatically lower than exterior-use paint pigments or plating. Recyclability is unaltered by anodizing and no intermediate processing is needed for anodized metal to reeenter the recycle chain, unlike thicker organic or plated metallic coatings. Anodized aluminum is the environmentally sound choice for various applications.

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LIMITS ESTABLISHED BY THE ITALIAN LAW N 319/76-650/79 (shown as an example of THE MOST severe limits in Europe)
Parameters M.U. Tab.A Parameters ppm PH Settled matter Tot.susp.matter BOD5 COD Aluminium Boron Cadmium Chromium III Chromium VI Iron Manganese Nickel Lead Copper Selenium Al B Cd Cr Cr Fe Mn Ni Pb Cu Se ml/l 5.5-9.5 Tin 0.5 80 40 160 1 2 0.02 2 0.2 2 2 2 0.2 0.1 0.03 Zinc Tot. cyanides Active chlorine Sn Zn CN Cl2 ml/l 10 0.5 0.5 0.2 M.U. Tab.A

Sulphides
Sulphites Sulphates

H2S
SO 3-SO 4--

1
1 1000

Chlorines
Fluorines Tot.phosphorous Amm.nitrogen Nitrous nitrogen Nitric nitrogen Fats/oils Mineral oils

Cl FP NH 4+ N 3+ N 5+

1200
6 10 15 0.6 20 20 5 2

Surface active agents

(TURSKA)