Cleaner Production in the Metal Finishing Industry, RSA

Ultra and micro filtration

Existing technology already implemented:

Method Ultra filtration Application Area Purification and recycling of oily water Purification and recycling of oily degreasing baths and cleaners Fine filtration of wastewater and process baths Micro filtration Purification and recycling of oily water Purification and regeneration of oily degreasing baths and cleaners Separation of precipitated metal hydroxide sludge Fine filtration of wastewater and process baths

New applications with less experience:

Regeneration of developing baths and resist stripping baths for the production of print circuit boards; Purification and recovery (combined with reverse osmosis of rinse water in the photographic industry; Purification and recovery (combined with RO) of wastewater from chemical precipitation plants for heavy metals Purification and regeneration of phosphating baths Purification and regeneration of vibration polishing water

Ultra and micro filtration, FD

DANCED - 09.10.2000

Cleaner Production in the Metal Finishing Industry, RSA

Ranges of membrane processes

RO Electrodialysis Ion exchange Dialysis Ultra filtration Ultra centrifugation Micro filtration Centrifugation Gravity sedimentation Cloth filtration my 0.001 Ionic range 0.01 0.1 1.0 10 Micron range 100 1000

Macromolecular range

Particle range

Ultra and micro filtration, FD

DANCED - 09.10.2000

Cleaner Production in the Metal Finishing Industry, RSA

Characteristics of cleaners and degreasers

Spent cleaners and degreasers contain oil and grease as well as active cleaner salt The impurities are accumulating in the bath during utilisation but a part of will be removed by drag-out together with the cleaning salt Cleaning salt contain normally silicates, phosphates, carbonate, caustic, complexing agents, surfactants etc. The inorganic part is also called builder components, while the surfactants (tensides) are called the soap. Cleaner salt may be a one component salt where all components are mixed or a 2-component salt where soap and builder components are separated. Builder components are primarily lost by drag-out while soap is lost by drag-out and by reaction with oil and grease for emulsifying.

Ultra and micro filtration, FD

DANCED - 09.10.2000

Cleaner Production in the Metal Finishing Industry, RSA

Purification and reuse of cleaning baths

By ultra and micro oil and grease can be removed by filtration while cleaner salt and tensides is passing the filter and returned to the process bath for reuse

high molecule faction concentrate low molecule fraction

flow

membrane permeate

Ultra and micro filtration, FD

DANCED - 09.10.2000

Cleaner Production in the Metal Finishing Industry, RSA

Purification and reuse of cleaning baths

Typical application
Evaporation Rinse water

Reuse

Cleaner

Rinse tank

Oily waste Buffer Concentrate

Permeate Micro filter

Ultra and micro filtration, FD

DANCED - 09.10.2000

Cleaner Production in the Metal Finishing Industry, RSA

Danish case-story from electroplating company using a ceramic micro filter for 4 lines
Filter surface: Typical flux: Total price incl. installation: 2.8 m2 40-80 l/m2.h R200,000

For purification of degreasing baths, electrolytic cleaning baths and acid pickling cleaners. Cleaning procedure is batch wise cleaning 700 litres solution in one batch. The purified solution is stored in a transportable container ready to be used for filling up by in the process tank by the next cleaning
Type of bath Pickling cleaner Soak cleaner Electrolytic cleaner Oil in dirty bath before purification 70 mg/l 7000 mg/l 500 mg/l Oil in clean bath after purification 40 mg/l 1200 mg/l 200 mg/l

Conclusion: 25-50% saving of chemicals and at least 5 times longer life time of the cleaning baths Necessary to use a 2-component cleaner and make a very accurate dosing Testing of cleaning efficiency is important to make the optimum dosing of chemicals (monitor surface tension of the bath)

Ultra and micro filtration, FD

DANCED - 09.10.2000

Cleaner Production in the Metal Finishing Industry, RSA

Precipitation of silver from photographic wastewater at CEWE COLOR DENMARK

Buffer

6000 liter

Wastewater

Sludge
P1

40%
SRP

Static mixer 20m tube reactor

60% H2SO4 Static mixer

50 m tube reactor

Carthridge filter 2*7

12 filter bags

Concentrate, 2 m /h Sludge to recovery

P3, 3,2 m3/h
Separation tank 1200 litre

Treated wastewater to sewer

1,2 m3/h P4, 60m3/h

58 m /h
P5 Buffer 550 litre

filter II P2, 60-240 l/h UF plant

Ultra and micro filtration, FD

DANCED - 09.10.2000