ISO 9001:2008 Certified Facility
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ISO 9001:2008 Certified Facility
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View any case history to read more about it.
Background
A hardware manufacturer purchased an automated in-line continuous vibratory system followed by a high-pressure rinse to clean, deflash, and finish aluminum die cast housings. Since the plant is a zero discharge facility, a recycling system based on centrifuging and reusing the water was part of the system. The finishing waste was recycled through the centrifuge system and reused. The production line could not produce acceptable painted parts due to a film residue left on the parts after the finishing process. The process was shut down and the capital investment was in jeopardy.
Solution
Precision Finishing Inc.'s process engineers met with the plant personnel to review the problem. A pilot study was conducted duplicating the plant process conditions. Based on the results of the pilot study, a Chemtrol® CTS 12/16-2 filtration and recycling system using a Chemtrol® antifilming compound was recommended. This original system has operated successfully for 3 years. The system runs 12 hours per day generating approximately 1200 gallons of clean water for reuse. To the reuse water is added 0.5% of a Chemtrol® antifilming compound. Part quality is consistently maintained while more then a quarter of a million gallons of water is reused annually.
Background
A mass finishing job shop generating 5000 gallons per day of a variable waste stream used a chemical flocculation system to treat their wastewater prior to discharge to sewer. Due to the variable nature of the waste stream, the chemical flocculation system required full time monitoring with frequent chemical feed adjustments. The waste stream nature is an abrasive, high solids waste with dissolved heavy metals particularly copper, zinc, and lead. The required high feed rate of the flocculation chemicals resulted in an annual chemical bill of $46,000 per year and excessive sludge generation.
The EPA required the local sewer authority to reduce their heavy metal discharges, which in turn reduced the heavy metal limits for the industrial dischargers. Some of the limits were reduced to as low as 0.1 ppm. It was determined that the chemical flocculation system could not achieve these limits on a consistent cost effective basis.
Solution
A pilot test was conducted using a small membrane filtration system and adding a Chemtrol® metal scavenger. The Chemtrol® metal scavenger chemically converts the dissolved heavy metal to an undissolved state, which is removed by the membrane filter. Analytical testing determined that this approach was successfully meeting the sewers low metal limits. A Chemtrol® CTS48-2 membrane filtration system was installed. The advantages were evident immediately. The variable waste stream did not upset the system. The Chemtrol® metal scavenger reduced the heavy metal concentrations to exceptionally low levels. The system required 50% less labor to operate and $30,000 per year was saved in chemical usage. The sludge volume was reduced 75%. The payback period was less than 2 years. In 2001 the system exceeded 19,000 hours of operation.
Background
A fabrication job shop cleaned, deburred, and finished steel, stainless steel, and aluminum parts in several vibratory bowls. The daily volume of wastewater was 500 gallons per day. Occasionally, the plant was in violation of its heavy metal discharge limits. The local sewer authority was also requesting the plant reduce it's discharge volume.
The plant operated an existing batch chemical flocculation system for treating plating bath discharges. Plant personnel desired an automated system for recycling the vibratory wastewater without sacrificing part quality.
Solution
Precision Finishing Inc.'s process engineers met with the plant personnel to review the problem. A pilot study was conducted duplicating the plant process conditions. Based on the results of the pilot study, a Chemtrol® CTS 8/16-2 filtration and recycling system using a Chemtrol® recycling compound was recommended. Supported by Precision Finishing Inc.'s sales and technical staff, plant personnel quickly assimilated operation of the system. The system requires a 30-minute cleaning once or twice a week and the automated system takes care of the rest. Routinely the concentrated solids or sludge is removed from the system and further dewatered in a drum evaporator. The small amount of dried sludge is a non-hazardous waste and is disposed of in the plant's industrial trash bin. Monthly, a sample of the recycled water is sent to Precision Finishing Inc. for evaluation. The results enable plant personnel to fine-tune the system operation for maximum performance. Approximately 125,000 gallons of water is reused annually.
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