Kevin L. Klink, P.E.
description
Transcript of Kevin L. Klink, P.E.
Tools and Techniques for Optimizing Metal Finishing Process/Environmental
MA Metal Finishing ForumMA Metal Finishing Forum
Tools and Techniques for Optimizing Metal Finishing Process/Environmental
MA Metal Finishing ForumMA Metal Finishing Forum
Kevin L. Klink, P.E.Kevin L. Klink, P.E.
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OverviewOverview
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
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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PROCESS/ENVIRONMENTAL PROJECTSPROCESS/ENVIRONMENTAL PROJECTS
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100%
0%
20%
40%
60%
80%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Ab
ilit
y t
o I
nfl
uen
ce T
ota
l C
ap
ital
Co
st
AdvancedPlanning
ManufacturingOptimization
Preliminarydesign
Detailed design
Construction and EquipmentInstallation
ConceptualDesign
Maximum project cost control is gained through effective early planning and engineering
Opportunity to Influence Project Opportunity to Influence Project
Project Timeline
Total Capital Cost
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Project Value is Maximized Through Systematic Planning and ImplementationProject 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
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
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WATER AND CHEMICAL RECOVERY AND REUSE
WATER AND CHEMICAL RECOVERY AND REUSE
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Water and Chemical Recovery and ReuseWater 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
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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Drag-outDrag-out
Process BathProcess Bath Rinse Tank Rinse Tank 11
Rinse Tank Rinse Tank 22
Drag-outDrag-outDrag-inDrag-in
Mak
e-u
p
Mak
e-u
p
Wat
erW
ater
Drag-outDrag-outB
atch
Dis
char
ge
to
Bat
ch D
isch
arg
e to
W
aste
Tre
atm
ent
Was
te T
rea
tmen
t
Mak
e-u
p
Ch
emis
try
Mak
e-u
p
Ch
emis
try
Co
nti
nu
ou
s D
isch
arg
e
Co
nti
nu
ou
s D
isch
arg
e
to W
aste
Tre
atm
en
tto
Was
te T
reat
me
nt
Mak
e-u
p
Mak
e-u
p
Wat
erW
ater
Co
nti
nu
ou
s D
isch
arg
e
Co
nti
nu
ou
s D
isch
arg
e
to W
aste
Tre
atm
en
tto
Was
te T
reat
me
nt
Metal Finishing Process Water Flow Metal Finishing Process Water Flow SchematicSchematicMetal Finishing Process Water Flow Metal Finishing Process Water Flow SchematicSchematic
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PurificationPurificationMaintenanceMaintenance
Chemicals/Water Chemicals/Water Separation Separation
SystemSystem
Water RecycleWater RecycleSystemSystem
Drag-outDrag-out
Process Solution Maintenance and RinseWater Recycling
ImpuritiesImpurities
Process BathProcess Bath Rinse Tank Rinse Tank 11
Rinse Tank Rinse Tank 22
Purified Rinse Purified Rinse Water (Low TDS)Water (Low TDS)
Make-UpMake-UpWaterWater
Drag-outDrag-outDrag-inDrag-in
Pu
rifi
ed W
ate
rP
uri
fied
Wat
er
Purified ChemicalsPurified Chemicals
Drag-outDrag-out
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A Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle CostA Balance of Integrated Pollution Prevention and Pollution Control Provides Lowest Life Cycle Cost
0 0.25 0.5 0.75 1
All pollution control
All pollution control
All pollution Prevention
All pollution Prevention
Incr
easi
ng
co
sts
Increasing pollution prevention
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SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT
SOFTWARE TOOLS FOR PROCESS/ENVIRONMENTAL IMPROVEMENT
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Navy Demonstrated Success with Off-the-Shelf Anodizing Process ControlsNavy Demonstrated Success with Off-the-Shelf Anodizing Process Controls
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Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing
Computerized Process Recipes, Monitoring, Control, and Verification Reports Improve Processing
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Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs
Process Modeling Provides Estimates of Facility Flow Balance, Energy, Material Use, and Annual Costs
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Process Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual CostsProcess Modeling Provides Estimates of Process Flow Balance, Energy, Material Use, and Annual Costs
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Process Cost Report Itemizes Nine Cost Categories for Each ProcessProcess Cost Report Itemizes Nine Cost Categories for Each Process
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Modeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual CostsModeling Production Ranges Produces Ranges for Flows, Energy, Material Use, and Annual Costs
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Process Model Data Can be Exported to Tankline SpreadsheetsProcess Model Data Can be Exported to Tankline Spreadsheets
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Chemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and InventoryChemical Usage Export to MS EXCEL Provides Basis for Chemical Consumption and Inventory
Initial Fill Monthly Usage AnnualChemical/Material Ordered Received Unit and Use Estimate Usage
Activated Carbon 500 500 lb 150 100 1200Ammonium Nitrate 2000 2000 lb 849 163 1957Anionic Polymer 110 110 gal 10 13 158Barrett Additive A 100 100 lb 0 11 127Barrett SN 2200 2200 gal 2200 NA NABarrett SNAC 200 200 lb 0 8 96Barrett SNAP AM 8 8 gal 0 8.7 104Barrett SNR-24 495 495 gal 0 177 2126Boric Acid 600 600 lb 344 171 2057Brush Plate 1 Lot brush plate brush plate brush plateCad. Concentrate brush plate brush plate brush plateCadmium Ball 2000 2013 lb 1000 16 193
Quantity Initial Fill Monthly Usage AnnualChemical/Material Ordered Received Unit and Use Estimate Usage
Activated Carbon 500 500 lb 150 100 1200Ammonium Nitrate 2000 2000 lb 849 163 1957Anionic Polymer 110 110 gal 10 13 158Barrett Additive A 100 100 lb 0 11 127Barrett SN 2200 2200 gal 2200 NA NABarrett SNAC 200 200 lb 0 8 96Barrett SNAP AM 8 8 gal 0 8.7 104Barrett SNR-24 495 495 gal 0 177 2126Boric Acid 600 600 lb 344 171 2057Brush Plate 1 Lot brush plate brush plate brush plateCad. Concentrate brush plate brush plate brush plateCadmium Ball 2000 2013 lb 1000 16 193
Quantity
Quantity After Months Order Contingent Minimum Months to MinInitial Fill Left Lead (mo) Quantity Inventory Inventory
350 3.5 3 50 350 0.001151 7.1 3 849 1338 (1.2)
100 7.6 3 0 39 4.6100 9.5 3 0 32 6.5
0 NA 3 1100 1100 0.00200 25 3 0 24 (22)
8 0.92 3 0 26 (2.1)495 2.8 3 0 532 (0.21)256 1.5 3 138 652 (2.3)
Chemical/MaterialActivated CarbonAmmonium NitrateAnionic PolymerBarrett Additive ABarrett SNBarrett SNACBarrett SNAP AMBarrett SNR-24Boric Acid
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Use of Data Management Software Provides Automatic Trend Plotting and Statistical CalculationsUse of Data Management Software Provides Automatic Trend Plotting and Statistical Calculations
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Linking Photos and Documents Into Data Software Enhances Value of InformationLinking Photos and Documents Into Data Software Enhances Value of Information
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Data Management System Software Implements Selected Automatic Responses to Data ResultsData Management System Software Implements Selected Automatic Responses to Data Results
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LIFE CYCLE INFORMATION MANAGEMENTLIFE CYCLE INFORMATION MANAGEMENT
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Planning1 year
Design18 months 2 years
Facility Management20 years
Construction
Planning Provides Awareness of Data Generation Over Project Life Cycle Planning Provides Awareness of Data Generation Over Project Life Cycle
DATA DATA DATA DATA
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A Data Warehouse Enhances Project Lifecycle Information Management and UseA Data Warehouse Enhances Project Lifecycle Information Management and Use
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Early Data Input Maximizes Data UtilityEarly Data Input Maximizes Data Utility
PlanningPlanning
Niklad 794Bright ElectrolessNickel Phosphorus ProcessProduct Code No. 78048
Technical Data SheetTable of Contents:1. Process description and advantages2. Deposit properties3. Process components4. Bath make-up5. Bath operation and control6. Solution analysis7. General guidelines8. Waste management9. Safety & handling guidelines10. Ordering informationMACDERMID INCORPORATED 245 FREIGHT ST. WATERBURY, CT USA 06702-9984 TEL (203) 575-5700 US FAX (203) 575-5630 INTERNATIONAL FAX (203) 575-7900
INCORPORATED
PlanningPlanning
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Data Warehouse Delivers Benefits Over the Entire LifecycleData Warehouse Delivers Benefits Over the Entire Lifecycle
DesignDesign
PlanningPlanning
Construction
Construction
Startup Commissioning O&M
Startup Commissioning O&M
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Access Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PCAccess Vast Range of Data On Fixed PC or Laptop, Tablet or Pocket PC
• IntranetO&M Manual
• O&M Logs, Notes
• IntranetO&M Manual
• O&M Logs, Notes
Design Files
Design Files
• Software Input/output
Load/Unload
Non
etch
Soa
k
Em
pty
Alk
alin
e E
tch
CC
R 1
CC
R 2
Des
mut
Spr
ay R
inse
Aci
d E
tch
Tri A
cid
CC
R 1
CC
R 2
Che
m F
ilm
CC
R 1
CC
R 2
Type
2 A
nodi
ze
CC
R 1
CC
R 2
CC
R 3
Type
2 A
nodi
ze
Type
3 A
nodi
zeA
dditi
ve A
Type
3 A
nodi
zeA
dditi
ve B
Type
3 A
nodi
zeA
dditi
ve B
Type
3 A
nodi
zeA
dditi
ve B
CC
R 1
CC
R 2
Bla
ck D
ye
Spr
ay R
inse
Dye
II
Dye
III
Type
1 A
nodi
ze
CC
R 1
CC
R 2
Sea
l 1
Sea
l 2
Sea
l 3
CC
R 1
CC
R 2
HW
RLoad/Unload
Load/Unload
Wet
Shu
ttle
Em
pty
Em
pty
Em
pty
Em
pty
Dry
er
Dry
er
Dry
er
Load/Unload
FogFog
Cr
Fog Fog Fog Fog Fog Fog
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
DD
Cr
Cr Collection Cr Treat
EqualizationPrimary pH
AdjustMF Recirc.
Acid NaOH
GAC
GAC
Final pH AdjustMicrofiltration
DRAFT
Integrated Pollution Prevention & Control Plan
SIZE FSCM NO DWG NO REV
C VisioDocumentVisioDocument
SCALE none SHEET 1 OF 2
Acid/Alkali
Process Water
Process Water
DD Feed
DD Bleed
Cr
Dye
Acid/Alkali Wastewater Discharge
Filter Press
Drum
Dialysate
Diffusate
Feed
2
3
2
4
1
1
4
2
3Water Treatment
Potable Water
Process Water
1
HW
R
AtmosphericEvaporatorME
Wet
Shu
ttle
Legend:
Evaporation
Process Water
Conc. Wastewater
Dilute Wastewater
Sloped Bottom
CC
R 3
Em
pty
AtmosphericEvaporator
CleaningSkid
MF
Line 1 Washdown
Line 2 Washdown
UV Oxidation?
2
WetScrubber
WetScrubber
2
2
3
Dye
Spr
ay R
inse
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Dye
Fog
Fog
Fog
Fog
Fog
Dye
IV
Spr
ay R
inse
Dye
V
Sea
l 4S
eal 5
3
3
Fog
Fog
Type 3AnodizingAdditive B
HoldingTank
Type 3AnodizingAdditive AHolding
Tank
Type 2AnodizingHolding
Tank
DyeHolding
Tank
DyeHolding
Tank
DyeHolding
Tank
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Benefits of State of the Art Project Data SystemsBenefits of State of the Art Project Data Systems
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
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 BenefitsIntegrated Process Planning and Information Tools Produces Excellent Benefits
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
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 ConsiderationsSupply Chain Considerations
Motivation Respond to Requirements Opportunity for Improvement
Impacts Efficiency Quality Profitability
Motivation Respond to Requirements Opportunity for Improvement
Impacts Efficiency Quality Profitability