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D 116 Bio-cleaning ( Date: 2004-07-08 )
Steel parts e.g. for construction are cleaned from oils, dust, corrosion protec., rust, welding residue and metal fines by a biological cleaning process in a multiple immersion plant (integrated pickling, fluxing and galvanising); thereafter galvanising
 


  Material  |  Dirt  |  Equipment  |  Agents  |  Process  |  Costs  |  Evaluate  |  Comparison  

Material:

Steel parts for galvanising especially for the construction and outdoor sector, like gratings, pillars, railings, stairs, fences, etc. Charging is done by racks on which parts ( 1 – 50) are suspended.
METAL / NON METAL : steel
Shape : smooth surfaces, hollow spaces, a complicated geometry, metal folding
Utilisation of equipment (throughput,workload) in % : 100
Maximum possible throughput of parts per year : 1.445.000
Max. area which can be cleaned per year : No statement

Dirt:

drawing oil, mineral oil, grease, sand, cooling lubricants, mud/dust, soot, corrosion protection layer, emulgators, graphite, grinding agents, polishing agents, rust, salt, sweat/fingerprints
Previous process : Cutting, welding, drilling etc.
Dirt1: Oil, grease (45.00%), 100.00 kg / Year
Dirt2: Dust, soil (45.00%), 100.00 kg / Year
Dirt3: Other (10.00%), 20.00 kg / Year

Equipment:

Bio degreasing plant
Immersion plant consisting of 12 baths/chambers, bath 1 for alkaline degreasing, bath 2 for biological degreasing/rinsing and at the same time biological treatment for bath 1 (achieving an almost indefinite operation life while waste is minimal and waste water is none). The following baths/chambers are for pickling, rinsing, dripping, galvanising and cooling down. The galvanising bath is heated by gas burners, the excess heat is used via exhaust heat exchangers for heating up the other baths.

Process:

Immersion cleaning by using a dipping bath,Multitask equipment,decentral cleaning station (integrated in production line),Biological cleaning

1. degreasing, alk. agent 3%, 60┬░C, agitation air blowing; 2. bio degreasing 45┬░C, same agitation; 3. pre-pickling, dilu. HCl, RT; 4. pickling, dilu. HCl, RT; 5. rinse-pickling dilu. HCl, RT; 6. rinse, tap water, RT; 7. fluxing, RT; 8. drying; 9. galvan.

Duration of cleaning process for one part (min.) : 35.00
Duration of cleaning process for the charge (min.) : 35.00
Recycling : Step:1 Agent and dirt are transfered to bath 2 as tramp liquid, where micro orgisms break down the matter to CO2 and H2O
Step:2 Dirt and cleaner from bath 1 are taken over continuously as tramp liquid to bath 2, where the micro organisms decompose it to CO2 and H2O. Only a very minor amount of sludge remains (dead micro organisms and fines, ca. 100 kg/a). To determine the disposal path, analyses will be carried out (most likely the dried stuff will be incinerated together with used engine oil, but a disposal together with sludge from waste water treatment plants seems also to be possible
Step:3 No statement
Step:4 No statement
Step:5 No statement
Step:6 No statement
Step:7 No statement

Quality:

free of oil and grease

Free of oil and grease, quality of gavanising

Subsequent process:

hot dip galvanizing

Costs:

Total sum : 38.290,00 EURO / Year

Total costs per removed dirt: 174,05 EURO / kg


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