Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft LCA

Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft • LCA • for Optimization • of electroplating SME’s Stand: 3/15/2018 Folie: 1 Seattle, 24. 9. 2003

Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Outline of the presentation 1. Methodology of ecological plant optimization - (EPO) 2. Participants of the project 3. Results 4. Benefit of the projects Stand: 3/15/2018 Folie: 2 Seattle, 24. 9. 2003

Methodology of ecological plant optimization - (EPO) Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Stand: 3/15/2018 Folie: 3 Seattle, 24. 9. 2003

Methodology of ecological plant optimization - (EPO) System boundary production plants for auxiliary material and operating supply item production Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Substrate production peripheral system (Educt) System view of the EPO peripheral system Core system Production plant System boundary Core system Separation of Substrate- Optional extension processing (product) Recycling and disposal- plants core system and peripheral system Stand: 3/15/2018 Folie: 4 Seattle, 24. 9. 2003

Methodology of ecological plant optimization - (EPO) Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Stand: 3/15/2018 Folie: 5 Seattle, 24. 9. 2003

Methodology of ecological plant optimization - (EPO) Changing elementary flows Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Overall system (core & peripheral system) Core systems Difference of Mass balances Stand: 3/15/2018 Folie: 6 Seattle, 24. 9. 2003

Methodology of ecological plant optimization - (EPO) Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Impact categories • • Resources Air acidification Depletion of ozone layer Eutrophication Aquatic ecotoxicity Human toxicity Green house effect Photochemical oxidants Stand: 3/15/2018 Folie: 7 Seattle, 24. 9. 2003

Methodology of ecological plant optimization - (EPO) Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Assessment method based on German UBA method Discussion of results in the society needs to have an assessment method accepted by the society Stand: 3/15/2018 Folie: 8 Seattle, 24. 9. 2003

Participants of the project Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Closed loop material flows for surface treatment processes About 40 companies involved Feuerverzinkung Hannover a ns Feuerverzinkung ha uft nik L Genthin ch Te nn Siemens chtma e. g. Na h hmp ic dr ie Fr rohe KME Rös ler G FSB Liebherr Conversion of existing electroplating plants using optimized material flow techniques Stand: 3/15/2018 Folie: 9 Seattle, 24. 9. 2003

analysed plants Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft ·PCB etching-inner layer ·Matt nickle plating ·Sodiumpersulfate • repairing- resp. Component electroplating in aircraft ind. process • electroplating for decorative surfaces ·Softend water process • electroplated deplating es ·Demetalization • acid polishing of glass ·Demetalization with sulfate • producing of printed circuit boards sludge separation ·Epal-pickle • anodisation of aluminia ·External Recycling of Al • electroplating of plastics etching waste • hot dip galvanizing ·Dyeing of aluminia ·Accelerate • vibratory finishing ·Cadmium-recycling ·Hot dip galvanzing ·Electroless nickel plating ·Chromatedetoxification ·Alodine ·Waste water traetment ·Chromium sulphuric ·Anodisation of aluminia acid incl. etching nanofiltration, ·Cyanidevaporization detoxification and recycling ·pickling ·alkaline rinsing ·E 0 -pickle; E 6 -pickle ·etching (pickling) ·Electrolytical degreasing etching with Na. PSRegeneration ·Neutralisation/ precipitation ·quality rinsing ·Nitric acid etching of copper ·Hydrochloric acid etching ·Acid rinsing ·Fluxing ·Acid polishing ·Glinting conventional and ·Sulphuric acid etching with of vaporation and recycling copper ·Glinting nickle plating ·Sealing and nickle ·Vibratory finishing sealing ·Hard chrome plating ·rinsing ·Ion exchanger circuit ·Rinsing water cascade installation ·Thermal conzentration ·Circuit rinsing ·drying ·PCB-slightly etching with ·Reverse osmose exchange, process heating ·Chromium plating and regeneration Stand: 3/15/2018 Folie: ·Copper plating 10 Seattle, 24. 9. 2003 ·Nickle plating

Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Results All optimised production plants have decreasing environmental impacts and Cost savings but Not every target and actual state are comparable Stand: 3/15/2018 Folie: 11 Seattle, 24. 9. 2003

Benefit of the project Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft • Pool of Excel-Models (about 900) of electroplating processes • Central Excel-Workbook supporting the modelling of core systems Stand: 3/15/2018 Folie: 12 Seattle, 24. 9. 2003

Benefit of the project Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Knowledge database with the SME qualitative results of the research projects „Optimizing of electroplating SME’s“ providing information for all technologies variants processes analysed, modeled and optimized processes and states of processes process-chains structure of the database for one SME Stand: 3/15/2018 Folie: 13 Seattle, 24. 9. 2003

Summary Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft • The development of the EPO-Method was successful • The plants were successfully optimised (environmentally and economical) • Several Excel-Models are ready for use • For new users there is a Database for the first steps of an EPO Stand: 3/15/2018 Folie: 14 Seattle, 24. 9. 2003

Contact Forschungszentrum Karlsruhe in der Helmholtz-Gemeinschaft Forschungszentrum Karlsruhe Gmb. H Institute for technical chemistry Department of Technology-Induced Material flow (ITC-ZTS) Dr. -Ing. Robert Ackermann P. O. box 3640 D-76021 Karlsruhe Phone: +49 7247 82 2712 Fax: +49 7247 82 6715 e-mail: Robert. Ackermann@itc-zts. fzk. de Stand: 3/15/2018 Folie: 15 Seattle, 24. 9. 2003