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Pilot Projects
Galvanisation and electroplating

Fluxing process in Zinc hot dipping galvanisation

Egypt:

Project title Pre-treatment in Zinc hot dipping galvanisation
Partners
  • ChL service provider: Zinc Misr S.A.E
  • ChL service recipient: El-Sewedy Co
  • Implementing agency: UNIDO-Egypt National Cleaner Production Center (ENCPC)
Industrial process Fluxing processes with a mixture of Ammonium Chloride and Zinc Chloride
Chemicals used Flux (Ammonium Chloride, Zinc Chloride)
Service provided under ChL Under the ChL it was suggested that Zinc Misr S.A.E will provide the ChL services related to the fluxing process (using Ammonium Chloride and Zinc Chloride) to El-Sewedy Co. The proposed basis for payment is tons of galvanised articles (final product) per month.
Benefits
  • Economical benefits:
    1. Expecting direct annual benefit of US $ 200,000
    2. Significant reduction in hard zinc and zinc ash production (cost reduction due to reduction in the consumption of zinc)

  • Environmental benefits:
    1. Recovery of flux waste and stop discharging to sewer system
    2. Closing the loop of solid waste (Zinc ash recovery and hard Zinc recycling)
    3. Better workplace conditions

  • Organisational and management benefits:
    1. Better performance and higher efficiency of galvanization process
    2. Improve the user's productivity by concentrating labour force in the core business of the company
    3. Enhancement of supply chain management and other environmental management systems
    4. Skilled and well trained operational staff at the user's plant in fluxing process

Nickel Use for Electroplating

Mexico: Mardi Inc - CRODEL (Cromadora Delgado) The main objective of the alliance between Mardi Inc (supplier) and CRODEL (user) is the reduction of chemicals, in particular the nickel consumption. Due to the ChL model the process of electroplating was modified. Prior to the ChL model 100% of nickel (e.g. 750 kg/year) was used whereas the consumption of nickel after process modification is 70%; the remaining 30% consist of iron (Fe). As a result the output increased (670,8 → 746 kg/year) and the amount of waste decreased (79,2 → 4 kg/year).

The existing process was optimised: the nickel consumption was reduced by 25% (constant quality) and nickel in waste was reduced by 95%. Due to the reduced nickel consumption of 25% the annual savings amount to $ 2,700 USD. With further process optimisation a potential nickel reduction of about 30% might be possible.