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Pilot Projects
Galvanisation and electroplating
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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)
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| 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:
- Expecting direct annual benefit of US $ 200,000
- Significant reduction in hard zinc and zinc ash production
(cost reduction due to reduction in the consumption
of zinc)
- Environmental benefits:
- Recovery of flux waste and stop discharging to sewer
system
- Closing the loop of solid waste (Zinc ash recovery
and hard Zinc recycling)
- Better workplace conditions
- Organisational and management benefits:
- Better performance and higher efficiency of galvanization
process
- Improve the user's productivity by concentrating labour
force in the core business of the company
- Enhancement of supply chain management and other environmental
management systems
- Skilled and well trained operational staff at the
user's plant in fluxing process
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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.
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