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The cleaner product assessment is done in completing 17 steps under the different phase which
are mentioned above. This assessment is done as detailed overview of implementation of cleaner
product for the hot dip galvanizing process of LTL Galvanizers (pvt) Ltd.
LTL galvanizers is the leading galvanizing company in Sri Lanka is equipped with German
machinery technology and has a production capacity of 150 Metric Tons per day. The LTL Hot
Dip Galvanizers has total production capacity of the plant is 6.2 metric tons per hour and operates for
24 hours per day. This production from the steel bath for large materials and from the centrifugal
bath for small materials. Steel bath has production capacity of 5 metric tons per hour and 7 m long
items can be single dipped. Maximum 13.5 m long items can be double dipped. The total process
consist of several main steps including,
The planning and organization is the initial step of the cleaner product assessment process. Main
task of this step is the allocating a team for this purpose.
Designate CP Team
The manager should appoint a cleaner production team to carry out the cleaner production
assessment. When doing so, the manager should keep in mind that the members should have the
necessary authority, skills and time to carry out the cleaner production assessment. The project
team should consist of representatives from ƒ
Management levelƒ
Accounting department
storage departmentƒ
Production department
Technical department
Maintenance department
Besides, it can be very useful to include external experts in the cleaner production team in order
to have a third-eye approach. The objectives of allocating this team are reducing energy and raw
material consumption, Identification of new techniques that can be applied for existing process,
reducing environmental impact, converting waste stream into reusable streams and improve
overall production efficiency.
Initially, the cleaner production team should make an overview of the entire company by listing
all unit operations and their main inputs and outputs. A detailed and elaborate flow diagram or
activity diagram can be guided for this. This is necessary to get a proper overview and
understanding of the manufacturing process. When analyzing process steps, the tasks that should
completed are identification process steps, select wasteful process step, developing process flow
diagram, conducting material and energy balance and allocating cost for waste streams.
Surface conditions of the material are further checked since it is necessary factor for the hot dip
galvanizing and the metal and check whether the metal is free of rust. If oil or grease present on
the metal, they are removed using a degreaser. If paint or excessive rust present on the metal,
they are removed by sandblasting process.
Pickling
Before pickling oil, grease, and other organic contaminates are removed from the surface of steel
and previously a degreasing bath has been used with sodium hydroxide solution. But now they
are removed manually. Pickling is removal of rust of the steel using a strong acid. In this plant
hydrochloric acid is used in this process. Pickling time depends on the concentration of the HCL
acid. Pickling reaction,
Rinsing
Pickled items then rinsed with water to prevent acid residues to be carried over to the next bath.
There are 2 rinsing baths in the plant. Average time for rinsing is 19 minutes. The pH value of
the rinsing water id recorded daily and when it exceeds 1, water is discharged.
Fluxing
Rinsed items are then immersed in a flux solution and flux is zinc ammonium chloride with
wetting agents. The flux solution removes the oxide film which forms on the highly reactive steel
surface after acid cleaning, and prevents further oxidation before galvanizing. Earlier the
temperature of the flux solution has been kept at 600C. For the initial flux preparation Triple Salt
having 54% Ammonium Chloride and 46% Zinc Chloride is used and this is prepared so that the
relative density is about 1.2. Flux renewing is done when the iron content exceeds 3g/L.
Oven Drying
After fluxing items are dried in oven which temperature is 1200C. Moisture is removed from the
steel surface using clean hot air blowing. Average drying time is 42 minutes for a frame.
Bath contains molten zinc at 4470C. Zinc blocks having purity of 99.95% is used for this. The
heat for the zinc kettle is supplied from a LP gas furnace. The steel is immersed at a fairly rapid
speed and Once the coating has formed, withdrawal is at a slower speed to ensure uniform
drainage and a smooth finish. Average dipping time is 6 minutes.
Quenching
Hot dip galvanized items then quenched by immersing in water. With this process the zinc
coating solidifies, as this ensure easy handling. It also arrests the alloying reaction in the case of
reactive steels, which continues well below the melting temperature of zinc. Quenched water is
recycled by air cooling.
Cleaning
Grinding edges is done to get good finishing. Zinc rich paints are sprayed at some places.
Damaged materials are kept at allocated area and will be retuned for galvanizing.
The pickled acid contains high amount of iron and chlorides. Rinsing water and quenching water
are also released and little considerable amount of zinc and little amount of arsenic. These all
waste are stored in a tank. The method used to remove iron is neutralizing with hydrated lime.
The neutralized solution is then to filterpress operation.
Based on the flow diagram and through site-inspection the team should identify wasteful unit
operations. Along with existing data on consumption of resources and materials, this work is the
base for deciding the focus of the cleaner production assessment. Preliminary priority setting
among process steps
In the hot dip galvanizing process the following steps are identified as wasteful steps considering
the economic, environmental and technical factors.
Pickling
High amount of HCL is removed from this process and sent to the effluent treatment process.
Initial concentration of pickling HCl solution is 18% by weight. This solution is prepared by
diluting commercial HCl with 36% w/w. with steel pickling, acid concentration reduces and iron
concentration increases. When iron concentration increases to 7% by weight acid top up or
renew is done.
About 0.05 lead is added to the kettle and lead layer on the bottom of the kettle will prevent
sticking of dross to the iron kettle-bottom and makes it possible to remove the dross from the
bottom of the kettle. Dross means some compound formed with zinc and iron. Dross formation is
a high amount of zinc loss and considerable amount of lead is added to remove the dross. Lead is
a heavy metal and dross is waste cost. Extra zinc amount of the galvanized surface means
another waste cost and keeping the required
Zinc bath is heated up to 4470C and maintaining the suitable bath temperature is more important
because less temperature means high dross formation. In the dipping process high amount of
smoke forms and this contains ZnO particles.
Quenching
In quenching process, some port of water is removed and other part is recycled. Removing
quench water contains lead and zinc.
Cleaning
In cleaning process, solidified galvanized are generated as waste and mostly zinc dust forms and
pollutions happens.
The cost assignment gives a very good picture of how much money is lost with each waste
stream. At the same time such figures creates commitment; indicates the potential of savings;
and shows how high investments may be to avoid or minimize the waste streams.
Generating cleaner product opportunities includes the giving solutions to overcome the
mentioned difficulties. The possible countermeasures are input material change, product
modification, technology change, production technology change, onsite reuse, good
housekeeping and production of useful byproduct.
Pickled acid Acid top up is HCL waste Instead of acid top-up, only
method and acid renewing is acid renew method can be
less HCL consumed process done.
in the pickling process.
Zinc bath Heating Commonly 4440C is used in Keeping the bath temperature
industrially but 4470C is most at 4470C
economical when consider
the dross formation.
Galvanized product Standard galvanized Hoisting speed can be done at
thickness is enough for the high speed value.
protection of metals. Extra
thickness means cost for the
extra zinc
Filtered effluent solution This solution cannot be In plant treatment process can
release to the environment be developed.
even after the treatment
process since this contains
high amount of chlorides and
suspended solids.
Additionally these methods, high amount of sand dispersion and sand dust can be reduced by using a
developed method such as fully covered area for the sand blasting process. High amount of fume
generation when steel galvanizing process can be minimized by using powerful fume blowers instead
of currently used blowers.
Selection of CP Opportunities
For the more complicated cleaner production options, it is necessary to carry out a detailed
feasibility study focusing on technical, economic and environmental aspects. The following
expected benefits are part of the technical feasibility study
Some of the aspects that should be covered during the technical feasibility include,
Product quality ƒ
Production capacity ƒ
Space requirementsƒ
Close-down-time during installation
Compatibility with the existing equipmentƒ
Operation and maintenance requirementsƒ
Occupational health and safety aspects
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