october 2011 Vol. 76 No. 1
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The new Precious Metals Save nickel, zinc and copper from going down the drain.
FABTECH 2011: HUGE preview beginning on p. 30
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C O N TE N T S volume 76 no. 1
pfonline.com
October 2011
features 16 Winning the Pollution Control Challenge
16
Electrowinning reduces waste, recovers valuable metals.
22 Flying High with BSAA
Environmentally friendly alternative to chromic acid anodize.
26 Drag Finishing of Delicate Parts
For complex parts with high surface finish specs, production deburring and surface prep can be done using the drag finishing process.
70 Ovens Showcase
Industrial oven technology has come a long way.
76 Tech Notes
A “smarter� technology for electric immersion heaters.
22
clinics 80 82 84 86 88
Painting Clinic Plating Clinic Powder Coating Clinic Parts Cleaning Clinic Mass Finishing Clinic
26
Columns 6 8 14 90 92 96
The Finishing Touch News NASF Report Financial Finish Never Finished End of the Line
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Standard ecoat giving you too many surprises? Let BASF remove the costly surprise of no coats and partial coats with its industryleading superior throw power CathoGuard® electrocoat!
The “white elephant” is the bane of the electrocoating industry, symbolizing no coats and partial coats on metal parts. BASF specializes in superior throw power electrocoats that minimize white elephant parts and film build distribution across a rack of parts; and maximize time and money savings for BASF customers. Learn how CathoGuard superior throw power electrocoats are leveraged as a competitive advantage by BASF customers by calling 1-800-347-BASF today! www.basf.com/ecoat
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www.pfonline.com
Ed i to ri a l
www.pfonline.com
Combining High Tech…
Publisher Donald G. Kline dkline2@gardnerweb.com Associate Publisher Todd Luciano tluciano@pfonline.com Editor Tim Pennington tim.pennington@pfonline.com Sr. Managing Editor Kate Hand khand@pfonline.com Editorial Assistant El McKenzie emckenzie@gardnerweb.com Contributing Editor Jim Lindsay, NASF Technical Editor Art Director Aimee M. Reilly areilly@pfonline.com
D i stri c t Offi ces
Midwest/ Todd Luciano Mountain/Pacific tluciano@pfonline.com Northeast/Canada Scott Walker Southeast swalker@pfonline.com Italy Nicola Orlando orlando@com3orlando.it India Sudhanva Jategaonkar sudhanva@infomedia18.in Europe Edward J. Kania ekania@btopenworld.com Asia Donald G. Kline dkline2@gardnerweb.com
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Richard G. Kline, CBC Steven R. Kline, CBC Melissa Kline Skavlem Ernest C. Brubaker Dianne Hight Allison Kline Miller Jessica Franks Ross Jacobs
Also publisher of: Products Finishing Directory • Automotive Design & Production • IMTS Directory of Exhibits • Modern Machine Shop • NPE Official Show Directory • Moldmaking Technology • Plastics Technology • Production Machining • PT Handbook • Composites Technology • High-Performance Composites PRODUCTS FINISHING (ISSN 0032-9940/82) is sent on a complimentary basis to selected production, engineering and management personnel in North American plants where electroplating, painting, and other finishing operations are performed. All other subscriptions per year are $89 in the United States, $99 in Canada and Mexico and $200 elsewhere. Published monthly and copyright ©2011 by Gardner Publications Inc., 6915 Valley Ave., Cincinnati, Ohio 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, Ohio and at additional mailing offices. If undeliverable, send form 3579. CANADA POST: Return all undeliverables to: Bleuchip International, P.O. Box 25542, London, ON N6C 6B2. Canadian publication mail agreement 40612608. POSTMASTER: Send address changes to Products Finishing, 6915 Valley Ave., Cincinnati, OH 452443029. Permissions: Libraries and other organizations registered with the Copyright Clearance Center (CCC, 27 Congress St., Salem, MA 01970) may photocopy any article herein for the flat fee of $2.00 per copy of the article. Payment should be sent directly to the CCC. Copying done for other personal or internal reference use without express permission of Gardner Publications Inc., is prohibited. Address requests for special permissions or bulk orders to the magazine. ISSN 0032-9940/82 $2.00.
With High Touch Asterion is a leading manufacturer of speciality chemical finishing products for all aspects of the metal finishing industry. State of the art technology is the basis of our chemistry. We offer a full line of easy to use, dependable and affordable electroplating and electroless processes as well as proprietary plating chemistries the way you want them when you want them. Call us today.
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pfonline.com
Living A Finisher’s Dream Wife of deceased powder coater volunteers in husband’s memory.
F
ess up: how many of you have spent an entire day working the zinc plating line or the powder coating booth and wondered what life after finishing would be all about? Maybe visiting the fishing hole, taking up a hobby, or just watching the grandchildren grow. Larry Tanner of Michigan had that same dream, although it was a bit unusual. Larry—a lifetime powder coater who owned Blu-Surf in Parma and Surfinco in Albion—and his wife, Faith, wanted to do what they truly loved, and that was to travel and attend PGA Tour events. Golf was a passion for Larry after he retired, and when he met Faith a few years later and they married in 2002, she fell in love with the game, too. So they decided they not only would travel the country and watch great golf, but they would volunteer at each of the 37 PGA Tour stops in the new motor home they bought. The plan was great, except that life got in the way. Or should we say, death. They were working a few events in 2008 just to get the hang of it when Larry began feeling a little different. News from the doctor was devastating: Larry had a frontal lobe brain tumor nearly the size of a softball. That week, the doctors performed an operation that left him in a coma. He died six weeks later. What a punch in the gut. Run your finishing shop for decades, pay salaries and taxes, retire and meet the woman of your dreams, plan an adventure and then this happens. Faith was devastated, but
beside her, she told herself. It was his dream and she would live it for him. Friends and family thought she was nuts, but Faith wanted to do this for Larry. She cashed in retirement savings, sold personal items and put off her real estate career to volunteer at the events; she handed out water, directed spectators, worked press tents and collected garbage, all the while thinking of Larry. “If I was prudent and waited five or 10 years to retire, then the tribute to him would lose its significance,” she says. “I do feel alone on this journey without him, and I literally have to stop to take deep breaths and mentally focus instead on the years of happiness we did share. Otherwise I would break down and sob frantically. I can’t help it … I loved him deeply.” By mid-August she had been to 31 events, having been home to Michigan only once this summer. She’s put close to 30,000 miles on the Honda Civic hybrid she drives to events. She tries to get by on just $15 a day, often eating in the volunteer area and staying with local families who hear about her and Larry’s dream. CBS Sports even aired a segment on national TV telling their story. “I keep in mind that these interviews help me keep beyond my wildest dreams a promise I made to my loving husband on his death bed,” she says. “And that is that he would never be forgotten.” While driving from an event in West Virginia, Faith realized that it was the anniversary of Larry’s death. When the thought struck her, she pulled off the interstate and
Faith was devastated, but she knew how much Larry was looking forward to the 37 cities they were going to visit to volunteer at the PGA Tour events. Still heartbroken, she sat down and planned the trip in Larry’s memory. she knew how much Larry was looking forward to the 37 cities they were going to visit to volunteer at the PGA Tour events. Still heartbroken, she sat down and planned the trip in Larry’s memory. He would be there
drove down a winding road, stopping at a small stream. She got out and sat on the hood of her car and began to cry, realizing that it was not just sadness over losing Larry, but also anger. “I was mad at him for dying,” says Faith. “He was supposed to be there with me. I was supposed to have him with me to share this beauty. That was our dream.” But the next day there she was at a Tour event, handing a microphone to golf star Rory McIlroy as a volunteer at a press conference and thinking “Larry would be digging this right now.” See photos of Faith's journey at PFOnline.com n
TIM PENNINGTON, Editor, tim.pennington@pfonline.com 6
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COLORFUL THINKING
Letting consumers introduce a little color into their lives, and a little of themselves into their color choices. PPG touches the lives of consumers in ways seen and unseen. As a color pioneer, we use innovative pigments and special effect colorants to engineer coatings that really speak to consumers and move products. Our vast product array and application expertise mean we can add color value to a variety of surfaces—including eye-popping consumer electronics, lustrous lawn furniture, vibrant washers and dryers, brilliant barbecue grills, even tool boxes. Beyond color, we work with our customers to help them achieve the desired look, feel, and image for their product’s surface. We also help make products tougher and greener—with everything from solvent-free powder coatings that emit virtually no VOCs to packaging coatings and inks that decorate metal cans. From consumer products to building materials, automotive to aerospace, marine and industrial coatings, we’re bringing innovation to the surface. Visit ppg.com to learn more.
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PAINTS - COATINGS - OPTICAL PRODUCTS - SILICAS - CHEMICALS - GLASS - FIBER GLASS “Bringing innovation to the surface.” is a trademark of PPG Industries Ohio, Inc.
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pfonline.com/news
EPA Issues New TSCA Chemical Reporting Rules Industry groups call them “burdensome.”
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he U.S. Environmental Protection Agency in August issued its final rules on chemical inventories, increasing the type and amount of information it collects on commercial chemicals from chemical manufacturers in a way the EPA says will allow them to better identify and manage potential health and the environment risks. Promulgated under the Toxic Substances Control Act (TSCA), the final rule was previously known as the “Inventory Update Rule” and requires that companies submit information electronically to EPA rather than on paper, and more significantly limits confidentiality claims by companies. Companies will be required to start following the new reporting requirements in the next data submission period, which will occur Feb.1 to June 30, 2012. “Collecting this critical information on widely used chemicals will enable EPA to more effectively identify and address potential chemical risks,” says Steve Owens, assistant administrator for EPA’s Office of Chemical Safety and Pollution Prevention. “The new electronic reporting requirement and limits on confidentiality claims also will bring EPA’s data collection effort into the 21st Century.”
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The renamed “Chemical Data Reporting Rule” requires more frequent reporting of critical information on chemicals, and requires the submission of new and updated information relating to potential chemical exposures, current production volume, manufacturing site-related data, and processing and use-related data for a larger number of chemicals. The EPA is requiring companies to submit the information through the Internet, using EPA’s electronic reporting tool. The agency says the on-line reporting will make it more accessible to the public. The American Coating Association was active in commenting on the adverse impacts of the EPA proposed rule, and says the final rule reflects a number of considerations recommended by industry regulatory specialists. “These recommendations offer some assistance in facilitating the required reporting, including retention of some prior exemptions and some clarifying definitional changes, but overall the final rule is still burdensome, and will be required on a new four year schedule,” an ACA spokesman says. More information about the CDR Rule and reporting program is available at epa.gov/iur.
OCTOBER 2011
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Durr Builds Green Paint Shop in China
Durr is building an environmentally friendly paint shop for BMW Brilliance Automotive Ltd. in Shenyang, China. According to the company, the shop will feature RoDip M rotational dip coating in the PT/ED area, reducing energy and chemical consumption. The Integrated Paint Process will eliminate the need for primer and a drying phase. Spray booths will be equipped with the company’s EcoDryScrubber technology, a dry separation method that requires no water or chemicals. The saturated binding material, which is a hazardous waste in conventional processes, can be reused without further treatment. Heat wheels will be used to recover heat from supply and exhaust air, and a waste heat boiler will recover waste heat from the dryers. The exhaust air stream from the clear coat booth will be purified before leaving the facility. The use of membrane technology in the pretreatment, electro dipping and waste water system, reduces both water consumption and the amount of waste water, the company says. For more information from Durr Systems Inc., phone 866387-7178 or visit durr.com.
Ecoat 2012 Conference Goes Back to Orlando
The Electrocoat Association and Products Finishing will sponsor Ecoat 2012 April 11-12, 2012, at the Rosen Centre Hotel in Orlando, Fla. The electrocoating conference will give attendees the opportunity to learn from suppliers and end-users; stay current with trends in the economy and new methods of managing electrocoat systems; learn about new technology and applications; and meet and network with industry colleagues. In addition to keynote speakers and concurrent programming choices, the conference will feature interactive workshops addressing topics such as advances in pretreatment, understanding the challenges of system optimization to maximize profit and minimize cost, and enhancing the performance of e-coat finishes. A roundtable discussion will offer the opportunity to “ask the experts” about the industry, technology and industry advancements. More information is available at electrocoat.org. pfonline.com 9
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News
NDSU Researchers Develop Coatings from Crops The resins are based on sucrose and vegetable oils, and can be varied to perform in many applications and industries, according to Dean Webster, professor in the NDSU Department of Coatings and Polymeric Materials. Webster’s research group includes NDSU graduate students Xiao Pan and T. J. Nelson, undergraduate student Adlina Paramarta and Partha Sengupta, former postdoctoral researcher at NDSU. The resins developed by the NDSU research group can be made from from sugarbeets, plus oils from soybeans, flax and sunflowers. When cured, the patent-pending resins show: • Significantly improved properties over current biobased materials and processes Dr. Dean Webster, North Dakota State University, Fargo, (center) and graduate • Mechanical properties comparable students T.J. Nelson and Xiao Pan are among a research group that developed to petrochemical-based materials a family of resins from renewable raw materials. Photo credit: Dan Koeck, NDSU • Dramatically increased renewable material content “These NDSU-developed technologies achieve what few Several agricultural crops could play a significant role in biobased materials have before,” said Webster. “They have biobased resins and coatings recently developed by researchvastly improved mechanical properties, reduced hazardous ers at North Dakota State University. Scientists at NDSU have chemical content and are made from readily available materials developed biobased resins that may prove to be a “game and common processes. The technologies have the potential changer” in coatings and resin technology. for significantly impacting biobased material markets.” The The NDSU researchers have developed a family of resins from biorenewable chemicals market is projected to reach $5 billion renewable raw materials, creating resins that eliminate hazardous by 2015. components such as formaldehyde and bisphenol-A.
Brazilian Coating Economy Starting to Slow
Brazil’s coating industry is suffering along with many global sectors, according to Dilson Ferreira, executive president of ABRAFATI Brazilian Coatings Manufacturers Association. While 2011 continues to be a good year for coaters in South America and specifically Brazil, the growth rate is falling tremendously, Ferreira said at the Aug. 25 ABRAFATI Forum of the Coatings Industry in São Paulo. “In the first half of this year, sales of residential coatings increased by only 0.5 percent compared to the same period in 2010. We should see a slight increase this second semester, that will lead to a 1 percent increase for the year”, says Ferreira. Brazilian coaters saw as much as 10 percent growth from 2009 to 2010, but that rate is slowing. “Due to the present uncertainties and the delicate international scenario, consumers are adopting a more conservative attitude by delaying purchases of coatings for remodels and self-building. Similarly, retailers avoid keeping stock and replace products more slowly”, Ferreira says. “However, 10
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we believe business will pick up at a stronger pace next year, when we expect a 4 percent increase in sales.” He says the overall growth of the coatings industry in Brazil this year should be 1.3 percent, reaching 1.377 billion liters, whereas a 4 percent expansion of sales is expected in 2012.
OCTOBER 2011
9/22/2011 4:06:51 PM
Elcometer Creates Online Resource
Elcometer has established Elcometer University, an online repository for interactive tutorials, field videos and FAQs for its products. It can be accessed at elcometeruniversity.com.
Serfilco Featured on TV Series
Serfilco was selected to be part of the television series “World’s Greatest!” The family-owned company develops and manufactures pumps and filters that handle chemical solutions. View the segment on the company’s website at serfilco.com.
PPG to Supply New Caterpillar Plant in Arkansas
PPG Industries industrial coatings business will be the sole heavy-duty equipment coatings supplier for a new Caterpillar Inc. motor grader assembly plant in North Little Rock, Ark. In addition to serving as a single-source coatings supplier, PPG is providing on-site technical and product approval support, and in-plant training of paint-line operators through its Knowledge College service in coating application technologies. John Valasco, PPG global account manager, said he believes this project will reward PPG’s renewed commitment to heavy-duty equipment coatings. “We’re not there just to sell a gallon of paint or a box of powder,” he says. “We’re working with customers such as Caterpillar to demonstrate our capabilities as a total finishing solutions provider.” For more information, visit ppg.com.
AkzoNobel Powder Coatings and BioCote Team Up for Interpon AM
AkzoNobel Powder Coatings has teamed up with BioCote, an antimicrobial specialist in Europe, to create Interpon AM, a powder coating that incorporates antimicrobial technology to offer protection in hygiene sensitive environments. “The possibilities that antimicrobial coatings can deliver are exciting and building hygiene protection into a coating provides a further line of defense in many diverse environments,” says Mark Reekie, market segment manager, Europe West AkzoNobel Powder Coatings. The company says the antimicrobial technology used in Interpon AM is shown to reduce levels of bacteria and fungi by up to 99.9% UK and after months of testing the new Interpon AM products will be available throughout Europe. For more information, visit interpon.com.
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Depending on your specific application, Coral will analyze your finishing process and recommend the best Coral Eco-Treat® solution for superior corrosion resistance and excellent finishing performance.
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News ON THE MOVE
Independent Plating has combined the operations of Standard Plating Inc. (West Springfield, Mass.) with its Worcester, Mass., facility. Both companies provide metal finishing services, including nickel, chrome, zinc and brass plating, as well as powder coat, electropolish and black oxide finishes. Standard Plating’s president, Michael Nahorniak, will become general manager of Independent Plating. Enthone has appointed Richard Lynch industry manager for its Automotive Functional Systems-Americas. He is responsible for marketing the company’s wear- and corrosionresistant coatings for automotive-related items, including fasteners, brake calipers, suspension systems, and drive train and engine components. Lynch holds a bachelor’s degree in business administration from Bryant University and an MBA from the University of Phoenix. BYK-Gardner has added nine staff members, including Rae Roby, regional sales manager for Michigan and Northern Ohio; Sam Cauchi, sales manager for all of Canada; and Sheila White, customer care center manager for North America. Also added were customer care center team members Mary Llewellyn, responsible for Canada; Scott Richeson, mid-Atlantic region of the U.S.; Sandrine Letendre, West Coast; and Patrick Weaver, Southwest. Corey Cohen is a new applications specialist and Josh Egbert is a service administrator. Coventya has been added to Chrysler’s Approved Global Chemical Supplier List detailed in PS-8810, which specifies the requirements for decorative electroplated nickel chromium finishes on plastic parts. Global Finishing Solutions LLC announced a $10 million dollar investment in its facilities at the Osseo, Wisc. corporate offices. This expansion is based upon supporting the company’s on-going growth and increasing demand for its products. The investment will be utilized for expansion of manufacturing facilities, offices, and the addition of new equipment and machinery within the manufacturing areas.
Travis Williams to its group of technical sales and service representatives. Scott comes to MacDermid with a strong sales background and will be responsible for accounts in the Chicago area. Williams brings more than 14 years of plating experience, including process control, new process installations and troubleshooting. He will be responsible for service in the Southeast region. BASF Automotive Refinish has named Vitor Margaronis marketing director for BASF Coatings, North America. In his new role, he is responsible for directing the marketing activities of the BASF Automotive Refinish, OEM, Industrial and Commercial Transport Systems businesses. Service Filtration Corp. has undergone recent organizational changes. Silvio Pioli, the current general manager/ COO of Baron-Blakeslee SFC Inc. (Williamstown, WV), will replace Jack Berg as CEO of Service Filtration Corp. Berg will remain as chairman of the board. As CEO, Pioli will be responsible for the entire SFC enterprise, including Serfilco Ltd., R.P. Adams Inc., Polymar Inc., Service Filtration of Canada Ltd., Serfilco International Ltd., Pacer Pump Inc., Baron-Blakeslee SFC Inc., and the Filterspun Division and will report to the Chairman. In addition, Michael Berg, current general manager of Serfilco, will be promoted to president, Service Filtration Corp. He will be responsible for the general management of all SFC companies and will report to the CEO. James Berg will assume the responsibilities of CFO of Service Filtration Corp. In this capacity, he will be responsible for all financial and accounting services to the corporation and will report to Pioli as well. Dorken Corp. recently celebrated the 10th anniversary of its presence in North America. The Grass Lake, Mich., company is an operating unit of Dorken MKS-Systeme, based in Herdecke, Germany. The company also has appointed J&M Plating (Rockford, Ill.) as a certified licensee for its coating products. J&M Plating provides engineered solutions to the fastener and small stamping marketplaces. n
MacDermid Inc., a global specialty chemical company, has expanded its facility in Santa Ana, Calif., to include a state-ofthe-art research and development laboratory capable of the following analytical procedures: high-performance liquid chromatography (HPLC), atomic absorption spectroscopy (AAS), failure analysis, STEP testing and routine troubleshooting. In other news from the company, MacDermid has recently promoted Scott Strahan to the position of technical sales representative for the Texas region. Strahan has more than 20 years experience in the plating industry and will be responsible for accounts in Texas, Louisiana and Oklahoma. In addition, the company has hired Ryan Scott and 12
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9/22/2011 4:07:03 PM
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R E PO R T
NASF Joins North American Metals Council The move is expected to advance science and policy issues.
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he output of federal regulations has reached historic levels, and metals and metal compounds are getting significant regulatory attention. To strengthen NASF’s response and effectiveness on behalf of its members, the NASF has joined the North American Metals Council, a group of metals producers and users representing a wide range of interests and industries across the value chain. The group was formed to provide a stronger, collective voice for the metals industry on significant science and policy-based issues that affect metals NASF will collaborate more closely with the group’s 23 members, which include: the American Zinc Association, the Nickel Institute, the Copper Development Association, the Aluminum Association, the International Molybdenum Associa-
There are more challenges than ever for the metals industry, and promoting the best science possible to inform regulatory decisions is an absolute necessity. Technical Papers Development of Ni-Based High Wear Resistance Composite Coatings Final Report: AESF Research Project #R-116 Branko N. Popov, Project Director and Prabhu Ganesan, Center for Electrochemical Engineering, Department of Chemical Engineering, University of South Carolina, Columbia, SC Hard chromium replacements have been actively sought for decades. In the Final Report for the AESF Foundation’s first Research Project since the formation of the NASF, the authors present the results of their extensive research into novel plating processes nickel-phosphorus, nickel-boron, and Ni-P-X and Ni-Zn-X composite coatings (where X=silica), and their properties. short.pfonline.com/NASFOct1
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tion, the Cadmium Association and others. “There are more challenges than ever for the metals industry, and promoting the best science possible to inform regulatory decisions is an absolute necessity,” says Tony Revier, president of NASF. “This is an important step to ensure we coordinate effectively with the many sectors we touch in the surface finishing industry.” For more information about NASF science and policy initiatives, contact jhannapel@thepolicygroup.com.
Edited by Jim Lindsay, NASF Technical Editor E-coating Simulation Robrecht Belis, Elsyca, Wijgmaal, Belgium Computer simulation of coating processes has made great strides in recent years. Proper design of plating racks, thickness and property distribution of plating systems and the performance of plated coatings on parts can be predicted with uncanny accuracy. Here, the author extends the application spectrum to include the e-coating of automobile bodies. short.pfonline.com/NASFOct2
A Pulse/Pulse Reverse Electrolytic Approach to Electropolishing and Through-Mask Electroetching E.J. Taylor, H. McCrabb, H. Garich, T. Hall and M. Inman, Faraday Technology, Inc., Clayton, Ohio Research at the authors’ laboratories has focused on pulse/ pulse reverse electrolysis on cathodic processes, such as hard chromium plating from non-hexavalent chemistries. This papers describes studies into pulse/pulse reverse electrolysis as applied to electrochemical metal removal processes, such as electropolishing and electroetching. The results show significant enhancement potential for these types of processes. short.pfonline.com/NASFOct3
OCTOBER 2011
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become a member at nasf.org NASF Membership & Dues Changes— Preparing for January 2012
North American manufacturing has seen unprecedented change in the last decade. The new landscape demands a more effective association and membership model. The NASF has taken important steps under new executive leadership to revitalize the association and strengthen its role and value proposition. As the NASF rebuilds core programs and value for members with a significantly reduced budget versus previous years, longdelayed membership structure and dues changes are in order. The NASF Board deferred changes anticipated for 2011, in order to review the impacts of a new membership and dues structure. Now, a revitalized NASF Membership Committee has developed a new NASF Membership website, nasfmembership. com, and NASF has been communicating with all affiliates and branches on pending NASF membership and dues changes, effective January 2012. Supplier dues will remain at a tiered level based on company size. Job and captive operations will move to a new tiered dues structure based on company size, and professional membership will have new eligibility requirements. For additional details and information, review the new NASF membership website or contact Phil Assante with questions at 703-887-7235 or passante@thepolicygroup.com.
New Legislation, Reports Released on Federal Chemicals Reform
Senator Frank R. Lautenberg (D-NJ) has introduced the Safe Chemicals Act of 2011 (S. 847), which is intended to modernize Toxic Substances Control Act (TSCA). The measure would require chemical companies to demonstrate the safety of industrial chemicals and the U.S. Environmental Protection Agency to evaluate safety based on the best available science. The Congressional Research Service (CRS) has released two reports on TSCA. The report summarizing the TSCA law and its major requirements is available at short.pfonline.com/TSCA, and the report comparing the recently introduced reform legislation with existing requirements is available at short.pfonline.com/TSCA2.
OSHA Changes Whistleblower Protection Program In a continuing effort to improve the Whistleblower Protection Program, the U.S. Department of Labor’s Occupational Safety and Health Administration is implementing additional measures to strengthen the program and is releasing an internal report detailing a recent top-to-bottom review of the program. OSHA enforces the whistleblower provisions of 21 statutes protecting employees who report violations of various workplace safety. Significant changes to the Whistleblower Protection Program include internal restructuring, a new training conference, new policies, and an improved internal system for ensuring that complaints are handled on a timely basis.
Upcoming NASF Events Oct. 5 - 7
Palmetto Conference
Myrtle Beach, SC The Palmetto Branch of the NASF/AESF hosts this conference. Guest speakers from government and industry will address a variety of topics, including an NASF update. Oceanfront rooms and more are available for this family fall getaway. For information, contact Kevin Helton at crossair@bellsouth.net.
Oct. 11
Cyanide Safety
Webinar While non-cyanide alternates to many plating solutions exist and in some cases are popular, this toxic ion is still present in many plating facilities conducting brass, bronze, silver, copper and cadmium plating. This one-hour presentation will cover basic cyanide safety issues and then provide time for audience questions. Contact Luke Zorich at lzorich@nasf.org to register.
Oct. 18
Cyanide Emergency Response
Webinar This session will focus on the proper procedures and protocol to follow in the event of cyanide emergencies, including: what to do in case of a spill; evacuation procedures; chemical protection measures; ventilation and clean-up; cyanide gas release; and medical treatment and first aid. Contact Luke Zorich at lzorich@nasf.org to register.
Nov. 15, 22, 29 & Dec. 6
Corrosion & Salt Spray
Online Course This four, two-hour session course is ideal for anyone running salt spray exposure tests and will cover preparation of samples, evaluation of exposed specimens and operation of the exposure cabinet. Contact Luke Zorich at lzorich@nasf.org to register.
Dec. 9
Troubleshooting Test Panels
Webinar This workshop is intended for individuals running ASTM B-117 salt spray exposure tests or anyone who wants to become more familiar with complications involving preparation of samples, evaluation of exposed specimens, and operation of the exposure cabinet. Contact Luke Zorich at lzorich@nasf.org to register.
March 11 - 15—Save the Date!
NASF 2012 Management Conference
San Juan, Puerto Rico The 2012 NASF Management Conference promises to be exceptional for its informative program, atmosphere and reasonable cost. Contact Cheryl Clark at cclark@nasf.org for more information.
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Winning the Pollution Control Challenge Electrowinning reduces waste, recovers valuable metals. By Tim Pennington, Editor 16
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andy Epner spits out numbers that make platers sit up and take notice: • Recover 20 kg of nickel per day • Or 100 kg of silver • Or 40 kg of gold Epner, owner of Precious Metals Processing Consultants in Palisades Park, NJ, is a pioneer in the electrowinning process that removes metallic ions from concentrated rinse water and spent process solutions. For several decades he had only been pushing his systems to those who deal mainly in precious metals such as gold and silver to capture the elements from tanks before they are disposed. But rising costs on nearly all raw materials had made Epner and other electrowinning system sellers like him go after a broader market. “Even though precious metals is in our name, we are looking to make recycling heavy metals easier as the price of all commodities are going up,” says Epner, who has been in the business for more than 30 years and whose main products are the GoldBug and the Ionnet systems. His systems use a metallic matrix of large surface areas, which is formed into a cylindrical cathode (in the case of the Gold Bug), or flat sheets (for the Ionnet). Epner says that combined with the turbulence created by a dedicated pumping system, it exposes the cathode to a continuously renewed concentration of fresh ions. He says this means fast plate-out to very low concentrations. “You’re taking the metals out in your own shop,” he says. “The water stays in your plant, therefore no drums of solution requiring hazmat documentation, no transportation costs for heavy drums, no insurance. It’s easy, inexpensive processing with
Above, a before and after look at PMPC’s “Gold Bug” system, which uses a metallic matrix of surface area in a cylindrical cathode. Below, combined with the turbulence created by a dedicated pumping system, it exposes the cathode to a continuously renewed concentration of fresh ions.
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EPA and Platers form Electrowinning Partnership The U.S. Environmental Protection Agency and several plating groups have formed partnerships over the years on electrowinning to help reduce pollution from finishing shops. The ‘Merit Partnership’ is a joint venture between EPA Region 9 (covering Arizona, California, Hawaii and Nevada), state and local regulatory agencies, community representatives, and private sector industries including metal finishing, represented by the Metal Finishing Association of Southern California It was created to promote pollution prevention—known as P2—and to identify P2 technology needs, and
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accelerate P2 technology transfer within various industries in southern California, including research and studies on electrowinning. A case study involves All Metals Processing Co., a small job shop in Burbank, Calif., that performs cadmium, bronze, and zinc electroplating and black oxide coating for aerospace and other industrial customers. All Metals employs 15 workers, and its facility has about 8,000 sq ft of space for plating operations. All Metals set a goal to reduce water use and eliminate wastewater discharge to the sewer, motivated by high city sewer fees and pressure
from the municipal wastewater treatment plant to decrease the metal concentrations in treated wastewater. In cooperation with the Merit Partnership, All Metals agreed to pursue its goal in two phases, focusing efforts on the cadmium electroplating line because it was the most frequently used process line; dragout from this line contributed the largest quantities of metals to the wastewater, and All Metals had exceeded its cadmium wastewater discharge limits on several occasions. Phase 1 involved evaluating overall process efficiency and control. The purpose was to reduce dragout and optimize rinse water use to the maximum extent feasible before selecting and purchasing recycling or recovery technologies. Phase 1 modifications resulted in a 50 percent dragout and rinse water reduction, a 60 percent wastewater treatment chemical reduction, improved rinsing quality, and more efficient work flow; the Phase 1 payback period was 1.7 years. By improving overall process efficiency first, All Metals was able to more cost-effectively apply a metal recovery technology and move toward eliminating cadmium wastewater discharges to the POTW. For Phase 2, electrowinning was determined to be the most feasible technology for All Metals to reduce or eliminate wastewater discharges from the cadmium electroplating operation. The electrowinning unit is operated at the All Metals facility 24 hours a day, 7 days a week. The cathodes are replaced every three months on average. Based on the start and finish weights of the cathodes, about 2 kilograms (4.4 lbs) of cadmium was recovered on the six cathodes after two months of operation. Spent cathodes are picked up by a scrap metal dealer for recycling. Before the electrowinning unit was installed, rinse water flowed
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through the counterflow rinse tank at a rate of 0.5 gal/min. Since the electrowinning unit was installed, all the rinse tanks have been operated in a stagnant mode, and the temperature of the rinse water in Rinse 2 has been maintained at about 115°F, resulting in the evaporation of about 15 gallons of rinse water per day. Consequently, 15 gallons of clean water per day is added to Rinse 3 in order to compensate for the water transferred into Rinse 2 to make up for evaporative losses. Based on comparison of water use on the cadmium electroplating line before and after installation of the electrowinning unit, rinse water use has been reduced by 94 percent and wastewater is no longer generated from the rinses. Because not all dissolved solids are removed by the electrowinning unit, conductivity is monitored in Rinses 1 and 3. Rinse 3 is drained to dispose of the dissolved solids buildup and replenished with clean rinse water every six weeks on average. The drained rinse water is evaporated onsite by All Metals. In addition, cyanide concentrations are periodically measured in Rinse 1; these concentrations have been significantly reduced by the electrowinning unit. After installation of the electrowinning unit, no increase in the number of reject parts occurred, and no adverse impacts on production were observed. Motivated by the success of the electrowinning unit for the cadmium operation, All Metals has installed another electrowinning unit in a copper electroplating stagnant rinse. For more information on EPA Region 9 pollution prevention programs, visit epa.gov/region9/ waste/p2/projects/metal.html
Electrowinning, which is also called electroextraction, is the electrodeposition of metals from their ores that have been put in solution or liquefied. Electrorefining uses a similar process to remove impurities from a metal. full accountability. You’re back in control.” But gold and silver remain the chief target of companies like Precious Metals Processing Consultants. Other major electrowinning specialists in the U.S. include Remco Engineering in Ventura, Calif., which has set up several electrowinning operations: • Joslyn Manufacturing, Chicago: zinc recovery, 800-2000 ppm input 20 gpm • Velie Printed Circuits, Costa Mesa, Calif: copper/lead 50 gpm • Astron Printed Circuits, China: copper/lead 180 gpm • Pulsatora, Columbia: lead, nickel and copper from recycling opera tion 25 gpm • Gorilla Circuits, San Jose, Calif: copper/lead 20 gpm • Pioneer Circuits, Santa Ana, Calif: copper/lead 25 gpm
Remco has a suggestion for who should be electrowinning: Rule o involves lean electrolyte containing 10 to 20 g/L sodium cyanide at pH >10.5—adjusted with sodium hydroxide—being heated to 90°C and pumped up flow at two bed volumes per hour through a stationary bed of activated carbon loaded with gold. “The gold that was adsorbed on the carbon as a sodium-gold cyanide complex will be desorbed from the carbon by a reversal of the adsorption mechanism,” says Webster. “The solution exiting the top of the column—which we know as rich electrolyte—will flow by gravity into the electrowinning cell and the gold will be recovered by plating onto steel wool cathodes.” An example of SX Kinetics success is a gold mining company in Indonesia that features 15 cathode boxes containing steel wool and 16 stainless pfonline.com 19
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A current is passed from an inert anode through a liquid solution containing the metal so that the metal is extracted.
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After installing the GoldBug system, Jack Seidler from Interplex Industries extracted almost 40 ounces of gold in the first month of use, essentially tripling his previous results. Metal is extracted as it is deposited in an electroplating process onto the cathode.
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