C.I.E. - Water treatment plants & Zero Liquid Discharge for the metal finishing lines

EXPERIENCE

WORLDWIDE LEADER FOR ZERO LIQUID DISCHARGE

QUALITY

KNOW-HOW

INNOVATION

R&D

KNOWLEDGE, COMPETENCE, EXPERTISE

•

38 YEARS OF EXPERIENCE

- Established in 1981 •

A YOUNG BUT HIGHLY QUALIFIED TEAM

- Average age: 38 years - Graduated Employees: 41% • GLOBALLY OPERATING AND GLOBAL THINKING • NO LICENSED TECHNOLOGIES: - CIE designs and develops Technologies and products for its own use • Worldwide leader in Z.L.D. (Zero Liquid Discharge) with more than 45 Z.L.D. fullfilled

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CIE Plants in the World

CIE has realized over 150 plants in the world, from the Automotive sector

to the Coil sector and in the Beverage Cans sector

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LEADER COMPANY IN WASTE WATER TREATMENT & Z.L.D. (Zero Liquid Discharge) PLANTS

AUTOMOTIVE

COIL COATING

ALUMINIUM EXTRUSIONS

ALUMINIUM CANS

APPLIANCES

ALUMINIUM WHEELS

Waste Water Plants specifically dedicated to METAL FINISHING LINES 4

ACTIVITIES FOR METAL FINISHNIG LINES

1)

REVERSE OSMOSIS UNITS

2)

DEIONIZING AND MIXED BED UNITS

3)

COALESCER DEOLING UNITS

4)

CHEMICAL DOSING AND CONTROLLING UNITS

5)

WASTE WATER PLANTS (PUR-ALL TECHNOLOGY)

6)

ZERO LIQUID DISCHARGE (Z.L.D.) PLANTS

7)

TELESERVICE AND TELEASSISTANCE 5

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RESEARCH & DEVELOPMENT

INTERNAL LABORATORY EQUIPPED WITH:  Inductive coupled plasma (I.C.P.)

 Spectrophotometers with variable and fixed wavelength  Nephelometer  Thermoreactor

 Conductivity meter  pH meter  Titration station

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LEADER IN CHEMICAL SPECIALTIES For Waste Water Treatment and ZLD plants

PUROSORBTM

Specific powder products and blend for adsorption on WWTP of:  COD < 150 ppm;  Oils;  Surfactants;  Organic substances.

PUR-ALLTM

Chemicals Specially formulated for WWTP to remove:  Sulphate < 50 ppm;  Fluoride < 4 ppm;

PUROFLOCTM

Anionic Flocculants for WWTP:  Medium and Heavy TSS concentration.

PUROSMOTM

Chemicals Specially formulated to manage:  Ultra Filtration Units;  Reverse Osmosis Units;  Evaporators Units 7

PUR-ALL Technology PUR-ALL is a special process developed by CIE to remove: • • • •

Sulphates Phosphates Fluorides Heavy Metals (Fe, Al, Zn)

PUR-ALL performances: • Resulting water good to dump in rivers or lakes • Resulting water good for irrigation • Resulting water good for reuse

PUR-ALL applications: • • • • • • •

Phosphating or Nanotechnologies Coat Pickling lines Aluminum Cr or Cr free lines Anodizing lines Galvanizing lines Electroplating Any acidic metal treatment

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Process dedicated to ACIDIC PRETREATMENT & ACIDIC SECTIONS of aluminium finishing lines

PUR-ALL ZERO ZERO REVOLUTIONARY TECHNOLOGY

100% of water recycling (ZLD)* • NO Ion Exchange • NO Reverse Osmosis • NO Evaporator • NO Liquor to dump



The unique technology to remove dramatically Sulphates, Fluorides and Aluminium



Sulphates, Fluorides and Aluminium are precipitated as unsoluble non toxic sludge to delivery outside

 Resulting waters are extremely pure: ʎ ≤ 200

Sulphates < 50

Fluorides < 2

Aluminium < 0,1 ppm

For irrigation use or to comply with any restricted limit, such as:

 PUR-ALL ZERO ZERO is developed by our R&D team for CIE

Sulphates Fluorides Aluminium



< 300 ppm < 4 ppm < 0.1 ppm

plants using chemical specialties studied by MST CHEMICALS Thanks to PUR-ALL ZERO ZERO it is possible:  In ANODIZING LINES: to reuse 50% of water, saving 50% of water consumption  In ALUMINIUM PAINTING LINES:

To dump according to European limits

•

To reuse 100% of water (ZLD)

•

To dump water respecting limits for rivers, lakes, and irrigation use 9

PUR-ALL TECHNOLOGY FOR PHOSPHATING LINES

PHOSPHATING OR NANOTECHNOLOGY

ALKALINE CLEANING

Usable for irrigation

Fresh water

RINSE 1

Neutralizing

RINSE 2

RINSE 1

ACTIVATION RINSE 2

PURAL Flocculation treatment

PURAL neutralization tank

Retaking tank

WATER QUALITY

Sludge Thickener

Filter Press

● CO3 ● PO4 ● Me ● Cond. ● PH

≤ 100 ppm < 10 ppm ≤ 0,5 ppm ≤ 400 µS 7

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WHY TO INSTALL Z.L.D.

 Extremely restrictive local limits  No available sewer  No available water  Expensive water cost

 97 – 98 % Washer Water Reuse  Environmentally friendly - Ethical Reasons  Risk of dispute with local authorities  Superior quality of reused water in comparison with Tap Water  Possibility to plan installations indipendently of local legislation 11

Z.L.D. Reusing Water Technology µs/cm

Alkaline Cleaning

Rinse 1

Rinse 2

Activation

Phosphating or Nanotechnology

D1

D2

D.I. Sludges

Neutralizing

Neutralized Water

•

Current technology

•

Consolidated experience

•

Superior Rinse Quality

ʎ ≤ 30 µs/cm

Regeneration

Evaporator

Distilled water

Liquor

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Z.L.D. Reusing Water Technology Case History

ZLD : for

Fe, EG, HDG Phosphating Lines Case history : SOFIND - Vicenza ( Italy )

Project data and parameters: - Customer - Subject to be painted - Cycle 1 (EG,HDG) - 80% - Cycle 2 (Aluminium)- 20% - Number of pieces per day - Surface (2 face) /hour - Production per day

: SOFIND (Vicenza-Italy) : Automotive parts : Zn Phosphating + CED + PC : Cr â&#x20AC;&#x201C; free + PC : 2000 p/h x 16 h = 32.000 p/day : 0,180 sqm/each x 2000 p/h = 360 sqm/hour : 16 hours (5760 sqm/day)

C.E.D. entrance of frames

EG, HDG (80%)

Back-flow Refilling

ALKALINE PRE_CLEANER

Back-flow Refilling

ALKALINE CLEANER

D.I. WATER RINSE

D.I. WATER RINSE

ACTIVATION

ZINC PHOSPHATING

D.I. WATER RINSE

ZINC PHOSPHATING

D.I . WATER RINSE

D.I. WATER RINSE

All. (20%) 13

PreCleaning/

level

Cleaning/

Rinse

level

level

D.I. Rinse

Zn Phospha ting

Activation

D.I. Rinse

Cr-Free All.Treat

D.I. Rinse

D.I. Rinse

D.I.: 9m3/h

Back-flow

Overflow

Z.L.D. Reusing Water Technology Case History

Sludges Filtration

Floating Oil Unit

Demin.

Water Retaking Tank

Retaking Tank

Retaking Tank

Dirty Demin.

Water Alcaline Exaust Tank

Acidic + spent regenerant Tank

CATIONIC

ANIONIC

CHARCOAL

DEMIRECYCLING DRD 9 CATIONIC ANIONIC

D.I. to CED

Acid +Alcaline Spent Regenerants

To recovery 150 l/h

To recovery 200 l/h

MIXED BATH

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Z.L.D. Reusing Water Technology Case History

3) PURIFIED WASTE RECOVERING

2) WASTE PURIFICATION SECTION ACIDIC wastes

By-product from Alkaline Rinsing Recovering

Distilled Water Recovering

Condensing unit

Vacuum pump

ALKALINE wastes

EVAPORATOR Acidification Neutralization Flocculation

Distilled Water

Settler Sludges Thichening Tank

CHARCOAL

Retaking Tank FILTER

Sludges Filter Press

Purified Water Storage

Spent Liquor Extraction pump

Sludge (40 % dry) :

Liquor waste for disposal :

Spent Liquor Tank

LIQUOR DISPOSAL

( NON TOXIC)

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PSD ® Process: Phosphating Sludges Detoxication INTRODUCTION: THE Zn PHOSPHATING, ALSO CALLED CRYSTALLINE PHOSPHATING, FINDS APPLICATIONS IN MANY AREAS: - GALVANIZED OR STEEL PRETREATMENT (AUTOMOTIVE, FRAMES , APPLIANCES, WHEELS , ) - METAL COLD FORMING (TUBE, WIRE, RODS, BOLTS, ) THE CRYSTALLINE PHOSPHATING BATHES ARE CHARACTERIZED BY A STRONG FORMATION OF SLUDGES WHICH ACCUMULATE IN THE TANK AND MUST BE CONTINUOUSLY REMOVED FROM THE BATH. ALL PHOSPHATING LINES ARE USUALLY EQUIPPED WITH A COLLECTOR (CONICAL THICKENER) OF THESE SLUDGES, OFTEN FOLLOWED BY FILTER PRESS TO REDUCE THE VOLUMES. THESE SLUDGES ARE ACIDIC AND CLASSIFIED AS ‘TOXIC WASTE’. AS SUCH, THEY REQUIRE A SPECIAL MANAGEMENT AND DISPOSAL COSTS ARE SIGNIFICATIVELY HIGHER THAN THOSE FOR SLUDGE CLASSIFIED AS ‘SPECIAL WASTE’ LIKE, FOR EXAMPLE, THOSE GENERATED BY USUAL PURIFICATION OF PHOSPHATING LINES. PSD PROCESS ALLOWS , WITH A SIMPLE AND LOW COST MANAGEMENT SYSTEM, TO TRANSFORM THIS ‘TOXIC WASTE ‘TO ‘SPECIAL WASTE’ EASIER AND LARGELY CHEAPER TO DISPOSE.

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PSD ® Process: Technology Description ● THE PROCESS IS APPLIED BY TAKING THE SLUDGE FROM THE EXISTING STORAGE TANK, BEFORE IT IS SENT TO THE FILTER PRESS (OR AT THE DIRECT DISPOSAL) ● IT IS SENT IN A SPECIAL REACTOR WHERE IT IS INERTED WITH A SPECIAL PRODUCT BASED ON Fe, Al AND Si MIXED OXIDES AND THAN NEUTRALIZED WITH LIME. ● THE PROCESS TAKES PLACE IN BATCHES OF SIZE PROPORTIONATE TO THE VOLUMES OF SLUDGE GENERATED DAILY OR WEEKLY. ● SO YOU GET THE PRECIPITATION OF PHOSPHATES IN THE FORM OF Ca, Al AND Fe PHOSPHATE WHILE METALS (Zn, Ni, Mn) ARE PRECIPITATED AS HYDROXIDES ● THE RESULT IS A HOMOGENEOUS AND INSOLUBLE SLUDGE, VOLUMETRICALLY EQUIVALENT TO THAT BEFORE TREATMENT BECAUSE IT IS MUCH DRYER AND EASILY FILTERABLE. ● THE FILTERED WATER IS ALREADY WITHIN THE DISCHARGE LIMITS. HOWEVER IT WOULD BE BETTER TO SEND IT TO THE EXISTIG PURIFICATION PLANT FOR A FINAL RECTIFICATION ● THE SLUDGES HAVE THE SAME COMPOSITION OF SLUDGES COMING FROM WASTE WATER PURIFICATION PLANTS AND SO CAN BE BLENDED WITH THEM AND FILTERED TOGETHER. ● THE ENCLOSED LAYOUT SHOWS HOW TO INSERT A PSD UNIT INTO AN EXISTING DESLUDGING LINE 17

PSD ® Process: Phosphating Sludges Detoxication

BATH STORAGE

PHOSPHATING BATH

EXISTING PHOSPHATING DESLUDGING LINE ‘TOXIC’ WASTE

SLUDGES

Filter Press

PSD ® UNIT PUR-ALL BATH STORAGE

Ca(OH)2 PH Meter

PHOSPHATING BATH

SLUDGES

‘SPECIAL’ WASTE Filter Press

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NEXT GOALS: PUR-ALL ZERO ZERO Z.L.D. FOR PHOSPHATING LINES

PHOSPHATING OR NANOTECHNOLOGY

RINSE 1

WATER QUALITY • CO3 < 10 ppm • PO4 ≤ 5 ppm • Me ≤ 0,1 ppm • PH 7 • Cond. < 300 µS

To reuse

Evaporator

ALKALINE CLEANING

High Pressure Reverse Osmosis

RINSE 1 Neutralizing

RINSE 2

RINSE 2 ACTIVATION

pH control

Flocculation

PURAL neutralization tank

Filter Press

Retaking tank

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Z.L.D. CASE HISTORY: ELVAL (Coil)

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Z.L.D. CASE HISTORY: METRA (Al Extrusion)

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Z.L.D. CASE HISTORY: ZANUSSI (Appliances)

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Z.L.D. CASE HISTORY: SCATTOLINI (Automotive)

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Z.L.D. CASE HISTORY: BEVCAN (Al beverage cans)

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CIE COMPAGNIA ITALIANA ECOLOGIA SRL Via I° Maggio, 20/22 – San Zenone al Lambro (MI) – Italy Tel: +39.02.9810470 – Fax: +39.02.98175079 www.cieeng.com – info@cieeng.com