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Case Studies |
Full Title: AESF/EPA Conference on Environmental Control for the Surface Finishing Industry
URL: /02/01109.pdf
Length: 3 pages
Date: 1991
Full Work Author: Abbott, James; Stevens, Bruce W.
Abstract: Abbott Plating Company uses ion exchange to prevent build-up of copper, iron nickel, and zinc in a chrome plating bath. The company also uses ion exchange to remove undesired metals from wastewater.
Full Title: Atmospheric Evaporative Recovery Applied to a Nickel Plating Operation
URL: /02/01055.pdf
Length: 34 pages
Date: 1988
Full Work Author: Wells, Brian E.
Abstract: A process feasibility study was successfully performed on an Atmospheric Evaporator System for the Department of Natural Resources. The study was made to determine the feasibility of a closed-loop rinse system on an electroplating line. Atmospheric evaporation is a process that converts liquid into a vapor and is discharged to the atmosphere. Results indicate that an atmospheric evaporator system successfully reduced head-space in the electroplating tanks sufficient to provide use of the rinse water to replace the evaporated water. Reuse of the rinse water effectively contained constituents of the electroplating bath that are normally discharged to the pretreatment system and subsequently disposed. These favorable results indicate that an adequately designed low-cost atmospheric evaporator system could be utilized to close the loop. The closed loop would eliminate any pretreatment of rinse water and disposal of sludge. Also recovery of the valuable constituents is achieved. Iii
Section Title: Ilco Unican Corporation
Full Title: Case Studies - A compilation of successful waste reduction projects implemented by NC businesses
URL: /01/0056538.pdf
Length: 1 page
Date: August 1995
Full Work Author: NC Office of Waste Reduction
Abstract: This key blank manufacturer saved enough by installing atmospheric evaporators on its nickel plating for a 7 month payback. This zero discharge system eliminates the need to add nickel chloride or nickel sulfate.
Full Title: Case Study: North Carolina Baptist Hospital
URL: /07/06163.pdf
Length: 2 pages
Full Work Author: NC DPPEA
Abstract: North Carolina Baptist Hospital encourages its employees to share ideas on waste reduction through its Viewpoints incentive program and Project Waste Watch. Projects resulting from this program include a battery exchange program, use of returnable packaging from vendors, washable coveralls, reuse of surgical trays, cafeteria discounts when employees use washable mugs, and reduction and return of packaging materials, recycling, and more. Waste reduction and annual savings are included.
Full Title: Caterpillar, Pennsylvania Recovers Hard Chrome
URL: /02/01280.pdf
Length: 2 pages
Date: 1992
Section Author: Jeanmenne, Bob; Perrone, Stephen
Abstract: Case study of a chrome recovery process at Catepillar, York PA. Includes savings info.
Full Title: Chemical and Water Use Reduction at Poly-Plating Inc.
URL: /01/00164.pdf
Length: 3 pages
Date: 1991
Full Work Author: MA Office of Technical Assistance
Abstract: Motivated by increases in sewer surcharges and water rates, this 16-employee, nickel plating shop began a six-year effort to reduce waste. By reclaiming and reusing acids, nickel, and plating solutions, disposal costs were cut by 91%. Water and sewer fees were reduced by 98%.
Full Title: Electroplating Case Study - Queensland Electoplating Pty. Ltd.
URL: /04/03624.htm
Abstract: Queensland Electroplating Pty. Ltd. (QE) is a small electroplating factory specializing in the tin plating of bus bars for electric transformers.
Full Title: Environmental Research Brief - Pollution Prevention Assessment for a Manufacturer of Combustion Engine Piston Rings
URL: /03/02819.pdf
Length: 7 pages
Date: August 1995
Full Work Author: Jendrucko; Richard J.; Thomas, Todd M.; Looby, Gwen P.
Abstract: The Waste Minimization Assessment Center team at the University of Tennessee performed an assessment at a plant that manufactures piston rings. Steel and iron rings are machined, chrome-plated or coated, machined again, cleaned, and shipped to customers. The assessment team's report, detailing findings and recommendations, indicated that wastewater savings would be substantial. By using plastic sleeves instead of masking paint to prevent chrome plating of piston ring inner perimeters, this manufacturer saved $214,000 per year. Improved rinsing to remove chromic acid also generated large savings.
Full Title: Fact Sheet: Rinsewater Reduction for a Metal Finishing Shop
URL: /11/10316.htm
Full Work Author: Virginia Waste Minimization Program
Abstract: A metal finishing job shop reduced rinsewater volume and ensured compliance with discharge regulations by installing a staged rinse system, segregating waste streams, and modifying processing solutions.
Full Title: Improved Wastewater Management for Electroplating - Premier Plating Company
URL: /04/03620.htm
Abstract: A custom-designed waste water management system is saving Premier Plating Company $14,400 a year on the cost of treatment and disposal of waste produced by the electroplating process.
Section Title: Eliminating Waste Discharge in a Reel-to-Reel Electroplating Shop
Full Title: Innovative Clean Technologies Case Studies
URL: /13/12366.pdf
Length: 7 pages
Date: August 1993
Full Work Author: US EPA
Section Author: Marino, Kenneth
Abstract: Orbel Corporation, a reel-to-reel electroplating facility, implemented several source reduction practices to reduce water usage.
Full Title: Modifying Tank Layouts to Improve Process Efficiency
URL: /02/01304.pdf
Length: 4 pages
Date: October 1996
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Section Author: Tetra Tech EM, Inc.
Abstract: This case study of a small cadmium, bronze, and zinc electroplating and black oxide coating shop illustrates how to improve tank layouts for recovery and reuse of plating solutions and rinses. A focus in this case was reducing waste from the cadmium cyanide and chromate solution processes.
Full Title: Options - Metal Finishing Services, Inc. - Our Goal - Near Zero Discharge
URL: /18/17232.pdf
Length: 2 pages
Full Work Author: Guerrein, Ray
Section Title: Never Dump Cleaner
Full Title: Products Finishing
URL: /02/01366.htm
Length: 3 pages
Date: June 1997
Section Author: Graves, Bev
Abstract: Article is about Chem-Plate's efforts to reduce or eliminate the practice of dumping their cleaner used to prep parts for zinc plating. The solution was to use a microdisplacement cleaner with an oil/water separation tank. They have not needed to change their cleaner in two years.
Full Title: Progressive Powder Coating: New Infrared Curing Oven at Metal Finishing Plant Increases Production by 50%
URL: /32/31228.pdf
Length: 4 pages
Date: May 2003
Full Work Author: BestPractices Office of Industrial Technologies U.S. Department of Energy
Abstract: The IR oven allowed the plant to increase its conveyor line speed and increase production by 50%.
Full Title: Rejuvenation and Recovery of Electroplating Acids Using the WADR Technology
URL: /12/11335.pdf
Length: 5 pages
Full Work Author: Jones. Evan O. et al.
Abstract: Acid baths at the U.S. Air Force/Oklahoma City Air Logistic Center will be rejuvenated by the use of a new technology called Waste Acid Detoxification and Reclamation (WADR), which is a distillation process that recovers concentrated metals for disposal or recycling. The WADR system is expected to reduce waste from acid baths by 80% to 90%, as compared with current treatment operations, while reclaiming spent acid for reuse. The technology is expected to meet the needs of various industries generating spent acids with increasing disposal and operating costs.
Fact Sheets |
URL: /23/22275.pdf
Date: 1985
Section Author: Dietz, J.D. and C.M. Cherniak
Abstract: A research program was completed to identify new and emerging waste management technologies in the metal finishing industry.
Full Title: Extending Electroless Nickel Bath Life Using Electrodialysis
URL: /02/01300.pdf
Length: 4 pages
Date: July 1998
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Abstract: This fact sheet provides background material for understanding electroless nickel plating chemistry and how electrodialysis regenerates spent electroless nickel baths by selectively removing orthophosphite and other contaminants. Maintenance and operation of electrodialysis equipment is discussed. The financial attractiveness is illustrated in a case study of a five-line shop plating bright and electroless nickel, zinc, copper, tin, and conversion coatings.
Full Title: Fact Sheet - Cartridge In-Tank Filtration Systems
URL: /01/00238.pdf
Length: 4 pages
Date: July 1997
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: This fact sheet discusses the advantages and disadvantages of cartridge in-tank filtration and is part of a series called the Metal Finishing Series which is produced by NC DPPEA. Some of the topics included in this fact sheet are: solution agitation, filter types and filter mechanisms, material selection, continuous carbon, metals and oil removal, tips for selecting in-tank cartridge filter systems, and filter life (dirt-holding capacity).
Full Title: Finding an Alternative to Solvent Degreasing - Ultrasonic Aqueous Cleaning
URL: /02/01302.pdf
Length: 4 pages
Date: December 1997
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Abstract: This fact sheet discusses the basic elements of ultrasonic aqueous cleaning, including equipment and operating costs. These are illustrated via a case study of a mid-sized plating copper nickel, and chrome onto die-cast zinc. This shop's replacement of its vapor degreaser with an ultrasonic aqueous cleaning had a payback of 1.7 years.
Full Title: Metal Finishing Series - Bag In-Tank Filtration Systems
URL: /01/00223.pdf
Length: 2 pages
Date: March 1997
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: This fact sheet highligts the advantages of in-tank BAG filters for electroplating. Includes cost estimation table for filter installation and media.
Full Title: Metal Finishing Series - Disc In-Tank Filtration Systems
URL: /01/00224.pdf
Length: 2 pages
Date: March 1997
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: This fact sheet highligts the advantages of DISC in-tank filters for electroplating. Includes cost estimation table for filter installation and media.
Full Title: Metal Finishing Series - Identifying and Reducing Contamination in Metal Cleaning, Plating, and Rinsing Baths
URL: /01/00225.pdf
Length: 2 pages
Date: April 1997
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: A fact sheet about in-tank filtration for electroplaters. Discusses sources of contaminants.
Full Title: Metal Finishing Series - In-Tank Filtration Systems
URL: /01/00226.pdf
Length: 3 pages
Date: March 1997
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: This fact sheet highligts the advantages of bath filtration for electroplating. Goes into material compatibility.
Full Title: Metal Recovery and Wastewater Reduction Using Electrowinning
URL: /02/01140.pdf
Length: 4 pages
Date: November 1997
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Section Author: Tetra Tech EM, Inc.
Abstract: Electrowinning is a process for the recovery of metals from electroplating rinse waters. In the example in this fact sheet electrowinning reduced water use on a cadmium line by 94%.
Full Title: Reducing Dragout With Spray Rinses
URL: /01/00749.pdf
Length: 4 pages
Date: January 1997
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Abstract: This fact sheet describes how improved spray nozzle designs can reduce dragout and water usage.
Full Title: Reducing Rinse Water Use With Conductivity Control Systems
URL: /02/01142.pdf
Length: 4 pages
Date: December 1996
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Section Author: Tetra Tech EM, Inc.
Abstract: Conductivity control systems can reduce the amount of rinse water used by nearly half, resulting in cost-savings and waste reduction.
Section Title: Merit Partnership and Tetra Tech EM, Inc.
Full Title: Reverse Osmosis Applications for Metal Finishing Operations
URL: /02/01303.pdf
Length: 5 pages
Date: February 1999
Full Work Author: Merit Partnership
Abstract: This fact sheet explains reverse osmosis for metal finishing applications.
Full Title: Toxics Release Inventory (TRI) Reporting of Nitrates for Metal Finishers - The Quick and Dirty Guide
URL: /14/13900.pdf
Length: 2 pages
Date: 12/00
Full Work Author: Woosley, Julie
Abstract: This fact sheet is a quick guide to help metal finishers determine if they fall into a category that must report releases of nitrates from their system. Includes information for small businesses and a list of contact names and numbers.
Full Title: Waste Reduction Fact Sheet - Water Conservation for Electroplaters: Counter-Current Rinsing
URL: /01/00051.htm
Length: 3 pages
Date: 1985
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: Back to basics: Fact sheet on counter current rinsing for electroplaters.
Full Title: Waste Reduction Fact Sheet - Water Conservation for Electroplaters: Rinse Tank Design
URL: /01/00050.htm
Length: 3 pages
Date: 1985
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: Back to basics: Fact sheet on rinse tank design for electroplaters.
Full Title: Waste Reduction Fact Sheet - Water Conservation for Electroplaters: Rinse Water Reuse
URL: /01/00046.pdf
Length: 3 pages
Date: 1985
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: A fact sheet on rinse water reuse for electroplaters. Includes capital and operating costs and expected pay back period.
Articles and Reports |
Full Title: AMPTIAC Newsletter - Volume 3, No. 3 - Fall 1999
URL: /05/04748.pdf
Length: 16 pages
Date: Fall 1999
Section Author: Sartwell, Bruce D.
Abstract: Functional hard chrome plating is a technique that has been in commercial production for over 50 years and which is a critical process associated with manufacturing and maintenance operations on aircraft, vehicles, and ships.
Full Title: Analysis of Pollution Prevention Investments Using Total Cost Assessment: A Case Study in the Metal Finishing Industry
URL: /03/02976.pdf
Length: 28 pages
Date: July 1996
Full Work Author: Causing, Myla; Jensen, Stephen; Haynes, Shawn; Marquardt, Wil
Abstract: This project demonstrated the feasibility of using Total Cost Assessment (TCA) as an effective decision-making tool for evaluating the costs and benefits of pollution prevention investments in the metal finishing industry.
Full Title: Extending Metal Finishing Bath Life
URL: /02/01301.pdf
Length: 4 pages
Date: December 1997
Full Work Author: Merit Partnership and Tetra Tech EM, Inc.
Section Author: .
Abstract: A guide to extending bath life, based on a case study of a mid-sized shop anodizing and chromate-conversion-coating aluminum. By maintaining good process bath control, adding rinses, using deionized water, and filtering continuously this shop decreased its spent bath solution by 74%.
Full Title: Guide to Cleaner Technologies - Alternative Metal Finishes
URL: /02/01052.pdf
Length: 65 pages
Date: September 1994
Full Work Author: US EPA
Abstract: This report documents available and emerging technologies in the metal finishing industry. General descriptions are given on each technology, ranging from the cost of installation to the required skill level of the worker. These technologies include: BlackholeTechnology, Ion Vapor Deposition, non-cyanide copper plating, non-cyanide metal stripping, zinc or zinc nickel alloy electroplating, physical vapor deposition, nickel-tungsten-silicon carbide plating, chromium-free aluminum surface treatments, etc.
Full Title: New Regulation Controlling Air Emissions from Chromium Electroplating and Anodizing Tanks
URL: /02/01257.pdf
Length: 5 pages
Date: March 1995
Full Work Author: US EPA
Section Title: Recovery/Recycling Methods for Platers
Full Title: Products Finishing
URL: /02/01363.htm
Length: 10 pages
Date: November 1998
Section Author: Schulte, Stephen
Abstract: This article is a good starting point for understanding the primary P2 technologies available to electroplaters. Topics include evaporators, ion exchange, diffusion dialysis, electrowinning, electrodialysis and reverse osmosis.
Full Title: Recovery of Metals from Metal Finishing Waste Streams Using Aluminum Displacement
URL: /03/02953.pdf
Length: 5 pages
Section Author: Meyers, Steven J.
Abstract: Refer to title.
Manuals |
Full Title: Best Practices for Metal Finishing Line Operators - Workshop Training at Gold Seal Plating
URL: /02/01144.pdf
Length: 45 pages
Date: March 1998
Full Work Author: Tetra Tech EM, Inc.
Abstract: This training presentation addresses process efficiency, bath monitoring, controlling dragout and optimizing rinsing operations. Includes several examples that illustrate cost and savings estimates for these type of improvements.
Full Title: Environmental Management Systems: A Guide for Metal Finishers
URL: /03/02853.pdf
Length: 103 pages
Date: December 1998
Full Work Author: Branson, Christine A.; Davis, S. Petie
Abstract: A comprehensive guide to implementing an EMS developed specifically for metal finishers. Useful for shops of all sizes. The discussion of the costs and benefits of an EMS in the introduction is particularly useful.
Full Title: Pollution Prevention and Control Technology for Plating Operations
Length: 382 pages
Date: 1994
Full Work Author: Cushnie, George C.
Abstract: The "blue book" is the most authoritative text on P2 for metal finishers. The text provides practical suggestions for waste reduction, chemical recovery, bath maintenance, and treatment. Data for specific commercial systems are presented along with ratings provided by over 300 plating shops. The book contains more than 150 tables, schematics, drawings, and graphs to help understand technologies and present cost information. This book is available on-line to paying members of the National Metal Finishing Resource Center at http://nmfrc.org.
Full Title: Pollution Prevention for the Metal Finishing Industry - A Manual for Pollution Prevention Technical Assistance Providers
URL: /03/02454.htm
Length: 194 pages
Date: February 1997
Full Work Author: Northeast Waste Management Officials' Association; Goldberg, Terri; Shearman, Jennifer et al.
Abstract: This manual provides information on the following topics: an overview of the metal finishing industry, a regulatory overview, planning and pollution prevention (P2) programs at a metal finishing facility, common P2 practices, pre-finishing operations, P2 in the plating process, P2 in rinsing, alternative methods of metal deposition, and design of a modern metal finishing facility.
Section Title: Environmental Training Workshop for Metal Finishers
Full Title: Pollution Prevention Technologies for Metal Finishing Operations
URL: /02/01146.pdf
Length: 85 pages
Date: July 1998
Full Work Author: Tetra Tech EM, Inc.
Abstract: This training presentation addresses process control, process bath recycling technologies (electrodialysis, diffusion dialysis, electrowinning) and rinse water recycling (reverse osmosis, ion exchange).
Full Title: Source Reduction Potential in the Electroplating Industry
URL: /23/22401.pdf
Length: 14 pages
Date: March 1985
Full Work Author: Jordan, Gregory R.
Abstract: The goal of this manual is to describe Source Reduction Techniques available to the Electroplating Industries. Source Reduction (SR) is defined as on-site activities that reduce the production of hazardous waste at the point of generation. Source Reduction includes good housekeeping practices, process modification, product substitution, waste segregation, reuse and recycling.
Section Title: Metal Finishing
Full Title: Water Efficiency Manual
URL: /01/0069209.pdf
Length: 7 pages
Date: August 1998
Full Work Author: NC Division of Pollution Prevention and Environmental Assistance
Abstract: Chapter 5 of North Carolina's Division of Pollution Prevention and Environmental Assistance Water Efficiency Manual, which addresses the metal finishing industry's water usage.
Sector Notebook |
URL: /01/00380.pdf
Length: 149 pages
Date: Sept. 1995
Full Work Author: US EPA
Abstract: This manual provides a general overview of environmental issues associated with the metal fabrication industry. This includes industries that form metal shapes, and those that prepare and finish or coat metal products. Includes information on the industry and its economic status, waste streams and management, pollution prevention, regulations and enforcement, TRI data, process updates, and contacts and resource materials.
Web sites |
URL: http://www.finishing.com
Abstract: This website has information on Anodizing, plating, powder coating, and the surface finishing arts. Technical references, FAQs, technical associations, links, commerce, and caller participation opportunities.
Full Title: National Metal Finishing Resource Center
URL: http://www.nmfrc.org/bluebook/forewor2.htm
Abstract: The National Metal Finishing Resource Center's homepage, a comprehensive and up-to-date resource. Includes : access to the Benchmarking Metal Finishing report, information on the new Metal Products and Machinery (MP&M) Effluent Guidelines, environmental news, a calendar, vendor information, regulatory information, membership opportunities, and more.
Full Title: National Metal Finishing Strategic Goals Program
URL: http://www.strategicgoals.org/
Abstract: The National Metal Finishers Strategic Goals Program homepage, a voluntary cooperative program between facilities and government agencies, to encourage companies to go beyond compliance and improve their environmental performance. Includes news, information, and contacts; a toolbox of resources and pollution prevention tips; information for and about participating facilities and state and local governments; and benchmarking tools.
Full Title: The Canadian Pollution Prevention Information Clearinghouse
URL: http://www.ec.gc.ca/cppic/en/search.cfm?txtSearchString=metal%20finishing
Full Work Author: The National Office of Pollution Prevention, Canada
Abstract: This site contains a searchable database of pollution prevention information. From the main page, choose the metal-finishing subsection and then search for specific areas of concern. Most documents are available on-line.
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