Good practices in CP: 4. Optimization of the washing process (FAMED Żywiec)

Cost (implementation of good practice): Low

Description of the problem: 

 

In its manufacturing processes the company uses chemical and electrochemical baths, in which steel is prepared before being bended, cut, welded and covered with varnish and nickel-chromium coating. The short life of the washing bath is a major problem. Standard baths used in the steel washing and passivation lines can be used for about six months. To maintain the high quality of steel surfaces subjected to further processing, the company had to prepare a new washing bath every six months. This process generated high costs and resulted in a considerable consumption of water, applied chemical solutions and electricity. It was also necessary to periodically dispose of the used-up bath agents.

 

The solution consists in the application of an emulsion separating agent in the bath, which resulted in a longer bath life. The bath, with a relevant component, has been used continuously for 13 years, still maintaining the same quality. It is regularly replenished, based on the tests of the concentration of its substances. The emulsion separating agent is dosed at intervals of 3-6 months (depending on the amount and the level of soiling of the washed elements). The  used-up emulsion is collected into a separator with a work tub and periodically handed over for utilization to external companies.