Photo by FOGO Sp. z o.o.
Good practices and investments related to Cleaner Production
Example No. 69
Reducing phosphorus content in wastewater and reducing chemical consumption by changing the chemical used in the degreasing process
Company:
FOGO Sp. z o.o., Wilkowice
Industry branch: electromechanical
Main products: electric power generators
Resources in question:
- Chemicals
- Wastewater
- Waste
Cost (implementation of good practice): None
(cost-free measure; the new degreaser has a price similar to the one used previously)
(cost-free measure; the new degreaser has a price similar to the one used previously)
FOGO's process line includes an installation for degreasing and passivation of metal parts. The degreasing and passivation processes take place in 4 spray chambers with spillage containers underneath. The water circulates in the containers in a closed circuit, in the opposite direction to the moving element being treated. The most heavily contaminated aqueous washing liquids from the first container (from the degreasing chamber) are classified as waste and transferred to an authorized recipient. Excess water from the remaining containers is returned to the process to next containers, and is discharged as industrial wastewater if it loses the required properties.
The results of tests on industrial wastewater from container no. 2 indicated frequent exceedances of the parameter “total phosphorus”, for which the threshold was set at 10 mg/l in the permit held, required under Water Law Act. Analysis of the chemicals used in the washer plant revealed that one of them contained phosphorus compounds. Therefore, it was decided to look for another degreasing agent with a lower content of this element.
The results of tests on industrial wastewater from container no. 2 indicated frequent exceedances of the parameter “total phosphorus”, for which the threshold was set at 10 mg/l in the permit held, required under Water Law Act. Analysis of the chemicals used in the washer plant revealed that one of them contained phosphorus compounds. Therefore, it was decided to look for another degreasing agent with a lower content of this element.
Applied solution:
The supplier of chemicals for the washer plant was asked to propose alternative agents with similar (not smaller) efficiency and degreasing capacity, that would not cause phosphorus concentration exceedances and at the same time would not cause exceedances of other parameters in the wastewater. In response, a proposal was received to replace the previously used agent with a new one with the same effect. The high effectiveness of the new agent has already been demonstrated by trial work, and confirmed by periodic measurements taken during use.
Obtained benefits and effects of the implementation:
- Reduction of average phosphorus content in wastewater by more than 97%, (values significantly lower than 10 mg/l, i.e. from <0.3 mg/l, to 0.8 mg/l).
- The new degreasing agent works at half the concentration per unit volume of the bath, which results in:
- reduced consumption of degreasing agents by about 12,000 kg/year, which results in fewer chemicals reaching wastewater and liquid waste
- reduction in purchase costs by about 50%; estimated economic savings (resulting from about half the use of the new chemical and the similar price of the old and new agents) are almost PLN 25,000/year
Sources:
- Report on the Cleaner Production Project No. 48.768, developed within the framework of the Cleaner Production Academy: "Modernization of technology and management in FOGO within the framework of implementation of the Cleaner Production Program"
- Materials (including photos) submitted by FOGO Sp. z o.o.
Polish version:
This
material has been subsidized by the National Fund for Environmental
Protection and Water Management. The Polish Cleaner Production Movement
Association is solely responsible for its content.
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