Green Chemicals and Alternative Products Neil Taylor Market Development Manager Atotech UK Ltd

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Green ChemicalsandAlternative ProductsNeil
TaylorMarket Development ManagerAtotech UK Ltd
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Reducing environmental impact and reducing costs
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Why Use Green Technologies?

• Environmental Impact
• Reduction of carbon emissions
• Reduction of natural resource consumption
• Reduction in waste produced
• Sustainability
• Legislative reasons
• Climate Change Levy, IPPC, RoHS, EoLV, BAT, SED,
  WEEE, CoMAH, etc.
• Tougher requirements and harsher penalties
• Improved Profits
• Reduced energy consumption
• New chemical technologies

The issue effects us all!
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New Chemical Technologies

• Over recent years new chemical processes have
  been developed to improve environmental impact
• Chemical supply companies have risen to the
  challenge of meeting these new demands
• Increasing costs and new legislation mean that
  these new technologies may warrant another look
• Many technologies now offer reduced environment
  impact AND reduced operating costs

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Methods of Improvement

• Various methods have been used in the development
  of new chemistries to meet new demands
• Improved energy efficiency
• Lower operating temperatures
• Improved electrical efficiency
• Improved productivity
• Reduced waste production
• Less waste
• Less hazardous waste
• Long-life processes
• Reduced downtime
• Reduced labour costs
• Less hazardous chemistries
• Safer operation
• Reduced treatment costs

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Energy Efficiency

• Lower Operating Temperatures
• Low temperature cleaners

Proposed Temperature
Existing Temperature
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Energy Efficiency

• Improved Electrical Efficiency
• High efficiency chromes
• Conventional system Working example
• At 30 A/dm2 (2.0 A/sq.in)
• 10 Volts
• Rectifier efficiency 86 (75 loading)
• Solution efficiency 13
• Calculation
• (1606 x10) / (1000 x 0.86 x 0.13)
• 143.65 KWH per kg CrO3 deposited

1606 ampere-hours are required to deposit the
chromium from 1kg of CrO3
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Energy Efficiency

• Improved Electrical Efficiency
• High efficiency chromes
• High efficiency system Working example
• At 30 A/dm2 (2.0 A/sq.in)
• 10 Volts
• Rectifier efficiency 86 (75 loading)
• Solution efficiency 22 (increases to 25 at
  higher c.d.)
• Calculation
• (1606 x10) / (1000 x 0.86 x 0.22)
• 84.88 KWH per kg CrO3 deposited

1606 ampere-hours are required to deposit the
chromium from 1kg of CrO3
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Energy Efficiency

• Improved Electrical Efficiency
• High efficiency chromes
• 143.65 KWH were required for 1kg CrO3 from
  conventional systems
• 84.88 KWH were required for 1kg CrO3 from
  conventional systems
• gt40 reduction in energy requirements

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Productivity and Waste

• Electro-Dialysis for Electroless Nickel
• The advantages of continuous electrodialysis
  systems for electroless nickel are now well
  documented
• Potential never-dump solution
• Consistent quality
• Consistent plating rate
• Consistent stress
• Over 2000 metal turnovers now achieved on large
  volume production plants (aluminium and ferrous
  substrates)

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Productivity and Waste

• Electro-Dialysis for Electroless Nickel offers
  safer waste and improved productivity alongside
  the other benefits
• Waste produced contains almost no nickel metal
• Higher productivity from
• Consistent high plating rate
• Less rework
• Higher bath loadings possible (up to 70 higher)
• Shorter process time to deposit the same nickel
  mass
• Up to 70 less energy used!

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Reduced Hazards

• The use of safer chemicals reduces operator risk
  and waste treatment costs
• Many examples of this are now in use in surface
  engineering applications
• Hexavalent chrome plating ? Trivalent chrome
  plating
• Hexavalent chrome passivates ? Trivalent or
  chrome-free passivates
• Nitric acid aluminium pretreatment ? Non-nitric
  pretreatments
• Cyanide zinc plating ? Non-cyanide zinc plating
• Tin-lead alloy plating ? Pure tin plating

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Methods of Improvement - Revisited

• Various methods have been used in the development
  of new chemistries to meet new demands
• Improved energy efficiency
• Lower operating temperatures
• Improved electrical efficiency
• Improved productivity
• Reduced waste production
• Less waste
• Less hazardous waste
• Long-life processes
• Reduced downtime
• Reduced labour costs
• Less hazardous chemistries
• Safer operation
• Reduced treatment costs

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New Technology

• There is a new technology that meets all of the
  methods of improving envrionment impact
• It does this whilst reducing operating costs

BIOTECHNOLOGY
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Biotechnology

• What is biotechnology?
• All lines of work by which products are
  produced from raw materials with the aid of
  living organisms - Karl Ereky, 1919

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Biotechnology

• Biotechnology has been used for thousands of
  years
• Initial uses were based on agriculture and
  production of breads, cheeses, and beverages
• Medical applications arose in the 18th century
  (vaccinations, military applications)
• Modern industrial applications for biotechnology
  are relatively new (the white sector)
• Oil spills
• Land reclamation
• Filtration systems
• Cleaning products

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Benefits of Biotechnology

• 1. Biochemistry can offer technical advantages
  that are not possible using conventional
  chemicals

• 2. Biochemistry delivers these technical
  advantages whilst minimising or lowering the
  environmental impact

• 3. Biochemistry can deliver technical advantages
  and reduced environmental impact whilst lowering
  operating costs

TECHNICAL ENVIRONMENTAL COST
BENEFITS BENEFITS
BENEFITS
?
?
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Biotechnology Applications

• Applications in Surface Engineering
• Degreasing and cleaning
• Phosphate descaling
• Paint stripping
• Paint detackification
• Pre-paint adhesion

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How Biotechnology Works
Biochemical Detackification uses the synergy
between Fungi and Bacteria
Bioremediation A natural process whereby an
organism converts complex organic molecules into
more simple ones
Bacteria are prokaryotes, unicellular, with no
distinct nucleus.

• The micro-organisms used are Class I Organisms
  (WHO Classification)
• Naturally occurring
• Non-pathogenic
• Safe for the environment and human contact

Fungi are Eukaryotes unicellular or
multicellular organisms, with distinct
nucleus and other organelles, larger in size.
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How Biotechnology Works

• Example Paint Detackification

Biochemical detackification
solvents
solvents
pigment
BiodetackifierBioflocculants
binders
Emulsification
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Biotechnology Advantages

• Safer chemicals (naturally occurring processes)
• Reduced energy consumption (lower temperatures)
• Reduced waste (long-life systems)
• Reduced downtime (less maintenance)
• Easy to operate and run (simple analysis)
• Production proven (see Case Studies)
• Improved performance (better results)
• REDUCED OPERATING COSTS

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Biotechnology Case Studies

• Cleaning / Degreasing
• Large job-shop electroplater
• Net annual savings of 10,980
• Capital cost was 10,980 payback period was 15
  months
• not including heating cost savings and downtime
  savings

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Biotechnology Case Studies

• Descaling
• Large automotive OEM in Europe
• Net annual savings of 44,480

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Biotechnology Case Studies

• Paint Stripping
• Large automotive OEM in Europe
• Cost to strip in conventional chemistry
  1.00/fixture
• Annual cost to strip conventionally 180,000
• Cost to strip in biochemical stripper
  0.56/fixture
• Annual cost to strip biochemically 100,800
• Annual saving of 80,000
• Capital cost was 70,000
• Payback in less than 12 months

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Biotechnology Case Studies

• Paint Detackification
• Large automotive OEM in Europe
• In two years achieved 61 reduction in sludge
  volume
• Cost reduction over two years of 18
• Increased time between changes of water from
  changing every six months to one change in two
  years
• Achieved during a 3 increase in production

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Biotechnology Case Studies

• Pre-Paint Adhesion
• Large job-shop phosphater in North America

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Summary

• Green technologies are available NOW
• In many cases they offer improved technology,
  safer environments, reduced waste, and reduced
  operating costs
• Biotechnology offers an exciting way forwards for
  the Surface Engineering Industry

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DONT GET MAD, GET GREEN
THANK YOU!