电镀清洁生产研究
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摘要
电镀行业在现代工业中有着重要作用，但是，电镀过程由于使用了大量强酸、碱、重金属溶液，甚至包括镉、氰化物和铬酐等有毒有害化学品，在生产过程中会排放有害环境和人体健康的废气、废水和废渣，因而电镀行业也成为重污染性工业行业之一，传统的末端治理不能有效的根除污染，也给企业带来了沉重的经济压力。为此人们需要转变观念，寻找污染治理的新途径。清洁生产是一种新的创造性的思想，该思想将整体预防的环境战略持续地应用于生产过程、产品和服务中，以增加生态效率和减少人类和环境的风险，因此电镀行业开展清洁生产势在必行。
本文以山东九鑫机械工具厂为研究对象，系统地研究电镀清洁生产。研究内容包括以下三方面：电镀清洁生产工艺研究、清洁生产审核、清洁生产和TPM的结合。通过这三方面的研究为电镀企业提供参考，企业间互相借鉴，提高电镀清洁生产的水平。最终的目的是实现工具厂电镀废水的零排放，资源利用率有效提高，实现清洁生产和TPM的有机结合。
本文首先对电镀清洁生产工艺进行研究，整个工艺研究在工具厂现场进行。研究过程中，在镀镍槽后增设2个静止的回收清洗槽，每生产班次都对挂具刷绝缘漆，通过镍的物流实测验证，镍的利用率从70％提高到87％。在镀铬槽后增设3个静止的回收清洗槽，并且使用稀土镀装饰铬，铬酐浓度为150-180g／L，并且添加抑雾剂F-53，通过铬的物流实测验证，发现铬的利用率从15％提高到43％。考虑工具厂各生产车间的用水要求，在全厂范围对电镀废水进行合理调配，电镀车间外排的废水被蒸发掉，实现电镀废水零排放，为电镀行业的清洁生产提供一种新思路。工具厂对挂具上析出的镍渣及时回收，通过电解镍渣回收原料镍用于镀镍，回收率达到92.86％，镀镍和镀铬废水经过化学沉淀处理得到废渣，用于制砖，在技术上成熟可靠，解决了废渣污染问题。
2005年，工具厂在山东大学专家指导下开展了清洁生产审核，经过省环保局验收获得A级证书。本文对审核过程中的清洁生产方案进行了分析和汇总，工具厂共提出方案21项，实施了18项，其中无／低费方案有8个，年取得经济效益可达10万元，并且在现场管理方面取得了显著效果；中／高费方案10个，年取得经济效益可达20多万元；工具厂在所有方案实施完毕后，每年可增加经济效益达30多万元，每年可节约用水5330m~3。企业各项单位产品指标有了显著提高。
工具厂开展清洁生产的同时，也在开展TPM活动，本文主要从理论和实践两方面对清洁生产和TPM的结合进行了简要的研究。清洁生产和TPM在产生过程、目标、内涵上有一定相似性，在理论上具有相互结合的可能性，可在开展TPM各项活动的过程中与清洁生产结合。实际操作中，利用TMP培训的七个阶段对职工进行清洁生产知识培训，利用小集团活动开展持续清洁生产，完成本轮清洁生产审核制定的持续清洁生产计划，为下一轮清洁生产打下坚实基础。对于TPM方案的提出明确加入清洁生产的要求，在收集整理TPM方案的同时也获得了清洁生产方案。
Plating played an important role in the modern industry. But much acid, alkali and heavy metal solution was used in the plating process, especially cadmium, cyanide, chromic acid and other noxious chemicals. Exhaust gas, waste water and waste residue was released endangering environment and health in the production. So plating is one of the heavy polluting industries. Final treatment can't thoroughly eliminate pollution and bring heavy economic pressure. In order to control pollution, people must change their conception to find a new route. Cleaner production is a creative idea, which made the pollution prevention environmental strategy used in the production, product and service continuously, increased zoology efficiency, and decreased the environmental risk. So cleaner production is imperative under the situation in the plating. The final aim is to achieve the zero emission of the waste water, rise the utilizing rate of source, and combine cleaner production and TPM integrally.
In this paper cleaner production on the plating was researched in the tool plant of Shan dong Jiu xin. The content of this research included three aspects: cleaner production technics on the plating, cleaner production audit, the combination of cleaner production and TPM. By the research of these aspects, plating corporations can absorb the experience and learn each other, which can improve the condition of plating cleaner production.
First this paper studied the cleaner technics. All the research of the technics was carried out in the tool plant. In the process of research, two quiescent troughs of reusing rinse were added after the nickel plating trough and insulative lacquer was painted on the device used for hanging tools every shift. By the validation of nickel testing, the utilizing rate of nickel rised from 70% to 87%. Three quiescent troughs of reusing rinse were added after the chromium plating trough, thulium additive was used in the decorative chromium plating, the concentration of chromic acid is 150-180g/L, and F-53 was added for restraining the chromium fog. By the validation of chromium testing, the utilizing rate of chromium rised from 15% to 43%. Considering the request of using water in every workshop of tool plant, by adjusting the plating liquid waste in reason in the whole plant, the plating liquid waste was vaporized and achieved the zero emission, which provided a new route of developing plating cleaner production. The nickel residue separating out on the device used for hanging tools was reclaimed and reused as the material of the nickel plating by the way of electrolysis. The rate of reclaiming reached 92.86%. The waste residue from the chemical sedimentation of waste water was used for making bricks. This method is mature technically and can solve the pollution of waste residue.
In 2005, the tool plant developed cleaner production audit under the instructions of the expert of Shandong University. The audit passed the checking of the province environmental protection bureau and gained the certificate of A grade. This paper analyzed and summed up the measures of cleaner production. The plant proposed 21 measures in which 18 measures were carried out. The measures contained 8 free and low cost ones which earned 100000 yuan annually and improved the management remarkably, and 10 high cost ones which earned more than 200000 yuan annually. All the measures can earn more than 300000 yuan and save water of 5330 m~3 annually. Every parameter of the unit product was remarkably improved.
The plant also developed TPM when developing cleaner production. This paper researched the combination of cleaner production and TPM from two aspects of theory and practice. They had some common grounds in the process of birth, aims and connotations. They had the possibility of combination in the theory and can combine from every aspects in the process of developing TPM. In the practice, the plant can educate the staff using the way of 7 steps belonging to TPM, develop cleaner production using the way of small groups, finish the sustaining plan of cleaner production audit this time, and establish steady ground for cleaner production audit next time. Adding the requests of cleaner production to the proposal of TPM measures, when gathering the TPM measures, cleaner production measures were also obtained.
本文以山东九鑫机械工具厂为研究对象，系统地研究电镀清洁生产。研究内容包括以下三方面：电镀清洁生产工艺研究、清洁生产审核、清洁生产和TPM的结合。通过这三方面的研究为电镀企业提供参考，企业间互相借鉴，提高电镀清洁生产的水平。最终的目的是实现工具厂电镀废水的零排放，资源利用率有效提高，实现清洁生产和TPM的有机结合。
本文首先对电镀清洁生产工艺进行研究，整个工艺研究在工具厂现场进行。研究过程中，在镀镍槽后增设2个静止的回收清洗槽，每生产班次都对挂具刷绝缘漆，通过镍的物流实测验证，镍的利用率从70％提高到87％。在镀铬槽后增设3个静止的回收清洗槽，并且使用稀土镀装饰铬，铬酐浓度为150-180g／L，并且添加抑雾剂F-53，通过铬的物流实测验证，发现铬的利用率从15％提高到43％。考虑工具厂各生产车间的用水要求，在全厂范围对电镀废水进行合理调配，电镀车间外排的废水被蒸发掉，实现电镀废水零排放，为电镀行业的清洁生产提供一种新思路。工具厂对挂具上析出的镍渣及时回收，通过电解镍渣回收原料镍用于镀镍，回收率达到92.86％，镀镍和镀铬废水经过化学沉淀处理得到废渣，用于制砖，在技术上成熟可靠，解决了废渣污染问题。
2005年，工具厂在山东大学专家指导下开展了清洁生产审核，经过省环保局验收获得A级证书。本文对审核过程中的清洁生产方案进行了分析和汇总，工具厂共提出方案21项，实施了18项，其中无／低费方案有8个，年取得经济效益可达10万元，并且在现场管理方面取得了显著效果；中／高费方案10个，年取得经济效益可达20多万元；工具厂在所有方案实施完毕后，每年可增加经济效益达30多万元，每年可节约用水5330m~3。企业各项单位产品指标有了显著提高。
工具厂开展清洁生产的同时，也在开展TPM活动，本文主要从理论和实践两方面对清洁生产和TPM的结合进行了简要的研究。清洁生产和TPM在产生过程、目标、内涵上有一定相似性，在理论上具有相互结合的可能性，可在开展TPM各项活动的过程中与清洁生产结合。实际操作中，利用TMP培训的七个阶段对职工进行清洁生产知识培训，利用小集团活动开展持续清洁生产，完成本轮清洁生产审核制定的持续清洁生产计划，为下一轮清洁生产打下坚实基础。对于TPM方案的提出明确加入清洁生产的要求，在收集整理TPM方案的同时也获得了清洁生产方案。
Plating played an important role in the modern industry. But much acid, alkali and heavy metal solution was used in the plating process, especially cadmium, cyanide, chromic acid and other noxious chemicals. Exhaust gas, waste water and waste residue was released endangering environment and health in the production. So plating is one of the heavy polluting industries. Final treatment can't thoroughly eliminate pollution and bring heavy economic pressure. In order to control pollution, people must change their conception to find a new route. Cleaner production is a creative idea, which made the pollution prevention environmental strategy used in the production, product and service continuously, increased zoology efficiency, and decreased the environmental risk. So cleaner production is imperative under the situation in the plating. The final aim is to achieve the zero emission of the waste water, rise the utilizing rate of source, and combine cleaner production and TPM integrally.
In this paper cleaner production on the plating was researched in the tool plant of Shan dong Jiu xin. The content of this research included three aspects: cleaner production technics on the plating, cleaner production audit, the combination of cleaner production and TPM. By the research of these aspects, plating corporations can absorb the experience and learn each other, which can improve the condition of plating cleaner production.
First this paper studied the cleaner technics. All the research of the technics was carried out in the tool plant. In the process of research, two quiescent troughs of reusing rinse were added after the nickel plating trough and insulative lacquer was painted on the device used for hanging tools every shift. By the validation of nickel testing, the utilizing rate of nickel rised from 70% to 87%. Three quiescent troughs of reusing rinse were added after the chromium plating trough, thulium additive was used in the decorative chromium plating, the concentration of chromic acid is 150-180g/L, and F-53 was added for restraining the chromium fog. By the validation of chromium testing, the utilizing rate of chromium rised from 15% to 43%. Considering the request of using water in every workshop of tool plant, by adjusting the plating liquid waste in reason in the whole plant, the plating liquid waste was vaporized and achieved the zero emission, which provided a new route of developing plating cleaner production. The nickel residue separating out on the device used for hanging tools was reclaimed and reused as the material of the nickel plating by the way of electrolysis. The rate of reclaiming reached 92.86%. The waste residue from the chemical sedimentation of waste water was used for making bricks. This method is mature technically and can solve the pollution of waste residue.
In 2005, the tool plant developed cleaner production audit under the instructions of the expert of Shandong University. The audit passed the checking of the province environmental protection bureau and gained the certificate of A grade. This paper analyzed and summed up the measures of cleaner production. The plant proposed 21 measures in which 18 measures were carried out. The measures contained 8 free and low cost ones which earned 100000 yuan annually and improved the management remarkably, and 10 high cost ones which earned more than 200000 yuan annually. All the measures can earn more than 300000 yuan and save water of 5330 m~3 annually. Every parameter of the unit product was remarkably improved.
The plant also developed TPM when developing cleaner production. This paper researched the combination of cleaner production and TPM from two aspects of theory and practice. They had some common grounds in the process of birth, aims and connotations. They had the possibility of combination in the theory and can combine from every aspects in the process of developing TPM. In the practice, the plant can educate the staff using the way of 7 steps belonging to TPM, develop cleaner production using the way of small groups, finish the sustaining plan of cleaner production audit this time, and establish steady ground for cleaner production audit next time. Adding the requests of cleaner production to the proposal of TPM measures, when gathering the TPM measures, cleaner production measures were also obtained.
引文
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