| | Benchmarking Metal Finishing |
| | 9,59 | | MB |
| | 154 | | stron |
| | 4277 | | ID | National Center for Manufacturing Sciences |
| | 2002 | | rok |
| | Table of Contents |
| | Section |
| | What You Will Find in This Report . iii |
| | List of Tables . ix |
| | Background and Acknowledgments . xiii |
| | What Is the Benchmarking Survey? . xiii |
| | What We Did xiii |
| | Why We Did It xiii |
| | Who We Are . xiii |
| | Acronyms and Abbreviations . xv |
| | Chapter 1 . The Benchmarking Survey . 1-1 |
| | 1.1 What We Asked in Phases 1 and 2 1-2 |
| | 1.2 Who Responded: a Profile of Survey Participants 1-2 |
| | 1.2.1 Processes . 1-2 |
| | 1.2.2 Multi-Process Operations .1-3 |
| | 1.2.3 Rack and Barrel Plating 1-3 |
| | 1.2.4 Comparison Between Survey Respondents and General Population . 1-4 |
| | 1.2.5 Other Descriptive Statistics 1-5 |
| | 1.3 What We Learned 1-7 |
| | 1.3.1 Overview of Our Approach 1-7 |
| | 1.3.2 Regression Results: Environmental Performance Versus Process Type 1-10 |
| | 1.3.3 Regression Results: Environmental Performance Versus Other Company Characteristics 1- |
| | 12 |
| | 1.3.4 Adjustment Formulas . 1-14 |
| | Appendix 1A: Phase 1 and Phase 2 Survey Forms 1A-1 |
| | Appendix 1B : Compilation of Survey Data . 1B- 1 |
| | Appendix 1C: Additional Details on Survey Methods and Analytical Approach 1C-1 |
| | Chapter 2 . Using the Survey Results 2-1 |
| | 2.1 Analysis of Phase 1 Data-Ranking Environmental Performance 2-1 |
| | 2.1.1 Wastewater Discharge Rate 2-2 |
| | 2.1.2 Sludge Generation Rate and RecycleDisposal Method . 2-2 |
| | 2.1.3 Electricity Use . 2-3 |
| | 2.1.4 Organic Emissions 2-3 |
| | 2.1.5 Finding the Rank . 2-4 |
| | 2.2 Analysis of Phase 2 Data . 2-8 |
| | 2.2.1 Production and Environment-Related Practices . 2-8 |
| | 2.2.2 Pollution Control Costs 2-13 |
| | Appendix 2A: Descriptive Data for Ranked Companies . 2A-1 |
| | Use arid dissemination of the information contained in this document are subject to restrictions on |
| | the Wright page 1 I |
| | Chapter 3 . Guide to Best Practices . 3.1 |
| | 3.1 Alkaline Cleaning 3-2 |
| | 3.1.1 Alternatives to Solvent Cleaning 3-2 |
| | 3.1.2 Process Characteristics . 3-3 |
| | 3.1.3 Water Use Reduction 3-3 |
| | 3.1.4 Bath Maintenance . 3-4 |
| | 3.2.1 Water Use Reduction 3-5 |
| | 3.2 Acid Dipping and Pickling 3-5 |
| | 3.2.2 Bath Maintenance . 3-6 |
| | 3.2.3 Process Conditions . 3-6 |
| | 3.2.6 Uses for Spent Baths . 3.7 |
| | 3.3.1 Water Use Reduction 3-7 |
| | 3.3.2 Anode Use 3-8 |
| | 3.3.3 Bath Maintenance . 3-8 |
| | 3.3.5 Special Practices for Chromic Acid 3.9 |
| | 3.4.2 Bath Maintenance . 3-11 |
| | 3.2.4 Inhibitors . 3-7 |
| | 3.2.5 Chemical Substitution . 3-7 |
| | 3.3 Anodizing . 3-7 . |
| | 3.3.4 Energy Use Reduction 3-9 |
| | 3.4 Cadmium Plating . 3-9 |
| | 3.4.1 Water Use Reduction 3-10 |
| | 3.4.3 Chemical Recovery . 3-11 |
| | 3.5.1 Water Use Reduction 3-11 |
| | 3.5 Copper Plating . 3-11 |
| | 3.5.2 Bath Maintenance . 3-12 |
| | 3.5.3 Chemical Recovery . 3-12 |
| | 3.6 Decorative Chromium Plating 3-12 |
| | 3.6.3 Air Quality 3-14 |
| | 3.7 Electroless Nickel Plating . 3-15 |
| | 3.7.1 Bath Maintenance . 3-15 |
| | 3.7.2 Disposal of Spent Baths 3.16 |
| | 3.8 Hard Chromium Plating 3-16 |
| | 3.8.1 Drag-out Recovery 3.16 |
| | 3.8.3 Air Quality 3-18 |
| | 3.9 Nickel Plating 3-18 |
| | 3.6.1 Water Use Reduction 3-13 |
| | 3.6.2 Bath Maintenance . 3-14 |
| | 3.7.3 Water Use Reduction 3-16 |
| | 3.7.4 Air Quality 3-16 |
| | 3.8.2 Bath Maintenance . 3-17 |
| | 3.9.1 Water Use Reduction 3-18 |
| | 3.9.2 Chemical Recovery . 3-19 |
| | 3.9.3 Additives . 3-20 |
| | 3.9.4 Bath Maintenance . 3-20 |
| | 3.9.5 Additional Methods 3 -21 |
| | 3.9.6 Air Quality 3-21 |
| | 3.10 Tin and Tin-Lead Plating . 3-21 |
| | 3.10.1 Alternative Processes . 3-21 |
| | 3.10.2 Water Use Reduction . 3-22 |
| | 3.10.3 Bath Maintenance . 3-22 |
| | 3.10.4 Chemical Recovery 3-22 |
| | 3.10.5 Disposal of Spent Baths and Sludge 3-22 |
| | 3.1 1 Zinc Plating . 3-22 |
| | 3.1 1.1 Bath Maintenance . 3-23 |
| | 3.1 1.2 Water Use Reduction . 3-24 |
| | 3.1 1.3 .Chemical Recovery 3-24 |
| | 3.12 Other Processes . 3-24 |
| | 3.12.1 Phosphating 3-25 |
| | 3.12.2 Passivation 3-25 |
| | 3.12.3 Black Oxide 3-26 |
| | 3.12.5 Painting . 3-26 |
| | 3.12.4 Electropolish . 3-26 |
| | 3.12.6 Polishing and Buffing . 3-26 |
| | 3.13 Additional Comments . 3-26 |
| | 3.13.1 General . 3-27 |
| | 3.13.2 Energy 3-28 |
| | 3.13.3 TreatmentDisposaVOff-site Recycling 3-28 |
| | Appendix 3A: Glossary 3A-1 |
| | Chapter 4 . Roadmap 4. 1 |
| | 4.1 Method Outline 4-1 |
| | 4.1.1 Starting Point 4.2 |
| | 4.1.2 Destination 4-3 |
| | 4.1.3 Factors Affecting “How Far” 4-4 |
| | 4.1.4 Factors Affecting “How Steep” 4-5 |
| | 4.2 Specific Process Benchmarks 4-7 |
| | 4.2.1 Zinc Plating . 4-7 |
| | 4.2.2 Nickel Plating . 4. 10 |
| | 4.2.3 Decorative Chromium Plating 4-11 |
| | 4.2.4 Electroless Nickel Plating . 4. 12 |
| | 4.2.5 . Anodizing . 4. 13 |
| | 4.2.6 Hard Chromium Plating 4-15 |