ENGINEERED SYSTEMS

KINETIC0 NICKEL RECOVERY SYSTEM

Kinetic0 Engineered Systems, Inc. Corporate Headquarters Newbury, Ohio 44065

ENGINEERED SYSTEMS INCORPORATED

Kinetico Nickel Recovery System

DESCRlPT10N The Kinetico Nickel Recovery System recirculates water from the first flowing rinse, removes nickel, sodium and organics and sends deionized water to the final rinse.

FEATURES Fully automatic regeneration and duplex design assure that the system stays on line during regeneration. The ion exchange system is non-electric and explosion-proof.

BENEFITS Sodium and organics are sent to waste treatment. Concentrated nickel sulfate is returned to the nickel bath. Sodium content is reduced 60 to 80 percent.

01990 Kinetico Engineered Systems, Inc. 6/90

8 I ? I 6 I I I 4 I 3 I 2 I I - .c( u.l 111 , u

-

3. PRODUCES DI WATER SOK OHM-CM CUR RINSE WATERS.

II .I. I"

SK-870 . D

CATION rl

I. CONCENTRATES NICKEL.

2.

3. REDUCED CONCENTRATION O F SODIUM.

REGENERANT WASTE CONSISTS OF NIS04

CATION G?

I. REMOVES ALL OTHER CATIONS.

2 REGENERANT WASTE TO NEUTRALIZATION. CONTAINS NO METALS.

ANION rl

1. RLHOVES ANIONS. COMPLETES 01 CYCLE.

2 REGENERANT WASTE TO NEUTRALIZA'TION. CONTAINS NO METALS.

/*

/- -\. -. \.

NOTES:

I. CATION REGENERANT - SULFURIC ACID 30%

2. ANION REGENERANT - SODIUM HYDROXIDE (CAUSTIC SODA) - (NOOH) - RAYON OR MERCURY CELL GRADE 36. OR 50. 8 A U W (10% OR 50%)

50% SODIUM HYDROXIDE MUST BE MAINTAINED ABOVE 65.F TO PREVENT CRY STALL1 LATI ON

3.

4. SYSTEM REWIRES 480 VAC 3 PHASE

5. ALL DIMENSIONS SHOWN IN INCHES (APPROX)

6. ADAPTERS AND IO F T (TOTAL) OF 1 / 2 ' 00 FLEXIBLE TUBING PROVIDED TO CONNECT TO ACID AN0 CAUSTIC CONTAINERS

AT 5 AMPS POWER SUPPLY

10 GPM N I C K E L R E C O V E R Y S Y S T E M

WATER PROCESSIN6 SYSTEM I

In some ways it seems strange to talk about problems in closed-loop nickel recovery, when there are so many recovery systems operating today and there are so many platers who add virtually no nickel chemicals to their baths.

Has the loop truly been closed by the recovery technologies available today or are substantial quantities of nickel still ending up as hazardous waste? As the EPA moves to restrict or possibly even to ban land disposal of this type of waste, what problems do nickel platers face and what alternatives do they have? This paper attempts to address these issues, to discuss possible ways to further close the loop, and the potential problems raised by them. Various papers1 2 3 show that most systems which are designed as closed-loop recovery systems actually recover only 80-95% of the nickel dragged out of the bath. Even when no nickel salts need to be added to the bath, this often represents substantially less than 90-95% recovery of dragout, due to the 3-50! difference between anode and cathode efficiencies.

Most studies on this subject also fail to take into account significant nickel losses from bath treatments, routine filter cleanings and the cleaning of the recovery equipment itself. If frequent carbon treatments or high pH treatments are required, losses from these can be almost as large a source of waste as the dragout itself, and it is doubtful that the operation can be accurately described by the term '%lased-loop".

If most nickel recovery systems recover less than 95% of the influent to a waste treatment system, how then can a nickel plater further close the loop without risking reduced quality, re-work or scrap? The essential problems are revealed by completing a materials balance for all bath constituents, including water and impurities. Selecting a recovery technology or technologies which best completes this balance, while avoiding problems due to bath contamination, is no simple task.

Since most efforts for nickel recovery have involved only one technology and were designed primarily to reduce purchases of nickel salts, little or no thought was given to the impurity problems they might create. Therefore, some discussion of impurity problems is apprnpriate.

system. Table 2 highlights just the impurity problems which occur in nickel plating baths and lists possible solutions. Each of these is amplified below.

Calcium is known to cause problems when it reaches a concentration of about 500 mg/l. Even a simple dragout rinse can cause calcium to rise to this level when hard water is used for evaporative make-up. Fortunately, calcium problems can be virtually eliminated simply by using purified water for all make-up to the bath. While using softened water for this purpose would avoid calcium problems, at high levels of recovery the eventual increase in bath salinity would also be deleterious. Therefore, only highly purified water is suitable for make-up to a nickel bath with a recovery system.

Sodium was virtually never a problem in nickel plating baths until the advent of nickel recovery systems. Plating problems begin to occur when sodium exceeds 20,000 mg/l and become progressively worse above this point. Our experience has been that until recovery exceeds about 75%, the sodium concentration in a bright nickel bath usually stays below 20-30,000 mg/ l and is manageable. There are platers today, however, who are struggling with 40,000 mgll. Even this high level of contamination usually represents only 85-90% recovery of the salts dragged out of the bath, or lost due to bath treatments.

At this time, only two recovery approaches can control sodium build-up problems at high levels of recovery. Precipitation and re-dissolution, an old techique which may see a revival, can effectively remove excess sodium from nickel values. Another technique, developed by my colleagues and I, is a modification to conventional ion exchange recovery. Figure 1 illustrates how this system works to remove sodium. The modification is simply to exploit the much greater affinity of ion exchange resins for nickel over sodium. By placing two cation resin beds in series, sodium can be “bled” out of the first bed while nickel is still concentrating there. The second cation vessel catches the sodium and thereby allows the water to be completely deionized by passing it through an anion resin. Fig. 2 is a picture of a system of this type which in operation has recovered over 95% of the nickel in rinse water while simultaneously removing over 83% of the influent sodim.

Table 1 lists technologies which have been used for open and closed-loop nickel recovery and some of the characteristics of each. This table highlights the impurity and materials balance problems which are the most formidable barriers to a truly closed-loop recovery

TABLE 1.

TECHNOLOGY

1. Precipitation

2. Evaporation A. Dragout Rinse

6. Atmospheric Evaporator

C. Vacuum Evaporator

3. R.O.

4. Ion Exchange

5. ED/EDR

COMPARISON OF NICKEL RECOVERY TECHNOLOGIES

CAPABLE OF CLOSING LOOP?

INITIAL COST

Moderate To High

v. Low

Moderate To High

High

Moderate To High

Moderate To High

High

OPERATING COST

Low

v. Low

High

High

Low to Moderate

Low to Moderate

Low to Moderate

POTENTIAL IMP PLATING BATH

N N Y N Y

N Y Y ' N N

Y Y Y Y N

Y Y Y Y N

Y Y Y Y N

? ? Y N Y

Y Y Y Y N

IlTY PROBLEMS RINSE WATER

Y Y Y Y (If rinse flow is limited)

Same as above.

N N Y Y

N N N N

Y Y Y ?

POTENTIAL MATERIALS BALANCE PROBLEMS

Y ?

Y N

Y N

Y N

Y Y

Y Y

Y Y

Y = Yes N = NO

TABLE 2.

IMPURITY

1. Calcium

2. Sodium

3. Heavy Metals

4. Excess Acid

5. Organic

NICKEL BATH

PRIMARY SOURCE(S)

Water Used

Addition Agents & Brighteners

Parts Being Plated

Ion Exchange or Precipitation Recovery

Brightener Breakdown

IMPURITY PROBLEMS MADE WORSE BY RECOVERY

EFFECT( S) POSSIBLE SOLUTION(S)"

Rough Plate Extra Filter Cleanings

Dull Plate Loss of Efficiency

Dull Plate Roughness Loss of Ductility

Lower Cathode Efficiency Dull Plate

Use only purified water for make-up and additions.

Modified ion exchange recovery. Precipitation and recovery.

Improved rinsing before nickel and improved

Continuous dummying. Selective ion exchange.

housekeeping.

Ion exchange to remove excess acid.

Dull Plate Excess Brightener Additions Decrease Corrosion Resistance

Possible use of regenerable Polymeric adsorbents. Ion exchange recovery.

(Duplex Nickel) Precipitation recovery.

*Batch bath treatments are not included on this list and due to the large quantities of sludge they produce, are considered to be a last resort.

FIGURE 1. ION EXCHANGE NICKEL RECOVERY SYSTEM

WHICH ELIMINATES SODIUM AND ORGANIC BUILD-UPS

Level control hi purity water

r ------- 1---t---- 1 I------- I I I I I I I I I 1 I

I I I I I I I

r- I I I I

I I I

I RI

-

small pump

-

;E

r--- 1

Jr RINSE

r------------ I I I -,,--I

I I L - - -- - --

4 RECOVERED

NICKEL

CATION UNIT CATION UNIT

$. sodium, magnesium, organics, etc.

r-- I I I I I i

I I I

I

z

I I I

r n I

DI WATER

A I ANION UNIT

TO WASTE --+ sulfate, chloride,

borate, etc.

Heavy metal contaminants are returned with recovered nickel by all of the recovery technologies listed. Therefore, better housekeeping and good rinsing before the nickel bath are essential to any successful system. If these are not sufficient, then continuous dummying is the most desirable remedial action since it produces no sludge. Because of the large volume of hazardous waste produced, batch treatments should be done only as a last resort; selective ion exchange and solvent extraction may provide alternatives to batch treatments to remove heavy metals in the future.

Excess acid is a problem which only occurs in precipitationhe-dissolution or ion exchange recovery systems. In most cases it is removed by a subsequent ion exchange step which removes most of the excess acid, leaving the nickel solution at or near the desired pH range.

Organic impurities represent one of the greatest barriers to high levels of nickel recovery. This is especially true for duplex nickel plating systems where even minute amounts of Class I brightener render the recovered nickel unsuitable for use in a semi-bright bath. Even in simplex bright nickel baths, however, breakdown products accumulate very rapidly with recovery and are not well removed by either continuous activated carbon filtration or even the slude-generating, batch oxidation and carbon treatments.4 The quick and dirty solution to this problem is to add ever-increasing amounts of brightner, but eventually this only further aggravates the problem.

Our lab has had some encouraging results using regenerable adsorbents rather than carbon to strip organic contaminants from nickel plating baths. It is to soon to tell, however, if this approach will be practical or economical.

There are only two approaches to recovery which do not contribute to the organic contamination problem. Precipitation and redissolution has been demonstrated5 to be an effective technique in this regard, and published reports6 7 as well as work done with systems of our own show that ion exchange can separate nickel from the troublesome organics present in nickel plating baths. Even duplex nickel plating systems can use and have successfully used ion exchange to convert bright nickel dragout into nickel solution suitable for semi-bright baths. Membrane recovery techniques are capable of slowing the buildup of organic breakdown products, but only if all or part of the “clean water” is discarded. Unfortunately, this approach results in nickel sludge and can also cause calcium problems if pure water is not used for make-up.

In addition to problems in the nickel plating bath which are caused and/or aggravated by nickel recovery systems, there are also potential rinse purity problems. Each type of recovery system has the potential for insufficient or contaminated rinsing as compared to no recovery at all, but some problems are associated with a particular technology. Some of these are summarized in Table 3.

Evaporation, due to its high operating cost, seeks to minimize rinse flows to the greatest extent possible. As a result, problems with subsequent chrome plating due to insufficient rinsing are likely unless good design is built into the system and regular maintenance is practiced. Atmospheric evaporators are particularly vulnerable to rinse-related problems, since their performance varies somewhat with seasonal variations in humidity. It is doubtful that a closed-loop evaporative recovery system can recover nickel economically and also provide adequate rinsing with fewer than four rinse tanks. Membrane systems like R.O. and E.D. have very poor rejection for borates and some organics.8 9 10 These systems require one or more rinses not in the recirculation loop, as shown in Fig. 2, or partial opening of the loop. Unfortunately, partially opening the loop invariably creates some added volume of nickel wastes.

Many membrane-based systems do not recycle part or all of the water; this can avoid rinse purity problems, but risks adding unwanted ions to the bath from the water used for make-up.

Likewise, precipitation does not usually create rinse purity problems, since the water is either not recycled, or the recovery rinse(s) is followed by one or more rinses flowing to a waste treatment system. Ion exchange systems rarely causes rinse problems because they usually recirculate water at much higher rates than are necessary for adequate rinsing, because they work best on relatively dilute solutions.

One way to solve rinse purity problems is by combining two technologies into a hybrid system. An example of this would be to use evaporation for recovery from one or two rinses and then ion exchange for the remaining rinses. While technically feasible, this approach is probably only economical for large plating installations due to the additional equipment costs.

TABLE 3.

IMPURITY

1. Organics

2. Chlorides

3. Borates

4. Nickel

RINSE IMPURITY PROBLEMS MADE WORSE BY NICKEL RECOVERY

PRIMARY CAUSE(S) EFFECT(S) ON CHROME POSSIBLE SOLUTION(S) DRAW BACK(S)

Insufficient Rinsing Poor Rejection '

Poor Coverage

Insufficient Rinsing Disrupts catalyst balance.

Add additional rinse tank(s). Physical space. Lost productivity.

Add make-up water to un- recirculated tank(s) (RO or ED).

Insufficient Rinsing Hazy Appearance Increase rinse flow. or poor rejection. (RO, ED) balance.

Disrupts catalyst

Same as above.

Equipment limitations

High cost. (E) (RO, ED, E, IX)

Insufficient Rinsing Loss of efficiency. Open the loop, 1 or more rinses to waste treatment. (Last resort.)

Some nickel sludge produced.

Hybrid systems, e.g. E/IX, or EIED.

Cost of added equipment. Complexity

RO = Reverse Osmosis .ED = Electrodialysis E = Evaporation IX = Ion Exchange

FIGURE 2. SOLUTIONS TO RINSE IMPURITY PROBLEMS

WITH NICKEL RECOVERY SYSTEMS

A. RINSES NOT IN THE RECIRCULATION LOOP

r--1 high purity water

3 r---- I

NICKEL RINSE RINSE

t RECOVERY

I I I I I I I v

RECOVERY SYSTEM

L------,,--.

recovered nickel

c

B. OPEN LOOP RECOVERY

r--- 1

2 h purity water

I

r--’- 1

U TO WASTE TREATMENT recovered nickel

Another frequently encountered situation which causes rinse purity problems is an undersized recovery system. Since all recovery systems are designed with a specific capacity, they are not always able to accommodate increases in productivity or changes in product mix which increase the dragout volume. Unless an oversized system is purchased initially, any expansion may force the unpleasant prospect of adding additional tanks to the line, opening the loop or buying additional equipment.

Materials balance problems in nickel recovery range from the trivial to the very difficult. Excess acid, heavy metal and organic build-ups, etc. which could also be considered as materials balance problems were treated as impurities instead because they directly interfere with the plating process. Likewise, insufficient rinse flow was considered separately.

Table 4 depicts one non-serious and one very serious materials balance problems to closing the loop on nickel: The volume of recovered nickel solution vs. bath evaporation and the excess of nickel which results from differences in anode and cathode efficiencies.

Ion exchange, reverse osmosis and some other technologies do not produce product solutions with high nickel concentrations. Operations with a high ratio of dragout to evaporation (typically 1:6) usually require supplemental evaporation in order to close the loop.

The most formidable barrier to true, closed-loop nickel recovery, however, is the difference between anodic and cathodic efficiencies in the nickel tank. Simply stated, nickel dissolves 3 4 % faster than it is plated out in most bright nickel plating operations, resulting in an excess of dissolved nickel. Normally, dragout more than compensates for this; however, a high level of recovery will inevitably cause nickel concentrations to rise to undesirable concentrations in the bath.

What this means to the nickel materials balance is illustrated in Fig. 3. A plater who plates 20,000 FT*/day with a thickness of 0.25 mils, will generate the equivalent of over 40 pounds of nickel sulfate per day additions in the nickel tank! Obviously, simply tabulating chemical additions will give only part of the materials balance for nickel. Similarly; the elimination of nickel chemical purchases is not actually an indication of a truly closed-loop system, since large quantities of nickel may still end up as hazardous waste.

Table 4 shows some potential solutions to the nickel balance problem, but no one solution is pre-eminent at this time. Lancy” proposed a combination of precipitation and electrowinning nickel for re-use as anode as a solution to organic contamination problems. This approach would solve the nickel balance problem as well.

Until now, most recovery systems have been designed with the idea of reducing or eliminating nickel chemical purchases, and not specifically to eliminate the generation of nickel hydroxide sludges. Now that the emphasis is changing, many platers are tightening up their operations to reduce the amount of nickel and other metals going to waste treatment. In many cases, they find that these efforts cause the concentration of bath constituents and impurities to rise to such high levels that plating quality is affected and/or the bath may actually crystallize at room temperature. At present, the only solution to this problem is to periodically dump a portion of the bath.

While most platers would like someone to buy this type of solution and recycle it, thereby relieving themselves of disposal costs and liabilities, there are very few people willing to accept this material now. Whether or not viable markets will develop for spent nickel solutions or sludges of this type is not yet certain.

On the other hand, electrowinning nickel for re-use as anodes can allow a plater to be in complete control of the nickel balance, without being dependent upon others. Since electrowinning requires an all sulfate solution, however, and of all the recovery technologies discussed only precipitation/re-dissolution or ion exchange can provide a suitable nickel concentrate, these are the only technologies suitable for this approach.

Since these two are the only demonstrated technologies which also solve sodium and organic contamination problems, any plater who wants to truly close the loop on nickel would do well to investigate them. More importantly, anyone with a nickel recovery system, or anyone considering the purchase of one, should carefully consider what problems may be associated with them and take steps to avoid or minimize them.

TABLE 4. MATERIALS BALANCE BARRIERS TO CLOSED-LOOP NICKEL RECOVERY

BARRIER POTENTIAL SO LUTl 0 N (S) DRAW BACK(S)

1. Volume of Recovered 1. Add supplemental evaporation. 1. cost. Nickel Bath Evaporation

2. Anodic vs. Cathodic 2. A. Plate at lower CD (partial solution). Efficiency

6. Combination of soluble and

C. Same as B., but with cation

D. Electrowin nickel for re-use

insoluble anodes.

membrane isolating insoluble anode.

as anode.

E. Re-use spent nickel to make other commercial chemicals.

2. A. Impractical, lower productivity.

6. Oxidizes organics rapidly causes plating problems.

C. Not demonstrated.

D. Cost of additional equipment.

Requires no chlorides in

Possible economies of

E. Must have sufficient market.

solution; only precip. or IX are suitable.

scale.

FIGURE 3. POUNDS OF EXCESS NICKEL SULFATE

GENERATED PER 1000 FT* OF PLATED AREA*

4 1 EQUIVALENT POUNDS OF NICKEL SULFATE AS

0.1 0.2 0.3 0.4 0.5

THICKNESS PLATED IN MILS

*Based on 40 ASF cathodic current density and 4% difference between anodic and cathodic efficiency.

FOOTNOTES 1, Cadotte, Monteith, and Golomb, “Contaminant Build-Up in the

Plating Bath Resulting from Closed Loop Operation”, Plating And Surface Finishing, (January 1979); pp. 42-48.

2. Tran, T.V., & PB. Clemens, “Recovery of Nickel Salts by Electrodialysis Reversal Process”, Proceedings of the 73rd Annual AESF Technical Conference, (June 1986); TP 334-ST.

3. Steward, F.A., “Conservation and Recovery of Materials and Treatment of Wastes”, in Metal Finishing Guidebook and Directory, (mid January 1981); p. 820.

4. Lancy, L.E., ‘Accumulation of Organic Impurities from Recovery of Nickel Plating Drag-out”, Metal Finishing, (April 1983);

5. Ibid. 6. Nadeau, T. and M. Dejak, “Copper, Nickel and Chromium

Recovery In a Jobshop”, Plating And Surface Finishing, (April 1986); pp. 48-54.

7. Cadotte et. al., Op. cit. 8. Ibid. 9. Mattair, R. and J. Keller, “Closed Loop Recovery of Nickel Plating

Rinse’; Proceedings 75th National Meeting American lnstitute of Chemical Engineers, (June 4, 1973).

10. McNulty, J., R. Goldsmith & A. Gollan, “Reverse Osmosis Field Test: Treatment of Watts Nickel Rinse Waters”, EPA Report No. EPA-600/2-77-039, (February 1977).

11. Lancy, Op. cit.

pp. 27-32.

OTHER REFERENCES 12. Gianelos, L., “Troubleshooting of Nickel Plating Solutions”, Plating

and Surface Finishing, (October 1977); pp. 32-35.

Metal Finishers Waste Reduction Survev I 1. What type of metal finishing operation 5 . Are you currently using a system

are you currently using? Rack - Barrel -

2 . What type of metal finishing process are you currently using?

Electroplating - Anodizing Phosphating Bright dipping Painting Electroless plating Electroformins - Chromate Conversion Other l -

containing one of the following?

Deionization equipment - - Softening equipment 6. If you are using deionized or soft water,

at what point in the finishing process is it utilized?

Bath make-up - Rinsing Cleaning or etching Other

- - -

7. Please rank the following systems in order of importance to you. (1 = greatest, 5 = lowest)

Metals recovery Waste minimization - Water recycling Bath purification Other

- 3. What is your daily water usage level? under 10,000 gallons per day

- 10,000 to 2 5 , 0 0 0 gallons per day - 25,000 to 50,000 gallons per day

50,000 to 100,000 gallons per day 8. What do you think deionized water costs? over 100,000 gallons per day

- -

- less than 1/10 cent per gallon 1 - 4 cents per gallon 5 cents or more per gallon

- - -

4. What type of water recovery or I recycling system are you using?

Evaporation - Electrodialysis

Electrowinnins

- -

Reverse Osmosis Ultra filtration Other None

-

I I COMPANY ADDRESS

TELEPHONE ( 1

ENGINEERED SYSTEMS INCORPORATED

METALS RECOVERY PROPOSAL SURVEY PROSPECT INFORMA TION Company Name Date Address City State Zip Phone ! 1 - Contact Person Title Lead Person on Job Title Salesman Salesman No. Survey conducted on-site by salesman? - yes - no

APPLICATION INFORMA TION 1. What is the name of the process line? 2. What are the customer's objectives?

3. How is the regenerant waste to be handled?

Recover metal from rinse water Recycle rinse water

Return to the process tank Send to Electrowinning Cell Batch treat Remove from site Undefined

PROCESS lNF0RMATlON 4. Nhat does the rinse schematic look like?

Complete the schematic using as much detail as possible. Be sure to s h o w the direction of the rinses and the flow rates if possible. PB - Plating Bath

DOR - Dragout Rinse FR - Final Rinse FFR - Free Flowing Rinse

C - Cleaner

R - Rigse SR - Spray Rinse

DR - Dead Rinse E - Etch

0 1990 Kinetiw Imrpcmted 5/90

SPECIFICATIONS 5. Flow rate of the 1st flowing rinse gpm 6. Metal concentration of 1st flowing rinse - mgll 7. Dragout rate - gph 8. Metal concentration of bath - mgn 9. Metal concentration of stagnant rinse - mgll IO. Type of rinse spray ~ dip. 11. Does the process use .-, rack barrel ~ baskets 12. What is the production rate?

- Square foot per load .-. Number of loads per hour

13. What are the process discharge requirements? Metal concentration - mgA

PH - TDS - PPm

14. Other information

Supplemental Proposal Survey For Nickel Recovergr

1. Name of process l i n e :

hours/day, days /we e k , 2. Operating cyc le : weeks /year .

3. Projected i n c r e a s e or decrease i n product ion %.

4. Attach copy of n i c k e l p l a t i n g b a t h s p e c i f i c a t i o n s , o r l i s t c o n t r o l l i m i t s for:

Nickel t o u n i t s u n i t s

S u l f a t e t o u n i t s u n i t s

Chlor ide t o

PH t o

u n i t s u n i t s

u n i t s u n i t s

Temperature to u n i t s u n i t s

5. Size of n i c k e l t ank X X l ength width - he igh t

6. Are p a r t s p l a t e d on ( c i r c l e o n e ) : racks , b a r r e l s , o t h e r ? I f o t h e r , desc r ibe

7 . Production r a t e i n racks o r b a r r e l s / s h i f t :

=P 8. Average n i c k e l b a t h amperage:

9. Is n icke l t ank a g i t a t e d (Yes/No)?

10. What company's b r igh tene r s o r a d d i t i o n agen t s a r e used?

11. L i s t annual o r monthly consumption and c o s t / l b . f o r :

A. Nickel S u l f a t e a s . / , $ /lb.

B. Nickel Chlor ide lb s . / , $ / l b .

12. L i s t c o s t p e r pound o r p e r g a l l o n f o r :

A. 50% l i q u i d c a u s t i c soda $ /

B. 30% s u l f u r i c $ /

Kinerico Incorporated 10845 Kinsman Road - Newbury. OH 44065 U.S.A.

' K*' I [ ! Engineered Systems Division

13. L i s t t o t a l d a i l y add i t ions of concentrated s u l f u r i c a c i d t o n i c k e l baths:

u n i t s

14. Is t h i s a duplex n i c k e l p l a t i n g process (Yes/No)? NOTE: In a duplex n i cke l process , parts a r e p l a t e d i n 2 o r more n i c k e l

b a t h s i n succession.

15. If a duplex n i c k e l process , inc lude a schematic of a l l n i c k e l p l a t i n g and r i n s e t anks a s s o c i a t e d with them.

16, Is a dragout r i n s e o r any o the r n i c k e l recovery technology i n use ( Y e s / N o ) ?

17. If yes , d e s c r i b e

18. If a dragout r i n s e , how i s it con t ro l l ed (circle one )? Manually Automatical ly

19. Is t h e r e any h i s t o r y of impurity problems i n the n i c k e l b a t h (Yes/No)? (NOTE: Comon impur i t ies a r e i r o n , copper, z i n c , l e a d , calcium,

organics . )

20. I f yes , d e s c r i b e

2 1 . How many f lowing r i n s e s a r e t h e r e between t h e n i cke l t ank and t h e next p l a t i n g ba th o r f i n a l r i n s e tank?

22. I f more than one, how a r e they piped ( c i r c l e o n e ) :

A. Separa te water feed t o each tank.

E. Counterflowed with water feed to l a s t r i n s e only .

2 3 . I f counterf lowed, is the design good o r poor ( c i r c l e o n e ) ? (NOTE: Good des ign has bottom to top water flow i n each t a n k and no s h o r t c i r c u i t between i n l e t and o u t l e t . )

24. Are t h e r i n s e s a g i t a t e d (Yes/No)?

- 25. L i s t r a t e of dragout . (Give b e s t es t imate i n ga l lons /h r . i f unknown.)

26. L i s t p r e s e n t r i n s e flow r a t e of rates.

27. Attach copy of water and sewer b i l l , o r l i s t combined c o s t f o r water and s e w e r p e r M G A L o r p e r MGF.

28. Attach copy of e l e c t r i c b i l l o r l i s t average cost/kwh.

29. Which vo l t age , etc. should system be designed f o r (circle o n e ) ?

120v 240V 240V 480V 1 phase 1 phase 3 phase 3 phase

Kinrico Incorporated - 10845 Kinsman Road. Newbury. OH 44065 U.S.A.

Ea- < "

lm Engineered Systems Division

30 tl

31.

32.

33.

List cost. h a : s ludge d i s p o s a l p e r drum o r p e r t o n including f r e i g h t , S /

L i s t any o t h e r u s e s for which t h e r e is i n t e r e s t i n D I water o r equipment.

Does customer have f a c i l i t i e s f o r n e u t r a l i z a t i o n and s o l i d s removal ( Y e s /No 1 ?

Is a source of D I make-up w a t e r a v a i l a b l e (Yes/No)?

Water Samwles

Please read i n s t r u c t i o n s befoxe t a k i n g samples.

Proper recovery system des ign depends upon good, r e p r e s e n t a t i v e samples. Three samples are needed t o design t h e recovery system, each i s important and should be taken with care.

1.

2.

3.

Tap Water. A one l i t e r sample i s needed. Make s u r e t o run t h e water long enough t o void any volumes which may have been s i t t i n g s t agnan t i n t h e pipes.

F i r s t Flowing Rinse. One p i n t . The flow of w a t e r i n t h i s r i n s e must be accu ra t e ly known or should be measured a t t h e t i m e o f sampling. This sample should o n l y be taken a f t e r a t least t h r e e hours of production and r i n s e flow i n o r d e r t o a c c u r a t e l y r ep resen t normal condi t ions. i f t h e amount of contaminants i n t h e r i n s e is known t o be h igh ly v a r i a b l e , a composite o f t h r e e s e p a r a t e samples taken a t d i f f e r e n t t i m e s is recommended.

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Sample from t h e t a n k immediately preceding t h e f i r s t flowing r i n s e . This w i l l be e i t h e r t h e n i c k e l b a t h o r t h e dragout recovery r in se . ounces maximum.

Four f l u i d

A I L samples should be labeled w i t h t h e following information:

- D a t e - T i m e - Company Name - I n d e n t i t y o f Sample - I n i t i a l s of Sampler

Each b o t t l e shou ld have some a i r space, should be t i g h t l y capped and should have a r i n g of e l e c t r i c a l t a p e wrapped around t h e cap and neck t o p reven t leakage.

The b o t t l e s should then be placed i n a s t u r d y cardboard box l i n e d wi th a p l a s t i c bag c o n t a i n i n g absorbent and cushioning material (such as vermicul i te) .

Kinefico Incorporafeu. 10845 Kinsman Road - Newbury. OH 44065 U S A .