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Sps Conferenc Essen 2009 Stenum Fresner


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Sps Conferenc Essen 2009 Stenum Fresner

  1. 1. ZERMEG Zero Emission Retrofitting Method in Z E i i R t fitti M th d i Galvanizing industry Dr. Johannes Fresner gefördert aus Mitteln der Fabrik der Zukunft (
  2. 2. STENUM GmbH  Environmental consulting and research company – National and international  Field of Work: – Consulting, research and training in the field of cleaner production, process optimisation and sustainable development – Eco-efficiency: energy, material, waste and water management – Environmental management systems according to ISO 14001 and EMAS g ZERMEG
  3. 3. The approach of ZERMEG I Calculation of ideal minimum consumption •Numerical model of ideal minimum consumption. p •Gap analysis. •Identification of options. ZERMEG
  4. 4. Pickling plants: Initial situation Identified losses:  High drag out  No defined rinsing criterium  Insufficient control  Over flow  Early dumping  Not exact dosage of chemicals g  Bad mixing  Bad removal of oil, grease and solids g  Violation of procedures  Inadequate rinsing technology or procedure ZERMEG
  5. 5. Results - overview ZERMEG
  6. 6. Example: A Heuberger A.Heuberger Specific water consumption at Anodisieranstalt Heuberger 1,2 1 0,8 0,6 0,4 0,2 02 0 1996 1997 1998 1999 2000 2001 2002 2003 ZERMEG
  7. 7. Example: A Heuberger A.Heuberger  Specific water consumption was reduced by 95%  Specific consumption of natural gas was reduced by 50%  Specific consumption of chemicals was reduced by 20%  P d ti i Production increase t 300% to  Rate of mistakes reduced to <<1% ZERMEG
  8. 8. ZERMEG II  TRIZ based  Uses function modelling (related to natural language)  Uses Ideal Final Result and backcasting  Uses „Trimming“ questions „Trimming ZERMEG
  9. 9. Flow chart plus IFR: brainstorming function modell CURRENT IDEAL SITUATION S O FINAL RESULT Current Intermediate Function achieved Design … solutions without cost or harm Set of questions: brainstorming Source: Support manual, Jantschgi, Mann, Grawatsch 2003 ZERMEG
  10. 10. Simple function model of pickling and rinsing f i kli d i i crane c ane holds rack ack holds part pa t holds holds controls film oxide dissolves dilutes deactivates operator water opens bath releases valve generates Waste water Spend bath ZERMEG
  11. 11. Trimming questions g  Can components or functions be eliminated?  Can the need for a function be eliminated?  Can functions of other components or the components themselves be taken over?  Can unwanted functions be eliminated by y other functions?  Can components be replaced by other components?  Can components be replaced by existing resources?  Can the system take over functions itself?  Can freely available resources be used? y ZERMEG
  12. 12. Results:  Omax Orient, Union Steel, Omax, Orient Steel Austria Buntmetall : -30% water 30%  Austria Email: -50% water, sulfuric acid: -75% lf i id 75%  SKM Leiterplatten: -30% water  Adapted to the textile p industry ZERMEG
  13. 13. Awards National Award for environmental and energy technology 2008 in the category: „Environmental technology and Environmental environmental services“ STENUM was nominated as a finalist for the awards: – ÖGUT Umweltpreis 2007 – Austrian Constantinus, Category „Management Consulting“ – Fast Forward Award Styria – Energy Globe ZERMEG
  14. 14. Thank you very much for your attention ! STENUM GmbH Geidorfgürtel 21 A- 8010 Graz Tel.: +43 316 367156-0 Fax: +43 316 367156-13 E-mail: