A thesis submitted in partial fulfillment of the academic requirements for the Degree of M-Tech in Chemical Engineering, Durban University of Technology Durban, 2008. / The waste generated by metal finishers is rated as the most toxic and harmful to the environment. Metal finishing wastewater consists of heavy metals, cyanides, acids and alkalis. Formal treatment of waste generated has not been of primary importance to metal finishers. It would be ideal to develop a generic model to assist finishers to predict the effectiveness of wastewater treatment. The model must be able to predict effectiveness of treatment based on a variety of equipment, chemicals and concentrations. / M

Submitted in fulfilment of the requirements of the egree of Master of Technology: Chemical Engineering, Durban University of Technology, 2011. / The South African electroplating industry generates large volumes of hazardous waste water that has to be treated prior to disposal. The main source of this waste water has been the rinse system. Conventional end-ofpipe waste water treatment technologies do not meet municipality standards. The use of technologies such as membranes, reverse osmosis and ion exchange are impractical, mainly due to their cost and technical requirements. This study identified source point reduction technologies, close circuiting of the electroplating process, specific to the rinse system as a key development. Specifically the application of a low flow counter current rinse system for the recovery of the rinse water in the plating bath was selected. However, the recovery of the rinse tank water was impeded by the low rates of evaporation from the plating bath, which was especially prevalent in the low temperature operating plating baths. This master’s study proposes the use of an induced draft evaporative cooling tower for facilitation of evaporation in the plating bath. For total recovery of the rinse tank water, the rate of evaporation from the plating bath has to be equivalent to the rinse tanks make up water requirements. A closed circuit plating system mathematical model was developed for the determination of the mass evaporated from the plating bath and the cooling tower for a specified time and the equilibrium temperature of the plating bath and the cooling tower. The key criteria in the development of the closed circuit plating system model was the requirement of minimum solution specific data as this information is not readily available. The closed circuit plating system model was categorised into the unsteady state and steady state temperature regions and was developed for the condition of water evaporation only. The closed circuit plating system model was programmed into Matlab and verified. The key factors affecting the performance of the closed circuit plating system were identified as the plating solution composition and operational temperature, ambient air temperature, air flow rate and cooling tower iv packing surface area. Each of these factors was individually and simultaneously varied to determine their sensitivity on the rate of water evaporation and the equilibrium temperature of the plating bath and cooling tower. The results indicated that the upper limit plating solution operational temperature, high air flow rates, low ambient air temperature and large packing surface area provided the greatest water evaporation rates and the largest temperature drop across the height of the cooling tower in the unsteady state temperature region. The final equilibrium temperature of the plating bath and the cooling tower is dependent on the ambient air temperature. The only exception is that at low ambient air temperatures the rate of water evaporation from the steady state temperature region is lower than that at higher ambient air temperatures. Thus the model will enable the electroplater to identify the optimum operating conditions for close circuiting of the electroplating process. It is recommended that the model be validated against practical data either by the construction of a laboratory scale induced draft evaporative cooling tower or by the application of the induced draft evaporative cooling tower in an electroplating facility.

published_or_final_version / Environmental Management / Master / Master of Science in Environmental Management

This study involved an assessment of the Pietermaritzburg Waste Minimisation Club (PWMC) during 2001, and a waste minimisation audit conducted at two coil coating lines. Waste minimisation is the reduction or elimination of waste at source4 • It is often achieved through waste minimisation clubs which comprise a small number of companies, generally in the same geographicaI area, that are interested in reducing waste 1"711 . The success of the PMWC was evaluated in terms of the degree to which members implemented waste minimisation principles. Two questionnaires were used to assess the success of the club. These indicated that although the training material gave the members a good understanding of the basic principles of waste minimisation, the material has not given the members enough practical information to implement a waste minimisation programme in their companies. The main barriers to waste minimisation identified include production pressure, operational constraints, lack of human resources and a lack of management time. The drivers for waste minimisation were financial savings, improved plant utilisation and improved environmental performance. Coil coating is a continuous process where a coiled sheet of aluminium is cleaned, pretreated and coated with paint. The flow rates, compositions and costs of all input and output streams to the cleaning and pretreatment sections were gathered from operators or measured. The data were collected over a three-month period to obtain a representative sample, and then analysed to determine waste minimisation opportunities using mass balances, monitoring and targeting, a scoping audit and a true cost of waste assessment. The scoping audit was found to be the most useful technique because it accurately prioritised the waste minimisation opportunities but required a relatively small amount of data for its application. However, the scoping audit underestimated the savings that could be achieved at the coil coating department and therefore the 'scope to save' percentages, which were developed for United Kingdom industries, need modification to better reflect South African industry. Opportunities for waste minimisation on Coil Coating Line 1 (CCL1) included reducing the water consumption, reducing the acid and chromium raw materials consumption, and finding a cheaper energy source for heating the process and rinse tanks. Potential fmancial savings of R116 000 and environmental savings of 18 200 kL of water or effluent per year were calculated for CCL1. The chromium and acid effluent treatment and solid waste disposal are the main areas for waste minimisation on Coil Coating Line 2 (CCL2). Savings could be achieved in these areas by using roller application ofthe chromium pretreatment rather than spray application, and by preventing a leak of chromium pretreatment into the acid process and rinse tanks. Other savings can also be achieved by operating the chromium process tank as a fed-batch process, and operating the alkali and acid process tanks as continuous processes at the specified chemical concentrations and with recycle of the rinse water (dragout). The total financial savings that can be achieved on CCL2 are R5.3 million, and potential environmental savings are 31 600 kL ofeffluent per year. / Thesis (M.Sc.)- University of Natal, Pietermaritzburg, 2002.

Take care how you place your moccasins upon the earth, step with care, for the faces of the future generations are looking upfrom the earth waitingfor their turnfor life - Lyoru, 1988 Increasing levels of pollution and the increase in demand for water and other resources by industry led to a number of policies and regulations being developed and revised in South Africa. According to the Constitution of the Republic of South Africa (Act 108 of 1996), everyone has the right to an environment that is not harmful to health or wellbeing. In order to have the environment protected and sustained for future use, it became necessary to move away from the traditional fragmented approach to pollution and waste management and focus on an integrated strategy aimed at achieving a balance between ecological sustainability and socioeconomic development. In the Durban Metropolitan Area (DMA) , the Durban Metropolitan Council (Metro) incorporated pollution prevention in their bylaws, which contained stringent discharge limits for heavy metal concentrations. This posed a potential problem for metal fmishers who were concerned about complying with these discharge standards. In addition, the metal finishing industry was considered to be a significant contributor to the pollution load in the DMA, and therefore needed to find suitable solutions to dealing with environmental problems, especially waste management. Waste minimisation was believed to be a good tool for this industry to utilise in order to reduce its pollution load. It was seen from the literature and case studies from international initiatives that waste minimisation results in an improvement in process efficiency and reductions in production costs and environmental impacts, generally at minimal costs. A waste minimisation club was initiated for the metal finishing industry in the DMA in June 1998. The club consisted of twenty-nine members of which the majority were small and medium sized companies. The club was run over a period of thirty months. A core group of sixteen companies actively participated in the activities of the club. During the period of investigation, a total of 391 waste minimisation options were identified for club members and 147 of these options were implemented. This resulted in a total financial saving in excess of R 4 million for the duration of the club's existence. The saving represents combined savings in water, chemicals, metals, energy, effluent treatment, and waste disposal. Corresponding environmental benefits were achieved including a reduced demand for water, reduced toxicity of effluent from chemical and metal reduction, and a reduction in energy requirements. Four companies were investigated in detail and presented as case studies. These companies showed that the payback on implementing waste minimisation options was mostly immediate. The size of the companies was not critical in determining the level of success from running waste minimisation programmes. Success depended mainly on commitment from companies and motivation of project champions. It was found that the greatest barriers to implementing waste minimisation, as identified by companies, were a lack of time, resources, and commitment. Companies joined the club mainly for benefit of reducing costs and complying with legal standards. Aside from successfully raising awareness and promoting the concept of waste minimisation, the waste minimisation club also resulted in an improvement in the relationship between the metal finishing industry and the Metro, and among club members. Based on the results achieved by club members, and from managing the club, it was evident that the club was effective in promoting waste minimisation in industry. For the future running of clubs, it is recommended that waste minimisation assessment training be given to all employees of a company. It would also be more useful if companies reported savings on a more regular basis and more formally. In addition it is recommended that club membership should be limited to between ten and fifteen companies to facilitate improved management of the club. / Thesis (M.Sc.Eng.)-University of Natal,Durban, 2002.