Chapter 2 - EnvProcE - WS2022 - Part 2

BUILDING, ENERGY & SOCIETY
Master programme: Energy and Transport Management
Example
Automotive Industry
(Metal Processing Industry)
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Automotive Industry
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Source: ACEA, The Automotive Industry, Pocket Guide 2022/2023
Automotive Industry (passenger car production)
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Automotive Industry (new car registration)
78
Automotive Industry (new vans)
79
Automotive Industry (new trucks)
80
Automotive Industry (direct manufacturing)
81
82
83
84
Automotive Industry (indirect manufacturing)

Indirect manufacturing
➔ Rubber tyres and tubes
➔ Computers peripheral equipment
➔ Electric motors, generators, transformers
➔ Die-cast products
➔ Bearings, gears, driving elements
➔ Colling system, ventilation system
➔ ………
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Aluminium Die-Casting
Aluminum is a lightweight alloy which processes
high dimensional stability in complex shapes and
design with thin walls.
Aluminum can withstand high operating
temperatures, offers good corrosion resistance and
versatility (products with complex shape/form can
be produced).
86
The liquid aluminium is injected at high speed and high pressure into a
metal mould (Die). The dies are very expensive, whereby pressure die-
casting is economical only for high-volume production
Energy is needed for aluminium melting and its maintenance in a molten

state.
Water is primarily used for cooling purposes but also as carrier medium for
water soluble release agents.
These release agents are highly responsible for the casting quality, the
surface finish, the ease of cavity fill and the ease of casting ejection. They
can also speed up the casting rate, reduce maintenance requirements and
reduce the accumulation of material on the face.
High Pressure Die-Casting
87
Aluminium Die-Casting release agent sprayed on the die waste heat collector
between each shot stack
product liquid aluminium

downstream delivery
processes
wastewater
treatment excess release agent
rejected pieces
88
Relevant cost factors (water related)
➔ Chemicals (release agent)
➔~ 18 t/a
➔ Hydraulic oil (die casting)
➔~ 54 t/a
➔ Process water (deionised water)
➔ Wastewater (indirect discharge)
➔~ 15 m³/d
➔~ 3,500 m³/a
89
Analysis Wastewater (raw wastewater)

Legal basis:
https://www.ris.bka.gv.at/GeltendeFassung.wxe?Abfrage=Bundesnormen&Gesetzesnummer=10010939
5,2
15 m³ wastewater / day
36 t aluminium per day
90
Legal Basis
Project: Integration of wastewater treatment (pre-treatment) to fulfil discharge limits for indirect discharge (facility:
processing of non-ferrous metals (aluminium)
Legal basis:
Key parameter for type of wastewater treatment

facility and technical configuration
91
Chemicals/Impurities released ….
……… to wastewater, i.e. ?
https://echa.europa.eu/de/
92
Excursus - Safety Data Sheets (SDS)

A safety data sheet, or SDS, is a standardized document that contains occupational safety and health data.
The International Hazard Communication Standard (HCS) mandates that chemical manufacturers must communicate a
chemical’s hazard information to chemical handlers by providing a Safety Data Sheet.
SDS's typically contain chemical properties, health and environmental hazards, protective measures, as well as safety
precautions for storing, handling, and transporting chemicals.
Safety data sheets have sixteen sections.
The early sections, one through eight, focus on quick access to essential information that might be required by chemical
handlers for safe handling practices or by emergency response personnel.
Sections nine through eleven contain technical and scientific data, e.g., stability, reactivity, physical & chemical
properties.
Sections twelve through fifteen are not mandatory; however, they are required to be fully GHS compliant.
The last section, section sixteen, contains information about the SDS itself, e.g., the revision date and changes since the
last version.
93

H Codes & Phrases
➔ H stands for ‘hazard statement’; n=2 for physical hazards, n=3 for health hazards,
and n=4 for environmental hazards; and xx is a sequential numbering scheme,
e.g.
➔ H220: extremely flammable gas
➔ H302: Harmful if swallowed
➔ H400: very toxic to aquatic life
P Codes & Phrases
➔ P stands for ‘precautionary statement‘; n=1 for general, n=2 for prevention,
n=3 response, n=4 storage, n=5 disposal precautionary statement; and xx is a
sequential numbering scheme, e.g.
P102: Keep out of reach of children
P260: Do not breathe dust or mist.
P314: Get medical advice/attention if you feel unwell.
P404: Store in a closed container.
P501: Dispose of contents/container to …
94
95
Selecting Appropriate (Wastewater) Treatment System

➔ Possible decision path for finding the appropriate wastewater
treatment system for the individual wastewater streams
➔ The presence of impurities/pollutants in the wastewater affects
the choice and the design of the system
➔ The targeted concentration needs to be considered
96
Process Overview – Industrial Wastewater Treatment

aerobic:
biological
activated sludge or biofilm
anaerobic
chemical oxidation
precipitation
chemical
ion exchange
Detoxification
Adsorption (Activated Carbon)
sedimentation
flotation
physical
filtration
electrodialysis
centrifugal separation
evaporation
thermal
destillation 97
Wastewater Treatment – Evaporation

aerobic:
biological
anaerobic Pollutants targeted

chemical oxidation
➔ Complex wastewater with low quantity
precipitation
chemical
ion exchange
Description
Detoxification ➔ Evaporation of wastewater is a distillation process where
Adsorption (Activated Carbon) water is the volatile substance, leaving the concentrate as
sedimentation
bottom residue to be disposed of.
flotation
physical
filtration
electrodialysis
evaporation
thermal
destillation 98
Vacuum Evaporator
The aim of this operation is to reduce the volume
of wastewater or to concentrate mother liquors.
The volatile steam is collected in a condenser and
the condensed water is, if needed after
subsequent treatment, recycled.
Evaporation is normally a wastewater free
process, because the condensate will be recycled
– with or without further treatment – and the
concentrate will be recycled or disposed of as
waste, e.g. by incineration.
99
Pilot Tests Vacuum Evaporation
1 m³ container
distillate
Emission Limit ?
1 m³ container
concentrate
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Large Scale WWTP
yearly energy demand?

yearly energy costs?
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Vacuum Evaporation - Possible System Solutions
Coalescers
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Coalescers
1. Oil micro-drops accumulate at the lamella
surface
2. Drops meld and form bigger drops
3. Bigger oil drops are rising faster to the
surface
4. The floating oil overflows into a collection
tub and drains
5. The de-oiles phase dicharges over a weir
103
Wastewater treatment – Filtration

aerobic:
biological
anaerobic Pollutants targeted

chemical oxidation
➔ Suspended solids and particulate-bound metals
precipitation
chemical
ion exchange
Description
Detoxification ➔ The separation of solids from wastewater by passing them
Adsorption (Activated Carbon) through a porous medium, e.g. sand filtration,
sedimentation
microfiltration and ultrafiltration.
flotation
physical
filtration
electrodialysis
evaporation
thermal
destillation 104
Example - Application Ultra-Filtration
Source: https://www.waterdropfilter.com/blogs/buyers-guides/guidence-
for-chosing-an-uf-system
105
Pilot Tests Membrane Filtration (UF)
1 m³ container
discontinuous feeding
Membrane
Pipe-Module, cut-off 100 kDa
surface area 0.82 m²
Filtrate – Ultrafiltration (UltraCut)

➔COD reduction: 77% (~ 5,000 mg/l remaining)
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Pilot Tests Membrane Filtration (UF)

glycolic substances – Leaks in the hydraulic
system of die-casting devices can lead to a
consequent transport of the leaked liquid into
the water system and therefore to the presence
of glycols in the excess release agent. These
glycolic substances can not be removed by the
technology of ultrafiltration, as their molecular
weight requires a cut off size < 100 Da
(0.001µm) ; glycolic substances in the excess
release agent can lead to product quality
problems when used again without adequate
Source: Melin, Th., Rautenbach, R. (2007): Membranverfahren –
Grundlagen der Modul- und Anlagenauslegung. 3., aktualisierte und treatment
erweiterte Auflage, VDI-Buch, Springer Verlag, Berlin, 2007; eigene
Ergänzungen 107
Alternative – Forward Osmosis (Emerging Technology)

Instead of high pressures, forward osmosis (FO) uses the
natural process of osmosis
➔ in osmosis, two liquids are separated by a semi-
permeable membrane, which is only permeable to
water
➔ If the two liquids have different salt concentrations and
thus different osmotic pressures, water begins to
diffuse through the membrane quasi automatically due
to the difference in osmotic pressure (Δπ) until an
equilibrium is reached and both liquids have the
identical salt concentration 108
Alternative – Forward Osmosis (Emerging Technology)

➔ In forward osmosis, the osmotic pressure difference is
used technically
➔ Water diffuses form a feed solution (with low osmotic
pressure) into a draw solution with a high osmotic
pressure
➔ the draw solution can be regenerated after forward
osmosis, i.e. the final product is clean water suitable for
reuse and the draw solution can be recycled
➔ Concentrate can be discharged external or regerated
➔ Energy demand (FO alone): ~ 0.25 kWh/m³ ➔ Feed solution is concentrated
➔ Draw solution is diluted
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Forward Osmosis - Possible System Solutions
Source: A.Haupt (2020): Application possibilities and performance for forward osmosis in industrial water management, Dresdner Berichte 46
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Possible System Solution

max. 15 m³ per day
(raw wastewater)
external discharge
Reverse Osmosis
Draw Solution (e.g.
NaCl, CaCL2, ….. )
Indirect discharge or
recycling
111
Pilot Tests Forward Osmosis
Emission Limit ?
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Activity 3: Emerging technologies for wastewater treatment

Task: Have a look on emerging technologies for wastewater treatment. Evaluate possible applications
within the fields of industry, energy production or resource recovery (e.g. treatment wastewater
through algae; phosphorus recovery from wastewater; ammonia recovery from wastewater;
membrane distillation; aerobic granular sludge process; …………….
Reaction: Summarize your findings (group A, B, C, D, E) on some ppt pages and upload them on
Moodle. Be prepared to present your results during next lecture (10 – 15 min).
Submission date: 07.11.2022, 08:00, via virtual campus, upload by team leader
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BUILDING, ENERGY & SOCIETY

Master programme: Energy and Transport Management

Automotive Industry (passenger car production)

Automotive Industry (new car registration)

Automotive Industry (new vans)

Automotive Industry (new trucks)

Automotive Industry (direct manufacturing)

Automotive Industry (direct manufacturing)

Automotive Industry (direct manufacturing)

Automotive Industry (direct manufacturing)

Automotive Industry (indirect manufacturing)

Energy is needed for aluminium melting and its maintenance in a molten

product liquid aluminium

Analysis Wastewater (raw wastewater)

Key parameter for type of wastewater treatment

Excursus - Safety Data Sheets (SDS)

Excursus - Safety Data Sheets (SDS)

Excursus - Safety Data Sheets (SDS)

Selecting Appropriate (Wastewater) Treatment System

Process Overview – Industrial Wastewater Treatment

Adsorption (Activated Carbon)

Wastewater Treatment – Evaporation

anaerobic Pollutants targeted

Pilot Tests Vacuum Evaporation

Large Scale WWTP

yearly energy demand?

Vacuum Evaporation - Possible System Solutions

Wastewater treatment – Filtration

anaerobic Pollutants targeted

Example - Application Ultra-Filtration

Pilot Tests Membrane Filtration (UF)

Filtrate – Ultrafiltration (UltraCut)

Pilot Tests Membrane Filtration (UF)

Alternative – Forward Osmosis (Emerging Technology)

Alternative – Forward Osmosis (Emerging Technology)

Forward Osmosis - Possible System Solutions

Possible System Solution

Pilot Tests Forward Osmosis

Activity 3: Emerging technologies for wastewater treatment

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