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The production hall for pre-treatment, powder coating and new water treatment.
Sustainable and economical production - this was also the wish of the company ZINKPOWER Coating Schopsdorf in Saxony-Anhalt. The company specialises in the powder coating of steel, hot-dip galvanised steel and aluminium components. The company opted for a VACUDEST vacuum distillation system for the water treatment process.
ZINKPOWER Coating Schopsdorf opened its new powder coating facility in 2016 for components made of steel, hot-dip galvanized steel and aluminium with dimensions of up to 10 x 1.2 x 3.2 meters and unit weights of up to 1.5 tons. The computer-controlled production system guarantees a powder coating in architectural quality that is largely outgassing-free.
The pre-treatment for powder coating of components requires around 4,000 m³ of rinsing water per year. This comes from alkaline or acid degreasing, passivation or VE rinsing. This rinsing water can either be disposed of by a specialist company or conventionally chemically/physically treated and fed into the public networks. Both are cost-intensive and no longer suitable for todays’ sustainable environmental standards.
The VACUDEST L 4.500 Clearcat prepares rinsing water from the pre-treatment and enables recirculation.
Sustainable solution
The wastewater treatment system from H2O GmbH in Steinen in southern Germany improves this. The water treated with VACUDEST vacuum distillation systems is ideally suited for your own processes and can be reused by ZINKPOWER as rinsing water without further consideration. After-treated with an ion exchanger offers the best demineralised water quality and conserves valuable fresh water resources. The contamination remaining during evaporation can be disposed of at minimum cost.
Since the foundation of the ZINKPOWER Group in 1973, ecological aspects have had a decisive influence on the decision and development of the locations. Thus the sustainable commitment to environmental protection and the conservation of natural resources pays off across the board for the owner family. Therefore, and because of the unique technologies of VACUDEST, ZINKPOWER decided for a VACUDEST vacuum distillation system size L 4.500 with Clearcat.
Thanks to energy recycling, VACUDEST vacuum evaporators are leaders in optimising energy efficiency and lowering operating costs.
Crystal clear distillate thanks to Clearcat technology
Vacuum distillation is a very efficient separation process for separating high-boiling impurities from industrial process water. Nevertheless, oils and fats in particular cannot be completely separated by distillation due to certain physical effects and traces are transferred to the distillate. This effect is known to all system manufacturers and can often lead to a clouding of the distillate. Common follow-up treatments are based on coalescence separators and activated carbon stages. In addition to the running costs, there is also the true follow-up treatment.
Not so with the patented H2O Clearcat technology - this guarantees highest distillate quality without the use of the usual follow-up treatment and consumables. This additional option for the innovative VACUDEST vacuum distillation system allows the safe and efficient treatment of industrial waste water containing oil and grease in a single process step.
The operating principle of the Clearcat condensation stage is based on physical and catalytic effects. Therefore, this cutting-edge technology requires neither energy nor auxiliary or operating materials. H2O improves the quality of treated water and sets new standards. The distillate thus becomes absolutely colourless and clear. This also achieves a significant CSB reduction - up to 60 percent better than with conventional distillation systems. In the end, H2O also convinced the responsible employees at ZINKPOWER.
The treated water with and without Clearcat: The clear colour and the high CSB reduction of over 60 percent is what convinced Zinkpower.
Low operating costs
A very decisive factor for the VACUDEST system were the lower operating costs due to the simple chemical cleaning. Hardeners in water and other impurities can coat the heat exchanger and result in increased energy requirements and additional expenditure for maintenance and cleaning. The problem is also known in the home - for example with the electric kettle. With vacuum evaporators, the risk for the formation of deposits is many times higher. Although chemical rinsing equipment can often delay cleaning, it can only completely replace it in a few cases.
The proven Activepowerclean equipment helps here: Activepowerclean represents an equipment development that uses small ceramic beads for continuous heat exchanger cleaning. Due to the natural circulation of the process water in the heat exchanger, the ceramic beads are continuously "boiled along" and clean the surface during the process. So this applies: Coating prevention instead of coating treatment!
Proven quality
The ZINKPOWER Wiener Neustadt already had evaporator equipment in use. Helmut Schieder, production manager, was therefore the project manager for procurement, installation and smooth commissioning of the production in Schopfsdorf. Employees and management are enthusiastic about the performance and treatment with the VACUDEST from H2O. This leads the way for further cooperation.
Author:
Thomas Nadler, Area Sales Manager Bavaria, Austria and South Tyrol
