Recognising challenges and ensuring operational safety. This is the job of the application centre for zero liquid discharge technology from Steinen, which has been consistently implemented at Werner Gießler.
Werner Gießler GmbH is a mid-size company in the metal-processing industry and delivers about three million parts monthly throughout the world. Founded 45 years ago in Elzach as a small business, the family company has developed into a specialist in the manufacturing of complex turned parts according to customer specifications in medium to large quantities. Seven days a week, milling, grinding, honing, and turning are conducted in three shifts.
Gießler turned parts are especially used in the automobile industry. As the sole supplier of individual components for diesel injection systems by Bosch, Gießler is a global market leader and innovator. These components are installed around the world in 70 percent of diesel injection truck engines. However, this market leadership also demands the utmost quality and dependability.
The internally developed chemical deburring system and other special-purpose machines, such as the 100-percent control systems are key factors in the success of the company, in addition to independently working employees. With the use of waste heat from production, the utilization of efficient cooling systems, and the decision to set up zero liquid discharge production, the managing partners have proven their commitment to environmentally conscious, resource-conserving production.
Since the beginning of 2011, Gießler has been using the vacuum distillation of H2O GmbH. A VACUDEST M 1.050 has been treating rinse water from chemical deburring since that time. Due to the capacity expansion of the deburring system, the amounts of process water have constantly increased, meaning that a decision was made to expand treatment capacity at the beginning of 2014.
The requirements and experiences were precisely defined by Markus Bayer, Head of Automation, and Christian Nemeth, Head of Special Mechanical Engineering:
• Material level 2, which withstands fluoride exposure
• Automatic as well as manual operation
• Operational safety
• Control system with remote access
• Process support
• Maintenance by the manufacturer ensured
The experiences of customer in treating process water from chemical deburring were optimally included in the specifications for a more high performance VACUDEST L 4.500.
The application centre analysed and optimised the process:
Chemical deburring with CULLYGRAT® as a current-less dipping method for fine deburring and smoothing of workpiece edges and surfaces places increased demands on water treatment and recycling. Chemical deburring removes material over the entire wetted surface of a workpiece by means of chemical dissolution. After deburring, the parts are rinsed with water in several steps in order to clean off the chemical. Here, the concentration of the deburring chemical in the rinse water is increased due to carryover. It was this situation in particular that placed increased demands on an overall concept.
The tests in the application centre of H2O GmbH provided important insight. It was discovered that no process reliability can be ensured without breaking down the H2O2 (hydrogen peroxide). The concept provided for a neutralisation system and a three-phase separator. This would prevent corrosion damage of the VACUDEST and the failure of key components. Without this targeted engineering, reliable process water treatment would not have been possible for the customer.
The process must be adapted to the requirements:
The experience of H2O GmbH and the examination of the overall process were the key to success here. A VACUDEST with the possible modules can only function as well as the team consisting of application engineers, chemical engineers, and designers assembles it. Werner Gießler GmbH benefits from this.