Code No: TMS047 Price: 675 Category: Environment: Recycling
Table Of Contents :
- industry
- Technology options for Recycling of Electronic Nickel solution
- Technology options for recovery of metallic Nickel & Nickel salts from liquid waste
- Technology status in India vis-à-vis the world
- Conclusions, Recommendations, spin-offs of this technology, Recommended Action Plan. Annexure-I Scientist, professional bodies, professionals from related industries contacted Scientists, Professional bodies, Professionals, participants in group discussion, professionals from related industries.
Annexure – II List of concerns which are presently in the manufacture regarding and recovery equipments. Name of concern and Address, References (Bibliography), Glossary
Introduction
Nickel is one of the few items of which entire national needs are met from imports.
The present annual consumption of nickel in India is around 20,000 MT. At the current international price of Rs. 2.3 lacs/Tonnes, about Rs. 460 crores of Foreign Exchange outflow is on account of Nickel imports. The present International Nickel price is US $ 7400/Tonne which works out to Rs. 2.3 lacs at current exchange rate. The landed cost inclusive of Duties to the actual user is around Rs. 380/kg. India’s consumption is about 2.33% of the World Nickel production. Of the total imports, 70% of Nickel is imported from USSR and rest from Canada, Japan and Norway.
At this juncture when our country is facing hard currency crisis, it is very pertinent on the part of TIFAC to explore possibilities for evolving technologies for recycling of Nickel, used in Electroplating, Electroforming and Electrolysis processes carried out in industries. On the basis of the research objectives, assigned by TIFAC, the assignment was carried out during July and November 1991, and the report is being presented.
Scope of the Assignment
As specified by TIFAC, the assignment was to cover Techno-Market Survey on technologies for recycling and reuse of Nickel in Electroplating, Electroforming and Electrolysis industries. It was observed that this sector of industry consumes about 20% of the total Nickel imported in the country, i.e. about 4,000 tonnes per year. Out of this total consumption, about 4% is broadly considered as going waste in the form of sludge, spent wash, Nickel containing solutions, et. It is possible to partly recover Nickel and recycle Nickel containing solutions so as to ultimately reduce relative Nickel consumption in these industries. Even at the initial stage, 25% of the total Nickel going as waste if recovered or recycled, means 40 tonnes of Nickel imports could be reduced at the current consumption levels. This would mean net foreign exchange saving of Rs. 92.0 Lacs. This could be accomplished b y appropriate use of recycling and recovery technologies in select high consumption concerns as well creating group recovery and recycling centres as select locations where several small scale electroplating units are existing.
Methodology
This research was carried out to assess the exact need for recycling and reuse opportunities in India, technologies available in the world and technology status in India, etc., by conducting an exhaustive study based on primary and secondary sources during the assignment.
The primary data was collected by interviewing several technologies in user industries, Research Institutions, product manufacturers and secondary data by referring to publications and research papers available on the subject & related to the subject. The list of persons contacted and secondary sources referred, are mentioned in Annexure I. on completion of draft report a Focus Group Discussion on the subject was arranged at Pune o 21st December 1991. In this discussion the representatives of five concerns participated. The findings of this discussion have been incorporated in the final report. The draft reports was reviewed by the panel of experts through TIFAC and their suggestions have also been incorporated. Back
This report is being presented through six chapters which cover fairly wide gamut of this technology sub–set. The broad aspects covered in this report are as follows:
Outline of Electroplating and Electroforming
Electroplating is method for electrolytic deposition of a layer of superior quality metal on a substance. It has been one of the principle manufacturing methods adopted for metal finishing. Use of Nickel as plating material is one of the several metals used for plating. However, more than 50% of the commercial metal finishing is by using Nickel.
On the contrary, Electroforming is a process similar to electroplating, but it is ionic fabrication of metal product which is directly used as an end product. I this process, electrolytic deposition of metal is achieved on a conductive removable mould or matrix and subsequently the latter part is released from metal coating to get an end product which is made of thin metal layer. The popular applications being manufacture of Nickel screens used for filtration in sugar plants and seamless perforated rotary printing screens used in textile mills.
Electro-winning or Electro fining is a technique used for electrolytic recovery of metals from solutions or melts containing the metal ions. This technique is used for recovery of metals which has many features common to Electroplating. All electrolysis processes use Nickel based salts. The recycling of Electrolysis solutions can lead to reduction in Nickel consumption through these salts.
Therefore, in this Chapter sufficient coverage has been given to highlighting the processes of electroplating, electroforming, equipments used in these processes, methodologies adopted and the role of various chemicals and operating parameters in these processes.
In addition to this, we have given coverage for various methods of Electroplating as it is pertinent to mention that appropriate choice of plating method can result in significant reduction in relative Nickel consumption.
Treatment of Effluents from Nickel Plating Industry
It is pertinent to mention that the waste Nickel discharged through waste water and sludge from electroplating and electroforming industry in U.S.A., is more than the Nickel consumption in India for this sector of the industry. Due to such significant drain of Nickel, the industry in U.S.A., has made rapid strides in evolving methods or recycling Nickel containing solutions and recovery of metal.
In Chapter II, different concepts of treatment of waste water and sludge from this industry have been mentioned.
These concepts of recycling of sludge are, very selectively, being adopted in industry. The reason being, most of the, electroplating and electroforming industries consider waste of Nickel as essential expense of the process and consider recovery as infractions attempt in comparison to their principal business objectives. The process of recovery has not been well established and compact plants are not available so as to easily put in line with the manufacturing route.
However, few concerns have certainly made strides to establish independent units. These units which to lift sludge and Nickel containing solutions at throw away prices and recover nickel for marketing to users who can accept purity levels of 98% to 99.7%. As is known, Nickel of extremely high purity i.e. above 99.9% is required in anode basket of electroplating and electroforming industries. Back
Technology options for Recycling of Electrolytic Nickel Solutions
In Chapter III, various latest methods like Electrolytic Recovery, Ion Exchange, chemical Precipitation, Hydrometallurgy, Evaporative Recovery, Reverse Osmosis, etc., have been discussed and briefly explained as these processes have reached a stage of commercial exploitation for such applications, by concerns in developed countries. These methods are likely to have possibilities of adoption in India, depending upon the quality and quantity of sludge and solutions available for recycling. The emphasis in this Chapter is on technologies of recycling as it amounts to reduction of Nickel consumption. In developed countries recycling is very important as the process water is expensive and several electroplaters do not draw fresh water from public system regularly, but recycle the solution. In India, the fresh water is inexpensive, but certainly all plating chemicals are expensive and it is worthwhile to recycle maximum possible solution to reduce consumption of plating salts and chemicals.
Technology options of Recovery of Metallic Nickel
In Chapter IV, methods of recovery of Nickel from solutions with medium and low concentrations have been discussed. Use of Ion Exchangers, Chemical Precipitation, Electro dialysis have been explained. As none of these methods, have been operated on prototype scale or experimental scale, in India and therefore exact economics of recovery could not be ascertained., as a prelude to the recovery process all solutions/ sludge have to be concentrated. The Ion exchange method is one of the methods being adopted for concentrating dilute solutions. The key factor for prototype and small scale exploitation of this technology would depend on the willingness on the part of large electroplaters to sell Nickel containing sludge ad solutions at reasonable cost of processors and subsequently assure them of supplying this material at the agreed cost without any interruption. The processors may be willing to make investment only if such kind of assured supply is available as they would not be able to source their raw material from any other sources.
Landmarks of Technological Developments in India
It is very well accepted globally, that Indian entrepreneurs are genius and they would not leave any stone unturned where some worthwhile can be recovered from the wastes. Obviously, through available technologies and possible resources, our concerns are not consciously allowing any significant waste of Nickel or Nickel containing solutions.
In Chapter V, we have mentioned about the work done by various institutions and concerns in India, in this direction. Most of the work has been done by new entrepreneurs and research institutions related to this subject. Not much work has been done by industry, as the large ones feel it as an infructuous effort and the Nickel containing salts. Considering the national importance, for conservation of foreign exchange and global concern for waste recycling, the technology development is fairly of paramount importance. In Indian scenario, the recommendations for reducing Nickel consumption is by adopting improved technologies of electroplating and electroforming, adequate training of operating personnel, availability of process literature and making available simple compact units of recycling Nickel containing solutions and recovery of Nickel.
Once this kind of technology is developed, it will have spin-offs in other sectors of industry where metals can be recovered and solutions can be recycled. A futuristic project, in this area could be, recovery of Nickel from electroplated parts, abandoned by users, metal scraps, process rejects etc. if stripping technology is developed, we may be able to recover Rs. 40 to 50 crores worth Nickel annually from scrap. Back
Conclusions
This report provides base line observation for pondering over this aspect for large cross section of metal finishing and electroforming industry. Collective attempt, coordinated by research body like Central Electrochemical Research Institute or IIT is essential for translation of this kind of technology in action.
Though, it does not lead to saving of several billion dollars of foreign exchange, but certainly efforts can lead to annual saving of about half million dollars [Rs. 1.08 crores] of foreign exchange for India, in next three to five years. At the current levels of caption of recovery plant and the metal cost the option of recovery may not be lucrative but at a future date may be after 25 years the technology will become relevant as the Nickel reserve depletion may lead to paucity of virgin metal.
Thus the most important benefit or developing technology routes of recovery & recycling of Nickel will eventually become pacesetter for applications in the several other industries.
