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Case Studies: Steel Parts: Replacing cyanide salts in the cementation process
| Steel Parts: Replacing cyanide salts in the cementation process
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INTRODUCTION
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The company is involved in the machining and assembly of power transmission components. The cementation process protects manufactured geared wheels, cogwheels, gearing and axles from friction and corrosion. Cyanide salts are used as a fuel medium, which involves the production of molten salts as well as the production of corrosive vapours that damage the facility’s metal structure. The company made the changes because of the possible environmental impacts associated with the handling and storage of cyanide salts, the complexity of the resultant special waste element?s inertization treatment and the effects of cyanide salt use on working conditions.
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FINANCIAL DETAILS
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Investment Amount:
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US $180,748 |
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Estimated Time to Recover Investment:
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36 month(s)
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Estimated Life Cycle of the Investment:
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15 years |
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Finance Sources:
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N/A |
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TECHNOLOGY
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Technology Used:
Instead of using the cyanide salts, the reductive gas is produced by a hydrocarbon-controlled drip system that, when ignited within a furnace chamber, produces the cementation or reductive atmosphere. The change from cyanide salts to the hydrocarbon required the redesign and replacement of the cementation ovens and their heating systems and of the tubing and control units. Once the required cementation depth is achieved in this new system, the part goes to the production line, avoiding the use of a tempering stage.
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Technology Provider:
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| TECHNOLOGY FEASIBILITY ANALYSIS: |
Technical feasability analysis:
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Economic feasability analysis:
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Environmental feasability analysis:
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Environmental assessment:
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ENVIRONMENTAL BENEFITS
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Benefits: Reduced Greenhouse Gas Emissions, Reduced Water Pollutants, Reduced Land Pollutants
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Details:
Annual savings:
cyanide salts: 3,349 kg (7,383 pounds), or 100% elimination;
related process wastes: 2,850 kg (6,283 pounds), or 100% elimination;
electricity consumption: 346,950 kWh, or 75% reduction.
The reductions were concurrent with the annual consumption of new inputs:
methyl alcohol: 820 l (213.2 U.S. gallons);
natural gas: 18,725 m3 (24,491 cubic yards).
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