Course work: galvanic production. Calculation of pollutant emissions from the welding section Department of Industrial Ecology

16.12.2023

To give metal products protective, protective and decorative functional properties that ensure reliable, long-lasting operation in various operating conditions, as well as to restore parts selected with relatively little wear, chemical and electrochemical coating processes play an important role.

Electrochemical (galvanic) coatings are widely used in the restoration of parts selected for relatively low wear.

Electrochemical methods produce coatings with zinc, cadmium, copper, chromium, and nickel. In mechanical engineering and instrument making, electrolytic deposition of copper, zinc, cadmium, silver and gold in baths is used.

The variety of galvanic and chemical processes, the use of chemicals, and temperature conditions determine the variety of qualitative and quantitative composition of released pollutants and their states of aggregation.

Technological processes of electrochemical application include a number of sequential operations: etching, grinding, chemical degreasing, coating.

All these operations in the production of metal coatings are accompanied by the release of various pollutants into the indoor air and atmosphere. Solutions of cyanide salts, sulfuric, chromic and nitric acids, etc. are particularly toxic.

Target: according to the given conditions, carry out a project for general ventilation to protect the atmosphere from emissions of pollutants during the application of metal coatings using the galvanic method.

Initial data:

1.Process - applying metal coatings by galvanic method (electrochemical method)

2. Application in the project of on-board suction (one-sided) with pressurization

3.The width of the stationary bath is 1000 mm. Fixed bath length 1500 mm

4.The temperature of the acid in the stationary bath is 18 C°.

2. Impact of galvanic production on the environment

Of the large volume of industrial emissions that enter the environment, mechanical engineering accounts for only a small part - 1-2%. This volume also includes emissions from enterprises in military-oriented industries and the defense industry, which is a significant part of the machine-building complex. However, machine-building enterprises have basic and supporting technological production processes with a very high level of environmental pollution. These include: in-plant energy production and other processes associated with fuel combustion; Foundry; metalworking of structures and individual parts; welding production; galvanic production; paint and varnish production.

In terms of the level of environmental pollution, the areas of electroplating and dyeing shops of both mechanical engineering in general and defense enterprises are comparable to such major sources of environmental hazard as the chemical industry; foundry is comparable to metallurgy; territories of factory boiler houses - with areas of thermal power plants, which are among the main polluters.

Thus, the engineering complex as a whole and the production of defense industries, as its integral part, are potential polluters of the environment: airspace; surface water sources; soil.

With all the diversity of sub-sectors of mechanical engineering, including military-oriented, defense enterprises, according to the specifics of environmental pollution, they can be divided into two groups: resource- and knowledge-intensive. Features of knowledge-intensive sub-sectors of mechanical engineering: their low material and energy intensity, low water consumption and significantly lower emissions of pollutants into the environment compared to resource-intensive ones. These sub-sectors and industries are characterized by a small emission into the atmosphere of such traditional mass pollutants as sulfur dioxide, nitrogen dioxide, etc., but at the same time other pollutants are emitted that are not so typical for resource-intensive branches of mechanical engineering. Recently, resource-intensive sub-sectors have prevailed over knowledge-intensive ones. The share of enterprises with galvanic production accounts for 15-20% of total atmospheric pollution from industry, which amounts to more than 10.3 million tons of harmful substances per year,

Environmental safety of the atmosphere, minimization of pollutant emissions can be ensured by the use of pollutant neutralization methods or the use of non-waste technologies, as well as the development of treatment facilities.

4 . Description of the general ventilation circuit

The most effective means of combating harmful substances in ventilated areas is to remove them at the point of release using exhaust systems. However, this is not always possible, for example, when places where people are located or sources of harmful emissions are located throughout the entire area of the premises. In such cases, general ventilation is arranged, when harmful substances are diluted to maximum permissible concentrations due to the influx of fresh air. In accordance with this, general ventilation systems must include a device for air intake, processing, transportation, and also for exhaust air removal. To prepare products for coating, stationary baths are mainly used.

Industrial baths are open tanks, most often quadrangular in shape, filled with liquid with various solutions, often very toxic.

Plating baths are made mainly of stainless steel and, if necessary, lined with various insulating materials.

The solutions contained in the baths, evaporating, spread throughout the room and thereby pollute the air in it. Harmful substances from production baths can be released in the form of vapors, gases and “hollow drops”, which are gas particles enclosed in a liquid shell. These drops, rising upward, are carried out of the bath and, bursting, mix with the air in the room. In ventilation practice, a suction device along the sides of the bath in the form of a continuous slit, called a side suction, has become widespread. For vigorous suction of harmful vapors into the slot of the on-board suction, blowing from a compressed air network is used . The use of blower makes it possible to reduce the influence of extraneous air currents in the room on the stability of the flow of gaseous pollutants to the receiver and reduce air consumption. The contaminated air then enters the filter . The filter purifies the air from aerosol particles of acids. The filter is equipped with a condensate collection pan, where condensate accumulates after air purification. It passes through the pipeline into a container for collecting condensate. From the filter, the air, cleared of sulfuric acid vapors, enters the air duct (corrosion-resistant stainless steel) using a fan. Through a hole in the ceiling in the general ventilation system, air is released into the atmosphere. To prevent precipitation from entering the ventilation, a ventilation umbrella is installed on the roof.

5.Equipment for electroplating

5.1 Stationary bath

To prepare products for coating, stationary baths are mainly used.

All parts subjected to chemical or electrolytic processing are divided into three complexity groups:

1.Plates and cylindrical parts (without thread)

2.fasteners, embossed, stamped parts without cavities in which the solution (electrolyte) can be retained

3. parts with blind holes in which the solution (electrolyte) is retained, for example, a glass with an internal thread, as well as parts with difficult-to-wash areas

Products are degreased in welded rectangular baths made of sheet steel. Degreasing baths are in most cases heated and have special ventilation devices. The baths are equipped with special “pockets” devices for removing foam and oil from the surface of the solution.

For etching copper and its alloys, ceramic baths equipped with ventilation devices are used.

Baths for electroplating are made mainly of steel and, if necessary, lined inside with various insulating materials. For acidic electrolytes, vinyl plastic is used for the internal lining. They are used for acid galvanizing, tinning,

5.2 Side suctions

Onboard suctions are used in cases where the large dimensions of the equipment or the technology for processing bulky parts do not allow the installation of fume hoods or other complete shelters. Side suctions are widely used in galvanizing shops, for degreasing and pickling of metal, for anti-corrosion and decorative coatings, which include the processes of galvanizing, chrome plating, nickel plating, etc.

Onboard suctions are located near the production baths. Industrial baths are open tanks, most often quadrangular in shape, filled with liquid with various solutions, often very toxic.

The most appropriate solution to the issue from a ventilation point of view should be to completely cover the bathtub or enclose it in a casing in the form of a fume hood with suction from it of such an amount of air that would prevent the penetration of harmful substances into the room. However, for technological reasons, this is extremely rarely possible, so in ventilation practice, a suction device along the sides of the bath in the form of a continuous slot, called a side suction, has become widespread.

Types of suction from baths. When the bath width is up to 0.7 m, single-sided suctions are used, arranged on one of its longitudinal sides. When the bath width is more than 0.7 m (up to 1 m), double-sided suction is used. In addition to the width, in this case the size and configuration of the product are important: if the product protrudes above the surface of the liquid in the bath, then in this case, regardless of the width of the bath, a double-sided suction is installed. Side suctions are called simple if the plane of the slit is vertical, or inverted when the plane of the slit is horizontal, i.e. facing the bathroom mirror. To avoid reducing the width of the bath when using inverted suction, you can shape it. To ensure uniform air suction through the slot, continuous side suction units are given a wedge-shaped shape. Standard section lengths from 500 to 1000 mm. The slot width is assumed to be in the range of 40-100 mm. Since acids and alkalis have a corrosive effect on metal, side exhausts should be made of materials that are resistant to corrosion, for example, vinyl plastic. If steel is used to make suction devices, then it should be taken with a thickness of at least 3 mm and coat both sides with anti-corrosion varnish. The same requirements must be applied to the materials of the air ducts that suck air from the baths.

Simple suction should be used when the solution level in the bath is high, when the distance from the suction slot is no more than 80 - 150 mm. The more toxic the harmful emissions from the bath, the lower to the surface of the solution you need to press them to prevent them from entering the breathing zone of the worker near the baths. Inverted side exhausts require significantly less air flow, especially at lower liquid levels (150 - 300 mm or more).

The design dimensions of the suction are selected according to the reference book of the master ventilation engineer, author B.A. Zhuravleva, depending on the specified dimensions of the bath and air flow.

5.3 Fan

Fans are machines that move air. In these machines, the exciter of air movement is a rotating impeller, which is enclosed in a casing that determines the direction of air movement. The wheel rotates by an electric motor. Based on the operating principle, fans are divided into axial and centrifugal.

Depending on the pressure developed, fans can be low, medium and high pressure. Low pressure fans create pressure up to 100 kg/m"2, average from 100 to 300 kg/m2, high from 300 to 1200 kg/l2. Low and medium pressure fans are used in general ventilation systems, air conditioning, in networks of pneumatic transport of materials and production waste and in other ventilation installations. As for high-pressure fans, they have mainly a technological purpose, for example, they are installed for blowing in cupola furnaces.

The air being moved can contain a wide variety of impurities (dust, gases, vapors of acids, alkalis) and explosive mixtures. Therefore, depending on the operating conditions, fans are subject to different requirements both in terms of the materials used for their manufacture and in terms of design.

In accordance with SNiP 2.04.05 - 91, fans are manufactured:

a) conventional design - for moving clean or low-dust air with temperatures up to 150°C; all parts of such fans are made of ordinary grades of steel;

b) anti-corrosion design - to move air containing impurities of substances that have a destructive effect on ordinary metal; in this case, for the manufacture of fans, materials that are resistant to aggressive impurities must be used - iron-chromium and chromium-nickel steel, vinyl plastic, etc.;

c) explosion-proof design - for moving flammable and explosive mixtures; the main requirement for such fans is that during their operation the risk of sparking due to accidental impact or friction of moving parts on stationary parts, for example the impeller on the casing, is completely eliminated; therefore, the wheels, casings and inlet pipes of such fans are made of a softer metal than steel - aluminum or duralumin; the part of the shaft washed by the moving flow of an explosive mixture must be covered with aluminum caps and a bushing, and an oil seal must be installed where the shaft passes through the casing;

d) dust fans - to move air with a dust content of over 150 mg/m3; To These fans are required to be wear-resistant, which is achieved by using materials of increased strength, thickening parts that are subject to abrasion by mechanical impurities, welding hard alloys on them, etc.

Depending on the calculated air flow, an anti-corrosion fan of the VTs 14-46-6.3 brand D=400 mm, n=600 rpm was selected.

Charging of suspended particles. In the electric field of the corona, charging of suspended particles occurs due to the adsorption of ions by the surface of the particles in the outer zone of the corona discharge. The magnitude of the ion flow to the surface of the particle determines the charging process.

The mobility, or speed, of an ion is proportional to the electric field strength (V/m) and the absolute temperature of the gas. Under normal conditions, negative ions are more mobile than positive ions. During the ionization of gas molecules by an electric discharge, the particles are charged. An electric charge creates an electric field around itself. The existence of a field is determined by introducing another electric charge into it, which is attracted to the first one (if the charges are of the same name) or repelled (if they are of the same name).

Movement of suspended particles in an electrostatic precipitator. When a particle suspended in gases enters an electrostatic precipitator, it acquires an electric charge, which in a fraction of a second reaches a value close to the maximum.

The following forces act on a suspended charged particle in an electrostatic precipitator: a) entrainment by a moving gas flow; b) severity; c) the mechanical effect of a flow of ions on gas molecules in an electric field, causing the movement of gas in the direction of the precipitation electrode - electric wind; d) interaction of the field and particle charge - Coulomb force

To select electric precipitators, you need to know the place of operation of the filter, gas flow, temperature, vacuum, and degree of purification.

Based on the intended purpose of the filter, a filter of the GP 75 - 3 brand for galvanic production was selected.

Filter for electroplating industries

Designed for sanitary cleaning of aspiration air from liquid and water-soluble solid aerosol particles in galvanic and pickling industries during such operations as chrome plating, sulfuric acid nickel plating, electrochemical degreasing and others. Aerosol particles are captured by a fibrous filter element, which is washed once every 15 days. filter housing or in the rinsing bath.

Air purification degree 90 - 95%

Aerodynamic resistance 500 - 700 Pa

Main advantages: ease of maintenance (ease of replacing the filter element), small size, ability to purify the air from aerosol particles of acids or alkalis.

G0ZV= 10-3·YЗВ·Fв·k1·k2·k3·k4·k5·k6·k7, g/s (6.3)

k6 - coefficient depending on the evaporation area is equal to 1

k7 - coefficient depending on the speed and temperature of the air flow above the evaporation surface, is equal to 4.3.

G0ZV= 10-3 YZV Fv k1 k2 k3 k4 k5 k6 k7 = 0.001 6.5 1.5 1 0.8 1.176 1.5 0.75 1 ·

·4.3 = 0.048 g/s

M0ZV= 3.6·0.001·YЗВ·Fв·k1·k2·k3·k4·k5·k6·k7·τ·D (6.4)

τ - duration of operation of the bath in hours

D - number of bathtub operation shifts per year

Mass amount of each pollutant (in tons) leaving the bath per year:

M0ZV= 3.6 10-6 YZV Fv k1 k2 k3 k4 k5 k6 k7 τ D = 3.6 10-6 6.5 1.5 1 0 .8 1.176 1.5 0.75 1 4.3 8 12 22 = 0.113 t/g

Calculation of the amount of pollutants (g/s or t/g) emitted into the atmospheric air from galvanic production, taking into account gas cleaning and gravitational settling of the aerosol in the air duct, is carried out using the formulas:

GVZVmax= (1 - η/100) GZVmax (k8 YaZV/ YZV + YgZV / YZV), g/s (6.5)

GVZV0= (1 - η/100)· GЗВ0 ·(k8· YaЗВ/ YЗВ + YгЗВ / YЗВ), g/s (6.6)

MVZV= (1 - η/100) MZV0 (k8 YaZV/ YZV + YgZV / YZV), t/g (6.7)

η degree of gas purification of the dust and gas treatment plant, %

η = 98%, then

GVZVmax= (1 - η/100) GZVmax (k8 YaZV/ YZV + YgZV / YZV) = (1- 98/100) 0.0105

·(1.2·6.5/6.5) = 0.02·0.0105·1.2 = 0.00025 g/s

GVZV0= (1 - η/100) GZV0 (k8 YaZV/ YZV + YgZV / YZV) = (1- 98/100) 0.048

·(1.2·6.5/6.5) = 0.02·0.048·1.2 = 0.0012 g/s

MVZV= (1 - η/100) MZV0 (k8 YaZV/ YZV + YgZV / YZV) = (1- 98/100) 0.113

·(1.2·6.5/6.5) = 0.02·0.113·1.2 = 0.0027 t/g

Transcript

1 Firm "Integral" Program "Galvanics" Version 2.0 User manual St. Petersburg 2016

2 CONTENTS 1. FROM THE PROGRAM DEVELOPER ABOUT THE PROGRAM GENERAL INFORMATION OPERATING MODES OF THE PROGRAM WORKING WITH THE PROGRAM IN OFFLINE MODE WORKING WITH THE PROGRAM IN THE MODE OF CALLING FROM ANOTHER PROGRAM MAIN WINDOW OF THE PROGRAM REFERENCE REFERENCES DIRECTORY OF SUBSTANCES DIRECTORIES OF SPECIFIC INDICATORS SETTINGS EXPORT DIALOG SOURCES OF EMISSION SOURCES OF EMISSION SOURCES CALCULATION OF SOURCE OF EMISSIONS PRINT REPORT POSSIBLE PROBLEMS AND WAYS TO SOLUTION Document version: 2.0 from

3 1. From the program developer The Integral Company is pleased to offer you a program for calculating pollutant emissions from galvanic production “Galvanika”. We sincerely hope that choosing our program will not disappoint you and that you will find this software product a convenient tool in your work. In this Guide, we have tried to provide answers to all questions that may arise when working with the program. Here, all aspects of operating the program are discussed in detail, a comprehensive description of its capabilities and user interface elements is given, and recommendations are given regarding the procedure for working with the program in standalone mode and in the mode of calling from an external program. Recommendations for troubleshooting possible problems with the program are also provided. I would like to emphasize that you can always count on our assistance in mastering and operating the program. All consultations are provided free of charge and for an indefinite period. You can ask your questions by e-mail, send them by fax ((812)) or by mail (191036, St. Petersburg, 4th Sovetskaya St., 15 B), and also call us on a multi-line phone ((812)). On the website (there is an environmental forum where you can ask us your questions, as well as communicate with your colleagues and other users of our programs. An ICQ consultant (#) is also at your service. When asking questions about the programs, please have your email number at hand key (indicated on the key and on the insert in the CD box) or the registration number of the user organization (displayed in the “About the program” window). This will significantly speed up the work with your question. We will be happy to hear any of your comments and suggestions for improving this and other our programs. Thank you for your choice and wish you pleasant and effective work! 3

4 2. About the program 2.1. General information The “Galvanics” program is intended for calculating emissions of pollutants into the atmosphere from galvanic production in accordance with: “Methodology for calculating emissions of pollutants into the atmosphere during the production of metal coatings by galvanic method (based on specific indicators)”, Research Institute Atmosfera, St. -Petersburg, 2015 The procedure for installing the program on a computer is described in the readme.txt file, which is included in the program distribution kit. The requirements for computer hardware and software are also listed there. System requirements Operating system: Windows 2000/NT/XP/VISTA/7/8/10. RAM capacity: 1GB, 2GB or more recommended. Monitor resolution: 1024x768. Reports are created in Word document format, which can be viewed using Word, Notepad, etc. To fully work with the program, you must have one of these software products on your computer. A necessary condition for installation and operation of the program is the presence of a working parallel port (printer port) or USB port and an electronic key connected to it, to which the program 2.2 is registered. Program operating modes Like all programs of the “Ecologist” series for calculating emissions of pollutants, the “Galvanika” program can be used by you in two modes: in standalone call mode (see paragraph 2.3 of this Manual) and as an external method for the Unified calculation program air pollution (UPRZA) “Ecologist”, programs “Inventory”, “PDV-Ecologist” or “2tp (Air)”. In the latter case, there will be an automatic exchange of data between the Galvanika program and the corresponding calling program (see section 2.4) Working with the program in offline mode To start the program in offline mode, just click on the “Start” button Windows version) in the taskbar, which is usually located at the bottom of the screen. Once the menu appears, select “Programs” and then “Integral”. In the list that appears you will see all 4 programs

5 episodes of “Ecologist” installed on your computer. Select "Electroplating (ver. 2.0)". The procedure for working with the program in offline mode: 1. Create an enterprise (see paragraph 2.5 of this Guide) 2. Enter one or more emission sources (see paragraph) 3. For each emission source, enter one or more emission sources associated with it ( see p. Error! The reference source was not found.) 4. Enter data about each selection source and carry out calculations based on it (see p.) 5. Determine the synchronization of the operation of the selection sources (see p. Error! The reference source was not found. ) 6. Carry out calculations for each emission source (see paragraph) 7. If necessary, generate and print a report on the calculation of emissions (see paragraph) 8. If necessary, transfer the calculated emission values to an external program (see paragraph) Working with the program in call mode from another program In order to use the ability to call the “Galvanics” program from other programs (UPRZA “Ecologist”, programs “PDV-Ecologist” or “2TP (Air)”), you must first register the “Galvanics” program in the list of external methods the specified programs. Registration is carried out using the corresponding button on the toolbar in the main program window (see paragraph 2.5). In the future, the procedure for working together with programs will be as follows: 1. In the calling program (UPRZA “Ecologist”, programs “PDV-Ecologist” or “2TP (Air)”), enter the source of emission (for appropriate instructions, refer to the user manual or help system of the corresponding program) 2. By clicking the Alt+M keys or a special button in the list of emission sources in the calling program, select 5 from the list of registered

6 techniques and launch the “Galvanics” program. Information about the enterprise and the source of the emission will be transferred to it. 3. Enter one or more emission sources associated with the accepted emission source (see p. Error! The reference source was not found.) 4. Enter data about each emission source and carry out calculations on it (see p) 5. Determine the synchronization of work emission sources (see p. Error! Reference source not found.) 6. Perform calculations for each emission source (see p.) 7. If necessary, generate and print a report on the calculation of emissions (see p.) 8. Submit the calculated emission values to the calling program (see paragraph) 2.5. Main program window The program uses a hierarchical representation of data on pollution sources. At the top level there are enterprises with a unique code. Each enterprise can have any number of emission sources, characterized by site, workshop, source and option numbers, each emission source can contain any number of emission sources. Emission sources give the user the ability to calculate complex emission sources. For example, through a pipe or fan (emission source), pollutants resulting from the operation of several installations (emission sources) may enter the atmosphere. Another option for using allocation sources is to operate the same source in different modes. In this case, two conditional allocation sources are entered into the program, corresponding to two operating modes. In the simplest case, the emission source contains one emission source. In order to start work, the user must either manually enter the necessary enterprises, or transfer the relevant data from the UPRZA “Ecologist”, the “PDV-Ecologist” or “2-TP (air)” programs. It should be taken into account that when transferring data on calculated emissions back to the calling program, the required enterprise will be located by its code, and the desired emission source will be located by the number of the workshop, section and site (as well as the option number, if used). The menu of the main program window consists of the following items: 6

7 Name of the item Objects Sources of emissions Sources of emissions Composition Add, delete, copy an object, generate a report on the object. Add, delete, copy, calculate an emission source Generate a report on the calculation results Export data about the source to an external program (see p) Simultaneity groups Add, delete, copy, calculate an emission source Generate a report on the calculation results Directories Directory of substances (see p) Directories of specific indicators () Settings Program settings (see p) Registration of methods (see p) Internet update (see p)? Information about the program Calling help The main window of the program also has a toolbar (buttons with images) that duplicate menu commands. The main (rest) part of the main program window contains a data area on objects (enterprises) and emission sources (on the left, see p.) and a data area on emission sources (on the right, see p. Error! Reference source not found.) Directories Directory of substances The substance code directory window is called up using the corresponding menu command “Directories” in the main program window (see paragraph 2.5). This directory of substances is a smaller version of the complete directory of substances that pollute atmospheric air. The full version of the directory is available as a separate program “Directory of Substances”. In this window you can: 7

8 add new substances to the directory. You can use this opportunity to indicate in the future program by which code emissions of particulate matter are normalized. edit data on substances Directories of specific indicators This group of directories contains data on specific emissions of pollutants during various technological operations. Directories contain information given in the methodological document that the program implements. You can supplement or change the data in these directories. If necessary, you can add new operations to the directories or create analogues of existing ones, as well as set the composition of specific emissions of pollutants. Settings The program settings window is called up using the corresponding menu command “Emission sources” in the main program window (see paragraph 2.5). Program settings Path to data The initial data entered by the user and the saved calculation results are placed by the program on the computer in a special directory called the working directory. When you start, the working directory is C:\INTEGRAL.LTD\GALVAN\DATA\. For convenience, you can change the default working directory to any other one, for example, specify as the working directory the directory located on another computer connected to your local network. You can also create several working directories and work alternately with one or the other. Selecting or changing the working directory is carried out in this window. Accuracy This section determines the accuracy of the floating point results. These settings affect: presentation of results in screen forms and program reports; data transferred to external programs (for example, UPRZA “Ecologist”). Default values for maximum one-time (g/s) emissions are 7 decimal places, for gross (t/y) emissions are 6 decimal places. Report settings 8

9 Currently, there is only one report setting available: You can specify whether the program should include detailed data on operations (allocation sources) in the report or be limited to total data on emission sources. Data conversion If you have already worked with the previous version of the Galvanika program ver. 1.0, then to transfer data to the new version 2.0 you need to use the “Data Conversion” tool. In the “Old conversion data of the Galvanika program” field, you must specify the path to the old working directory (see figure). After selecting the old working directory, the program will warn you that after conversion, all data from the new version of the program will be lost. Registration of a method A command that allows you to register a program in other programs of the Ecologist series. Online update It is possible to replace a program release within the same version of the program using the “Online update” function. You can call this function through the main menu of the “Settings” program “Internet update”. To do this, your computer must be connected to the Internet. After calling this function, a dialog box will appear in which the size of the downloaded file will be indicated. After clicking on the “Update” button, the update procedure will start, after which the program will be restarted. If the computer has 9

10 the latest release of the program is installed, a message will appear that an update is not required. Export dialog This window is designed to transfer information about the selected emission source to an external program (UPRZA “Ecologist”, “PDV-Ecologist” or “2tp (air)”). Upon completion of the calculation of source emissions, you can transfer its results to an external program (UPRZA “Ecologist”, program “PDV-Ecologist” or “2tp (Air)”). The procedure for solving this problem is described below. If you called the “Galvanics” program from an external program, you won’t have to change or enter anything in the export window; you just need to click on the “Export” button. Checking the box “Update maximum permissible concentrations and hazard class in the directory of substances of the Ecologist and MDV programs” allows you to transfer all the information about substances that are not in the working directory of substances of the UPRZA Ecologist or the MDV-Ecologist program. If you launched the Galvanika program autonomously: 1. Specify any directory for temporary placement of the data file. 2. Click on the “Export emission source” button. 3. For information about the procedure for receiving data in an external program, see the user manual or the help system of the corresponding program. Emission sources The left part of the main program window is dedicated to entering information about emission sources for your enterprises. Each source is characterized by the number of the site, workshop, source and variant. The combination of these four numbers must be unique, otherwise a user error message will appear when entering data. Each release source must contain at least one release source. There may also be several of them; The main purpose of emission sources is to provide the user with a flexible mechanism for calculating complex emission sources. The procedure for working in this part of the program: 1. Add (the “Add” command in the “Objects” menu in the main program window) or find the desired previously created object (enterprise). 2. Add a new emission source to this object (the “Add” command in the “Emission Sources” menu in the main program window) or find the one you need previously created. 10

11 3. In the right part of the main window, enter a list of allocation sources, determine the synchronism of their operation, and carry out calculations for each of them. 4. Perform the final calculation for the emission source (the “Calculation” command in the “Emission Sources” menu in the main program window). 5. Generate a report (command “Report” in the same place) and/or transfer data to an external program (command “Export”, see p) Sources of selection The right side of the main program window contains a list of sources of selection for the emission source that is selected You are on the left side. Using the buttons located below the list of selection sources, you can add or remove a selection source, go to the window for entering data about the selection source (another way to go to this window is to double-click the left mouse button on the selection source) and generate a calculation report for the selection source . If some selection sources work simultaneously, check them in the “Sync” column. The maximum one-time release of an emission source is determined by the program as the maximum of the following values: 1. The sum of emissions of sources marked as operating synchronously. 2. Selection of other sources of selection Calculation of the source of selection This window is intended for entering data about the source of selection. The set of initial data depends on the type of operation (technological process) and the type of equipment, which are selected here. If you have dust and gas cleaning, you can enter the cleaning efficiency (in percent) in the appropriate fields, and the program will automatically calculate emissions after cleaning. In this case, when calculating the gross emission, the average degree of purification is taken into account, and when calculating the maximum one-time emission, the minimum. Having entered the initial data, click on the “Calculate” button, after which the “Calculation Results” window will appear on the screen. It will indicate the maximum one-time and gross emissions of pollutants calculated by the program for this operation. eleven

12 Printing a report In order to format the calculation results for an operation in the form of a report, you must click on the “Report” button in the “Calculation of allocation source” window (see paragraph). To generate a final report on the emission source, use the “Report” command from the “Emission Sources” menu in the main program window. The report generated by the program appears on the computer screen in a separate window. The report consists of a title, source data used in the calculation, formulas and results. You can view the report, print it on a printer, save it as a file on disk, or open it for editing in Microsoft Word (or another program installed in the operating system as an RTF file editor). 12

13 3. Possible problems and ways to solve them We tried to do everything possible to make our program universal and save you from the need to make any settings on your computer or operating system. However, sometimes, when the program for one reason or another cannot perform the necessary actions on its own, the recommendations given in this section may be useful to you. Please note that all of the following actions must be performed with system administrator access rights. When you start the program, you receive an error message like “Electronic key not found” or “Invalid electronic key” 1. In this case, you must do the following: 1. Make sure that the electronic key is connected to the computer, and exactly the one for which the program you are launching is made . 2. Make sure that the key is in reliable contact with the corresponding (USB or LPT) connector on the computer. 3. Make sure that when installing the key you followed the instructions that came with it, including installing the electronic key driver located in the Drivers directory on the CD with the Ecologist series programs. 4. Perform the electronic key diagnostic procedure. To do this, follow these steps: 4.1 Connect the electronic key to the computer; 4.2 Find the electronic key testing files (KEYDIAG.EXE and GRDDIAG.EXE) on the distribution disk (in the KeyDiag folder); 4.3 Run KEYDIAG.EXE; 4.4 Send us the keys.xml file by email, which will be created by the utility in the root directory of the C: drive; 4.5 Run GRDDIAG.EXE, then, in the program window, click: if the key driver version is 5.20 and higher, then you need to click on the “Full report” button in the lower left corner. Driver versions below 5.20 are not recommended for use at this time; if the key driver version is 6.0 or higher, then you need to click on the “Full report” button in the upper right corner. After which a diagnostic utility report will be generated in your Internet browser. This report must be saved (CTRL+S) in html format (or better *.mht). 1 This message may also appear when working in Windows-7/8-x64 operating systems and with the dongle driver version installed. In this case, you must update the dongle driver to version 6.31.

14 The received reports must be sent to us by email. Testing utilities can also be downloaded from the Internet at the following addresses:

15 In conclusion, we would like to emphasize once again that you can always count on our support in all aspects of working with the program. If you encounter a problem not described in this Guide, please contact us at the coordinates indicated below. Firm "Integral" Tel. (812) (multichannel) Fax (812) For letters: , St. Petersburg, st. 4 Sovetskaya, 15 B. Internet address:

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MINISTRY OF EDUCATION AND SCIENCE OF THE RUSSIAN FEDERATION

KAZAN NATIONAL RESEARCH TECHNICAL UNIVERSITY named after. A.N. Tupolev - KAI

Department of Industrial Ecology

I CONFIRM AGREED
Head Department of Pre-Education Lecturer of the course
Safety
_____________A.V.Demin ___ _______()

"______"___________20 "______"______20

EXERCISE
for a course project in the discipline
"Safety"

Student ______________________________ _________________gr.__________ __

Project topic ______________________________ ___________________________

______________________________ ______________________________ __________

Initial data for the project ______________________________ ________________

______________________________ ______________________________ ___________
______________________________ ______________________________ ___________
______________________________ ______________________________ ___________
______________________________ ______________________________ ___________

Date of issue of the assignment: ___________________20

Project Manager __________________ (full name _____________________)

The task was accepted for execution ______________________________ __________
(signature)

Kazan

Content
Introduction………………………………………………………… ……………………………...3
1.Galvanic production……………………………………………………………….5
1.1.Galvanic coating…………………………………………………………………….5
1.2.Galvanic processes…………………………………………………………………….5
1.3. Description of technological processes at the design site…………………...10
1.4. Requirements for technological processes……………………………………………………………….11
2.Measures to ensure the safety of galvanic production processes.15
2.1 Analysis of hazardous and harmful production factors (HPPF) of galvanic production…………………………………………………………………………………………15
3.Emissions from galvanic production………………………………………………………..19
3.1. Characteristics of harmful substances used in electroplating production.....19
4.Calculation part………………………………………………………………… …………….23
4.1.Selection of source data…………………………………………………………………..23
4.2.Calculation of gross emissions……………………………………………………………………..24
4.3. Calculation of the volume of air removed through on-board suction ..............................31
4.4. Mechanisms of formation of harmful emissions………………………………………………………..35

5. Ventilation………………………………………………………………………………...38

5.1. Classification of exhaust ventilation……………………………………………………………………. ..39

5.2.Ventilation system of the cadmium plating shop……………………………………………41

6. General safety requirements…………………………………………… …………………41
6.1.Safety requirements before starting work……………………………………………………..41
6.2.Safety requirements during operation……………………………………… ………42
6.3.Safety requirements after completion of work………………………………………………………...44
6.4.Safety requirements in emergency situations……………………… ……………....45

Conclusion………………………………………………………………………………...46

References……………………………………………………………………..47

Introduction.
The purpose of this course project is to design the galvanic section of an automobile repair enterprise.
Electroplating was discovered in 1836 by the Russian physicist and inventor in the field of electrical engineering B.S. Jacobi and is based on electrocrystallization - electrochemical deposition on the cathode (which is the main product) of positively charged metal ions when passing a constant electric current through an aqueous solution of their salts current In this case, metal salts disintegrate into ions under the influence of electric current and are directed to different poles: negatively charged ones - to the anode, and positively charged metal ions - to the cathode, that is, to the product whose surface layer we want to change by applying galvanic coating.
One of the most important functions of the anodes in this system is to replenish the ions discharged at the cathode, therefore the quality of the metal playing the role of the anode must be very high, with a minimum amount of foreign impurities. To maintain a constant composition of the electrolyte, the introduction of salts or other compounds of the deposited metal is carried out periodically.
In the workshop, all electrochemical processes for producing galvanic coatings are carried out in special baths of enameled cast iron, lead-lined steel, depending on the required bath size and the degree of aggressiveness of the electrolyte. Baths for obtaining galvanic coatings in the chrome plating and iron plating area are semi-automatic (products in such a bath rotate or move in a circle or in a horseshoe shape).
The strength of adhesion of galvanic coatings to the main product is ensured, first of all, by thoroughly cleaning the surface from oxides and fatty contaminants by etching or degreasing, removing roughness by grinding and polishing.
The list of galvanic coatings at the enterprise is varied, but the course project will cover the most basic ones. The choice of galvanic coating is carried out depending on the purpose and material of the part, its operating conditions, the purpose and necessary properties of the coating, the method of its application, the admissibility of contacts of mating metals and the economic feasibility of using this coating. Galvanic coatings provide increased corrosion resistance (zinc plating, cadmium plating, tinning, lead plating), wear resistance of rubbing surfaces (chrome plating, iron plating), protective and decorative function of surface finishing (copper plating, nickel plating, chrome plating, silver plating, gold plating).
Cadmium plating. The peculiarity of cadmium coating is that it provides electrochemical protection of steel in tropical conditions. Cadmium is much more ductile than zinc, so parts with threaded connections are preferred to be plated with cadmium. However, parts in contact with fuels should not be coated in atmospheres containing volatile organic substances (drying oils, varnishes, oils) and sulfur compounds.

1.Galvanic production

Galvanization is one of the most common methods of protection
metal products from corrosion and giving them certain properties
or improving them by applying special metal or chemical coatings. Currently, galvanization is widespread in mechanical engineering and construction.

1.1.Galvanic coatings

Galvanic coatings are metal films with a thickness ranging from fractions of a micron to tenths of a mm, applied to the surface of metal and other products using the electroplating method to give them hardness, wear resistance, anti-corrosion, anti-friction, protective and decorative or simply decorative properties.
Galvanic coatings are very diverse. When choosing, you should take into account the purpose and material of the part, its operating conditions, the purpose and necessary properties of the coating, the method of its application, the admissibility of contacts of mating metals and the economic feasibility of using this coating.
Galvanic coatings can provide increased corrosion resistance (galvanizing, chrome plating, tinning, lead plating), wear resistance of rubbing surfaces (chrome plating, iron plating), protective and decorative function of surface finishing (copper plating, nickel plating, chrome plating, silver plating, gilding, anodizing). Electroplating of products made of polymers, plexiglass, plastic or composites is used to give an aesthetic appearance, increase the strength of the surface of the product, and give electrically conductive properties to the parts.

1.2.Galvanic processes

Galvanizing. Zinc coating protects ferrous metals from corrosive destruction not only mechanically, but also electrochemically. Zinc coatings are widely used to protect machine parts and fasteners from corrosion; they are used to protect against corrosion water pipes, feed tanks in contact with fresh water at a temperature not exceeding 60-70? C, as well as to protect ferrous metal products from gasoline and oils, etc.
Cadmium plating. The chemical properties of cadmium are similar to those of zinc, but it is more chemically stable. Unlike zinc, cadmium does not dissolve in alkalis. Coating, like zinc, is used to protect ferrous metals from corrosion.

Nickel plating.
Electrochemical nickel plating. Nickel is used to coat products made of steel and non-ferrous metals (copper and its alloys) to protect them from corrosion, decorative surface finishing, increase resistance to mechanical wear and for special purposes. Nickel coatings have high anti-corrosion resistance in the atmosphere, in alkali solutions and in some organic acids, which is largely due to the strong ability of nickel to passivate in these environments. The nickel coating is highly polished and can be easily brought to a mirror shine.
"Black" nickel. Some instrument parts require a coating that is highly corrosion resistant combined with low reflectivity. These conditions are met by “black nickel” coatings.
Chemical nickel plating. Chemical nickel coating containing 3-12% phosphorus, compared to electrolytic coating, has increased anti-corrosion resistance, wear resistance and hardness, especially after heat treatment. Has low porosity. The main advantage of the chemical nickel plating process is the uniform distribution of metal over the surface of a relief product of any profile.
Tin plating. The main areas of application of tin coatings are protecting products from corrosion and ensuring solderability of various parts. This metal is stable in an industrial atmosphere, even containing sulfur compounds, in water, and in neutral environments. In relation to products made from copper alloys, tin is an anodic coating and protects copper electrochemically. Tin coatings are extremely ductile and can easily withstand flaring, stamping, and bending. The coatings have good adhesion to the base, provide good corrosion protection and a beautiful appearance. Freshly deposited tin is easily soldered using alcohol-rosin fluxes, but after 2-3 weeks its soldering ability deteriorates sharply.
Tin - Bismuth. Tin-bismuth alloy coatings deposited on a copper base are quite common; they prevent the oxidation of copper and copper alloys, have high corrosion resistance when operating products in the presence of hydrogen sulfide and other aggressive environments, and retain good solderability after a long shelf life (up to one year).
Tin – Zinc. This alloy is of particular interest due to the possibility of its use in tropical climates, i.e. in conditions of humidity and significant temperature fluctuations. The use of a tin-zinc alloy makes it possible to realize the positive qualities of both metals: reduce porosity and reduce the rate of corrosion.
Copper plating. Copper coatings are used to protect steel products from carburization, to increase electrical conductivity, and also as an intermediate layer on products made of steel, zinc, zinc and aluminum alloys before applying nickel, chrome and other types of coatings, for better adhesion or increased protective ability. As a rule, it is not used as an independent galvanic coating either for decorative purposes or for protection against corrosion.
Silvering. Silver has high electrical conductivity, reflectivity and chemical stability, especially when exposed to alkaline solutions and most organic acids. Therefore, silver coatings are used mainly to improve the electrically conductive properties of the surface of current-carrying parts, to give the surface high optical properties, to protect chemical equipment and instruments from corrosion under the influence of alkalis and organic acids, as well as for decorative purposes.
Anodic oxidation of aluminum. Parts or products made of aluminum and its alloys are widely used because they are resistant to atmospheric conditions due to the presence of an oxide film. The anodizing process involves the growth of an anodic film on a product under the influence of current. The film obtained through the anodizing process is waterproof, corrosion-resistant in atmospheric conditions, wear-resistant, has good electrical insulating properties, and the porous film adsorbs dyes well. The latter makes it possible to obtain surfaces of various colors.
Chemical oxidation and passive coatings.
Oxidation of ferrous metals. Oxidation of steel products is used to protect against corrosion when used in light operating conditions.
Oxidation of copper. Protects the surface of copper and copper alloys from oxidation and darkening for a short time. Has the ability to cover small parts.
Aluminum oxidation. The coating is electrically conductive, has low protective properties, and good adhesion strength to the base metal.
Passivation. In order to preserve the decorative appearance and increase the corrosion resistance of the coatings, they are treated with special passivating solutions containing mainly chromium compounds.
Phosphating. Phosphating is most often used for processing steel products, less often for aluminum, magnesium and zinc. The valuable properties of the phosphate layer determine the areas of its use. Phosphating is used to protect parts from atmospheric corrosion that are not required to have a decorative appearance; increasing the adhesion of paints and adhesives; as well as an electrical insulating coating.
Electropolishing. Electrochemical polishing is used mainly for finishing products made of steel, copper and their alloys that are not complex in shape. The result of polishing is the appearance of shine on the metal surface, which is accompanied by the dissolution of its outer layer and, in most cases, the smoothing of micro-roughness.
Chrome plating. Chrome coatings are among the most versatile in terms of their functional applications. With their help, they increase the hardness and wear resistance of the surface of products and tools, and restore worn parts. This is due to the presence on its surface of a very dense passivating film of an oxide nature, which is easily restored at the slightest damage. Widely used for corrosion protection and for decorative finishing of product surfaces. Depending on the process mode, coatings with different properties can be obtained.
Ironing. Iron plating as a galvanic coating is very rare. It is mainly used in the printing industry for coating matrices, and more recently also in the finishing of machine parts or in the repair of worn tools. In addition, this method can be used to prepare especially pure iron for physical and chemical research. The main element of the electrolyte is ferric sulfate or ferric chloride.
In this course project, the cadmium plating process is used, the technological process for it is considered, and the gross emission is calculated.

1.3.Description of technological processes at the design site

Technological process of cadmium plating:

Hydrochloric or sulfuric acid is used to pickle steel. Hydrochloric acid dissolves scale, while sulfuric acid etches scale, weakening its adhesion to steel. Ordinary steels, already degreased, are pickled in 30% hydrochloric acid at room temperature until scale and rust are completely removed. After washing, anodic degreasing is used to remove the etched sludge at / 5 - MO A / dm2 for 1 - 2 minutes. After washing, the surface is activated for 10 s in a 10% solution of sulfuric acid at room temperature.

Occupational safety requirements must be observed:
- when preparing electrolytes and solutions;
- when preparing the surface before applying coatings;
- when applying coatings.
The application of all types of metal coatings at all stages of production must comply with the requirements of GOST 12.1.010-76, GOST 12.3.002-84, Interindustry rules for labor protection when using chemicals and these rules.
The safety of technological processes for applying metal coatings must be ensured:
- automation and sealing of processes that are a source of dangerous and harmful production factors;
- mechanization and automation of manual labor;
- replacing toxic and flammable substances with non-toxic and non-flammable substances;
- eliminating direct contact of workers with substances and solutions that have a harmful effect on the human body;
- using automated methods for determining the concentration of substances of the 1st hazard class in the air of the working area;
- use of blocking devices and means of light and sound signaling in case of violations of the technological process;
- timely removal and neutralization of production waste, which is a source of hazardous and harmful production factors. When applying metal coatings, it is necessary to take into account the following dangerous and harmful production factors:
- increased dust content in the air of the working area;
- increased contamination with vapors of harmful chemicals;
- toxic, irritating, carcinogenic effects of substances (acids and alkalis, electrolytes and solutions) on the worker’s body;
- increased air humidity;
- increased level of noise and vibration;
- increased level of ultrasound;
- a dangerous level of voltage in an electrical circuit that can close through the human body;
- increased level of static electricity;
- increased surface temperature of the product and equipment;
- fire and explosion hazard;
- movement of parts of mechanisms and machines;
- scattering of particles of abrasive materials;
- physical activity of the employee, accompanied by increased expenditure of his energy.
The content of harmful substances in the air of the working area should not exceed the maximum permissible concentrations (MPC) established by GOST 12.1.005-88, GN 2.2.5.686-98 and GN 2.2.5.687-98.
Noise levels in workplaces should not exceed the permissible levels established by GOST 12.1.003-83 and GN 2.2.4/2.18.562-96.
Vibration levels at workplaces should not exceed the values established by GOST 12.1.012-90 and GN 2.2.4/2.1.566-96.
Ultrasound levels at workplaces should not exceed the values established by GOST 12.1.001-89, GOST 12.2.051-80, SanPiN 2.2.4/2.1.8.582-96, Sanitary rules and regulations for working on industrial ultrasonic installations.
Touch voltages and currents flowing through the worker’s body during operation of electrical installations must not exceed the standards established by GOST 12.1.038-82.
The electrostatic field strength at workplaces should not exceed the standards established by GOST 12.1.018-93, Sanitary and Hygienic Standards for Permissible Electrostatic Field Strength.
The microclimate of production premises must comply with the requirements of GO ST 12.1.005-88 and SanPiN 2.2.4.548-96.
When carrying out technological processes for applying metal coatings, fire safety requirements must be met in accordance with the requirements of GOST 12.1.004-91 and Fire Safety Rules in the Russian Federation.
The tools used in technological processes for applying metal coatings must meet the relevant requirements of state standards, technical specifications and technological documentation.
When using abrasive tools, it is necessary to comply with the requirements of GOST 12.3.028-82 and Interindustry Rules for Occupational Safety and Health in the Cold Processing of Metals.
Loading and unloading operations must be carried out in accordance with the requirements of GOST 12.3.009-76, GOST 12.3.020-80 and Interindustry rules for labor protection during loading and unloading operations and placement of cargo.
Work with harmful and explosive substances must be carried out with the ventilation systems turned on and using personal protective equipment.
The presence of unauthorized persons in the working space of the equipment for cleaning parts and applying metal coatings during its operation or adjustment is not allowed.
Technological processes for applying metal coatings must be carried out in accordance with the technical documentation of the organization that developed the technological process.
For each method of applying metal coatings, the organization must develop and approve in the prescribed manner technological instructions and labor protection instructions.
Technological processes for applying metal coatings should, as a rule, be mechanized and automated and carried out in accordance with established technology. When working on automatic, semi-automatic and other mechanized installations and production lines for applying metal coatings, the occupational safety requirements stipulated by the operating instructions of the manufacturer must be met.
Industrial waste must be collected in specially designated areas and subjected to disposal or other types of processing in accordance with the regulatory and technical documentation for the technological process being carried out, taking into account the chemical composition and physical state of the waste.
The technological documentation for the application of metal coatings must set out occupational safety requirements in accordance with the requirements of GOST 3.1120-83.
When working with molten metals, devices for loading baths, immersed products, and metal added to the bath must be dry and heated to 70 - 80 ° C.
Loading into and unloading baths of large-sized products weighing more than 20 kg must be carried out by lifting devices.

2.Measures to ensure the safety of galvanic production processes.
2.1. Analysis of hazardous and harmful production factors (HPPF) of galvanic production.
In electroplating shops, sources of danger are the technological processes of surface preparation, preparation of solutions and electrolytes, and application of coatings. Surface cleaning methods are characterized by increased dust, noise and vibration. Alkalies, acids, and salts used to prepare solutions can cause poisoning or occupational illness when exposed to the body. Using hand-held vibration tools for grinding surfaces can cause vibration disease. Working in ultrasonic cleaning baths involves exposure of the worker to sound and ultrasonic vibrations. In addition, the abundance of rinsing baths in the room creates increased humidity. Normal working conditions are ensured by good lighting, supply and exhaust ventilation and maintaining normal air temperature in the workshop.
The most harmful and dangerous substances in handling are:
- Caustic soda (NaOH)
If the solution or dust gets on the skin, a soft scab will form. Ulcers and eczema occur, especially in the articular folds of the fingers. Getting even the smallest amounts of NaOH into your eyes is dangerous; Not only the cornea is affected, but also due to the rapid penetration of NaOH into the depths, the deep parts of the eye also suffer. The outcome may be blindness. In case of contact with skin, wash the affected area with a stream of water for 10 minutes, then apply a lotion with a 5% solution of acetic or citric acid. In case of contact with eyes, immediately rinse thoroughly with a stream of water or saline solution for 10 minutes. MPC -0.5 mg/m3.
Personal protection: overalls made of thick fabric, rubber gloves, sleeves, aprons, shoes.
-Hydrochloric acid (HCL)
At high concentrations - irritation of the mucous membranes, especially the nose, conjunctivitis, clouding of the cornea, tingling in the chest, runny nose, cough, chronic poisoning causes catarrh of the respiratory tract, tooth decay, changes in the nasal mucosa and even the disappearance of the nasal septum; gastrointestinal disorders, possible inflammatory skin diseases. Usually the cause of poisoning is not HCL gas, but HCL mist, which is formed when the gas reacts with water vapor in the air.
In case of poisoning, immediately remove the victim to fresh air and remove clothing that restricts breathing. Oxygen inhalation. Rinse eyes, nose, rinse with 2% soda solution. If the eyes are affected, after rinsing, inject 1 drop of 2% novocaine solution into the eyes. If strong acid gets on the skin, immediately wash it with water for 5 minutes. MPC - 5 mg/m3.
Personal protection: filtering industrial gas mask of grade B, sealed safety goggles. Overalls made of acid-resistant fabric. Mittens and gloves made of resistant rubber. Boots made of acid-resistant rubber.
-Ammonia (NH 3)
Ammonia vapors strongly irritate the mucous membranes of the eyes and respiratory organs, as well as the skin. This is what we perceive as a pungent odor. Ammonia vapors cause excessive lacrimation, eye pain, chemical burns of the conjunctiva and cornea, loss of vision, coughing attacks, redness and itching of the skin. When liquefied ammonia and its solutions come into contact with the skin, a burning sensation occurs, and a chemical burn with blisters and ulcerations is possible. In addition, liquefied ammonia absorbs heat when it evaporates, and when it comes into contact with the skin, frostbite of varying degrees occurs. The maximum permissible concentration in the air of the working area of the production premises is 20 mg/m³.
Cadmium sulfate CdSO 4. Colorless orthorhombic crystals, mp = 1000°C, density 4.72 g/cm 3 . Reduced by hydrogen to sulfide. Easily soluble in water, slightly soluble in alcohol. There are crystal hydrates of CdSO 4. nH 2 O (n=7, 6, 4, 1). The molar electrical conductivity at infinite dilution at 25 o C is 268 cm. cm 2 /mol. It is obtained by dehydration of crystalline hydrates or heating of cadmium sulfide in hydrogen sulfide. It is used to produce cadmium compounds and in the pharmaceutical industry.

Calculation of pollutant emissions from the galvanic section

There are three baths in the galvanic section, the characteristics of which are given in Table 5.

Table 5 - Characteristics of technological processes in galvanic baths

All galvanic baths are equipped with on-board suction, the gases leaving the baths are transported through the air ducts of the V-2 exhaust system and enter the atmosphere through a pipe with a diameter of 75 mm, a height of 20 m, the volume of the gas-air mixture is 1.9 m 3 /s, the temperature is 20 O C. There is no gas cleaning equipment. The site operates 240 days a year, 8 hours a day. Gross emissions of vapors released during the processes of degreasing products (bath 1-2), t/year, are determined by the formula

Gross emissions of pollutants during galvanic treatment (bath 3), t/year, are determined by the formula

Maximum one-time emissions of pollutants during degreasing and coating, g/s, are determined by the formulas

where g about, g about - the specific amount of pollutants released from a unit surface of the bath under normal load, respectively during degreasing and coating, g/hm 2, Table 6.11;

F is the area of the bathtub mirror, m2;

t - degreasing time per day, h; n - number of working days per year;

m 2 - coefficient depending on the evaporation area, table 6.21;

k B is a coefficient depending on the state of aggregation of the substance. For gases k B =1.

We summarize the calculation in Table 6.

Table 6 - Calculation of pollutant emissions from galvanic baths

Calculation of pollutant emissions from the welding area

The welding area has three stationary welding stations equipped with local suction. Gases exhausted during welding work are transported through the air ducts of the V-3 exhaust system and enter the atmosphere through a pipe with a diameter of 0.45 m, a height of 12 m, the volume of the gas-air mixture is 1 m 3 / s, the temperature is 20 ° C. There is no gas cleaning equipment. The site operates 240 days a year, 6 hours a day.

The number and brand of electrodes are given in Table 7.

Table 7 - Characteristics of welding stations

The gross emission of pollutants during electric arc welding, t/year, is determined by the formula

where is the specific indicator of the emitted pollutant, g/kg, of the welding or surfacing material, Table 4.11; B is the mass of welding or surfacing material consumed per year, kg.

The maximum one-time emission of pollutants during electric arc welding, g/s, is determined by the formula

where is the specific indicator of the emitted pollutant, g/kg, of the welding or surfacing material, Table 4.11; B 20 - maximum consumption of welding material in 20 minutes, kg. We summarize the calculation in Table 8.

Table 8 - Calculation of pollutant emissions from welding stations

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Federal State Budgetary Educational Institution of Higher Professional Education

Department of Life Safety

Calculation and graphic work

discipline: Industrial ecology

Topic: Selection of a device for purifying emissions from the galvanic section of workshop No. 41 of OJSC PSZ "Yantar"

Kaliningrad, 2011

INconducting

The fundamental solution to the problem of protecting the environment from emissions from industrial enterprises is to create closed technological cycles (non-waste systems). However, their development and implementation require new technological and design solutions, as well as large capital investments. In modern conditions, methods of protecting the environment from harmful substances are often used, consisting in their capture or neutralization in special devices. However, such solutions are not possible in all cases. Unfortunately, to date, one of the most common ways to reduce the concentration of harmful substances in the atmosphere from ventilation and technological emissions is their dispersion in the atmosphere.

Hundreds and sometimes thousands of tons of various harmful substances enter the air of our city with emissions from industrial enterprises and transport every year. In a city with a population of 394 thousand inhabitants, the average content of benzopyrene and carbon disulfide in the air exceeds the norm by more than 5 times. The annual average concentrations of dust, nitrogen dioxide, and ammonia are approximately at or slightly above the norm.

The problem of environmental protection is global in nature and therefore must be solved not only in relation to a specific enterprise or production cycle. When planning the further development of industrial production, it is necessary to evaluate the effectiveness of its development not only from the standpoint of the interests of a given enterprise, its economic benefits, but also from the standpoint of the interests of society and environmental safety.

1 . Aanalysis of environmental activities of the galvanic section of workshop No.41 OJSC PSZ "Yantar"

Electroplating is one of the industries that seriously affects environmental pollution, in particular with heavy metal ions, the most dangerous for the biosphere.

Electroplating is the electrolytic deposition of a thin layer of metal on the surface of a metal object to protect it from corrosion, increase wear resistance, protect against cementation, for decorative purposes, etc. Electroplating is an electrochemical process in which a layer of metal is deposited on product surface. A solution of salts of the applied metal is used as an electrolyte. The product itself is the cathode, the anode is a metal plate. When current passes through the electrolyte, metal salts disintegrate into ions. Positively charged metal ions are directed to the cathode, resulting in electrodeposition of the metal.

The main processes of the galvanic section of workshop No. 41:

Chemical oxidation;

Etching;

Chemical degreasing;

Chemical passivation;

Phosphating;

Galvanizing;

Cadmium plating;

Copper plating.

In terms of the level of environmental pollution, areas of electroplating production are comparable to such major sources of environmental hazard as the chemical industry.

The environmental impact of electroplating production is threefold:

Emissions of harmful substances into the atmospheric air from exhaust ventilation;

Generation of wastewater containing toxic components;

Formation of solid toxic waste.

1.1 Ambient air pollution

Technological processes for applying electrochemical coatings include a number of sequential operations: electrochemical or chemical degreasing, etching, loosening, grinding and polishing, pickling, coating.

All these operations are accompanied by the release of various pollutants into the indoor air and atmosphere. Solutions of cyanide salts, chromic and nitric acids, etc. are particularly toxic.

The main pollutants released are: aerosols of alkalis, acids, metal salts, as well as vapors of ammonia, nitrogen oxide, hydrogen chloride and fluoride, hydrogen cyanide.

Depending on the process, the composition of pollutants may vary. Thus, when phosphating products, hydrogen fluoride is released; during preparatory operations in galvanic shops (mechanical cleaning and degreasing of surfaces), dust, gasoline, kerosene, trichlorethylene fumes, and alkali mists are released.

In the air removed from galvanic shops, harmful substances are found in the form of dust, fine mist, vapors and gases. The most intensively harmful substances are released in the processes of acid and alkaline etching.

Based on the results of certification of workplaces in the galvanic section, chemical substances were identified whose concentration exceeded the maximum permissible values (Table 1).

Table 1 - Actual and regulatory values of harmful substances

Equipment for purifying emissions from harmful pollutants has not been installed.

1.2 Hydrosphere pollution

Electroplating production is one of the most dangerous sources of environmental pollution, mainly surface and underground water bodies, due to the formation of a large volume of wastewater.

Galvanic wastewater undergoes physical and chemical treatment, with initial treatment of wastewater with solutions of chemical reagents and subsequent flotation of polluting components on a MINICELL pressure flotation unit of type MNC-6, as well as post-purification of clarified water on a self-washing filter KS, type KS-3.2 from KWI, which ensures complete return of wash water to the coating bath.

Thus, galvanic section No. 41 does not discharge into water bodies (the Pregolya River).

Domestic wastewater is discharged into the city sewer through outlet wells.

1.3 Lithosphere pollution

All equipment for wastewater treatment facilities from the galvanic section is located inside the housing at the site of the neutralization station. In this case, production waste (galvanic sludge) is generated from the dewatering of flotation sludge in special non-woven bags.

A special place has been allocated on the territory of the building for temporary storage of waste before sending it to the city industrial waste disposal site.

2 . Formulation of the problem

Having analyzed the environmental activities of the galvanic section of workshop No. 41, I consider it urgent to develop a system for purifying emissions from harmful pollutants, since wastewater does not enter water bodies, solid waste is transported to the city landfill for industrial waste disposal, and equipment for purifying emissions from harmful pollutants does not installed.

Based on the above and taking into account the results of the certification of workplaces in the galvanic section of workshop No. 41, I believe that it is necessary to select a device for purifying the exhaust air from mists and vapors of alkalis and acids.

3 . Selection of cleaning method and apparatus inemissions from the galvanic sectionworkshop no.41 OJSC PSZ "Yantar"

galvanic emission pollution cleaning

The fundamental solution to the problem of environmental protection is the reduction and complete elimination of emissions of harmful substances into the atmosphere. To prevent and minimize emissions of harmful substances into the atmosphere, the most modern technological processes and cleaning methods that correspond to modern scientific and technological progress must be used.

Purification of the sucked air from harmful substances is carried out in various ways. Some of the harmful substances released in the form of aerosols settle on the way from the side of the bath to the exhaust center. The exhaust center captures remaining harmful substances from the exhaust air before releasing it into the atmosphere.

Air purification from dust is carried out in dust collectors of various designs.

To purify the air from aerosols, vapors and gases of harmful substances, various types of devices are used - condensers, absorbers, fiber filters, ion exchange filters, etc.

When choosing a cleaning method, the aggregate state of the pollutant is first taken into account. According to their state of aggregation, pollutants are: in the solid state (suspended particles); in a gaseous state (sulfur oxides, nitrogen oxides) and in a liquid state (water vapor).

The classification of cleaning methods and apparatus depending on the state of aggregation is given in Table 2.

When choosing cleaning equipment, they take into account the efficiency of its cleaning, capital costs, operating costs, reliability of operation, ease of maintenance, ease of control, availability of repairs, occupied space, costs of electricity, water and reagents.

Based on the above and due to the fact that during chemical degreasing, chemical oxidation, etching the air is polluted with liquid aerosols (mists), splashes and vapors of alkalis and acids, we can conclude that the cleaning method necessary for us is electrical, mechanical and sorption methods, and suitable devices are:

Foam devices;

Fiber filters;

Absorption fiber filters FAV;

Wet electrostatic precipitators.

Table 2 - Classification of methods and apparatus for cleaning industrial emissions

Purpose of cleaning		Devices
Cleaning from dust and smoke	Dry methods Wet methods Electrical methods	Dust settling chambers, dust collectors, cyclones, filters. Gas washers (scrubbers). Dry electrostatic precipitators
Clearing fog and splashes	Electrical methods Mechanical methods	Wet electrostatic precipitator Mist eliminator filters, mesh splash eliminators
Cleaning from gaseous impurities	Absorption methods Adsorption methods Catalytic methods Thermal methods	Absorbers: plate, packed, film. Adsorbers: with a fixed, moving layer. Reactors Furnaces, burners
Cleaning from vapor impurities	Condensation methods	Capacitors

3 .1 Foamdevices

An intensified foam apparatus with a foam layer stabilizer (Figure 1) is an improved design of a foam apparatus. It is a body of rectangular or circular cross-section 1, in which a horizontal working grid 2 is installed, having round or slotted holes.

Figure 1 - Intensified foam devices with stabilizers:

a - with one stabilizer; b - with two stabilizers; 1 - body; 2 - working counter-flow grid; 3 - foam stabilizer; For - additional stabilizer; 4 - irrigation device; 5 - splash trap.

A foam stabilizer 3 is installed on the grid, which is a honeycomb grid of vertically arranged plates. Air enters the apparatus through a pipe into the space under the grate and, passing through the grate, when interacting with the liquid coming from the irrigation device 4, forms a layer of moving foam. The purified air passes through the spray trap 5 and leaves the apparatus through the upper pipe. The waste liquid flows through the grille holes and is discharged through the drain fitting. The body of the apparatus has an expansion in the upper part to reduce splash entrainment and reduce hydraulic resistance in the drop catcher.

3 .2 Fibrousfilters

Fiber filters of the FVG-T type are intended for sanitary cleaning of aspiration air from oxidation and etching baths containing fog and splashes of electrolyte in the form of a mixture of chromic (concentration up to 250 g/l CgO3) and sulfuric (concentration up to 2.5 g/l) acids (Fig. .2).

Figure 2 - Fiber filter type FVG-T:

a - versions I, VI, VII; 1 - air outlet chamber; 2 - hatch; 3 - body; 4 - air inlet chamber; 5 - cassette; 6 - installation hatch; 7 -- washing device; b - versions VIII and IX.

3 .3 AbsorptionfibrousfiltersFAW

Filters are designed to clean and neutralize the air in working spaces from gaseous impurities and soluble aerosol particles. Air temperature - up to 60°C (Fig. 3).

Figure 3 - FAV type absorption fiber filter:

1 - cover; 2 - body; 3 - fitting for filling the solution; 4 - ball nozzle; 5 - support legs; 6 - device for draining the solution; 7 - filter element; 8 - fitting for monitoring the solution level.

Contaminated air enters the lower part of the housing through the inlet pipe, passes through the support distribution grid and, capturing the absorption solution, forms a gas-liquid medium in which the ball nozzle moves freely, and then passes through the filter element. The frequency of washing the filter, changing the absorption solution and neutralizing it is established during commissioning, depending on the type of substance being captured.

3 .4 Wetelectrostatic precipitators

Electrostatic gas scrubbing is a versatile solution suitable for all aerosols, including acid mists, and all particle sizes. The method is based on the ionization and charging of aerosol particles when gas passes through a high-voltage electric field created by corona electrodes. Particle deposition occurs on grounded precipitation electrodes. Industrial electrostatic precipitators (Fig. 4) consist of a series of grounded plates or pipes through which the gas to be purified is passed. Wire corona electrodes are suspended between the collecting electrodes, to which a voltage of 25-100 kV is applied.

Figure 4 - Diagram of a tubular electrostatic precipitator:

1 - guide vanes; 2 - corona electrodes; 3 - throttle valve; 4 - insulator boxes; 5 - supply of water for periodic washing; 6 - the same, continuous washing; 7 - collecting electrodes; 8 - gas distribution grilles; 9- water seal; 10 - waste trays.

4 . DevelopmenttechnologicalschemeOcleaningemissionsgalvanicplotworkshops№41 OJSCPSZ"Amber"

Based on the existing conditions, the arrangement of baths and the free areas of the galvanic section of workshop No. 41, for the sanitary cleaning of the aspiration air of the oxidation, degreasing and etching baths, we accept fiber filters of the FVG-T type, version I (Fig. 5).

Figure 5 - Fiber filter type FVG-T, version I:

1 - air outlet chamber; 2 - hatch; 3 - body; 4 - air inlet chamber; 5 - cassette; 6 - installation hatch; 7 -- washing device.

The main characteristics and overall dimensions are given in Table 3.

Table 3 - Characteristics and overall dimensions of fiber filters type FVG-T, version I

Filter size	Throughput, m3/h	Filter surface area, m3	Overall dimensions, mm, no more, weight, kg

Based on the fact that the throughput of the exhaust ventilation fan is L=4300 m3/h, we accept the FVG-T-0.37-I fiber filter.

Symbol for filter size: F - filter; B - fibrous; G - for galvanic baths; T - titanium (case material); numbers - filter surface area (m2); Roman numeral - design option.

Inside the filter housing there is a cassette with filter material placed on the frame and pressed with a clamping grid made of rod material. The cassettes are made in the form of vertical folds. Installation and replacement of cassettes are carried out through the installation hatch.

The filter operates in the mode of accumulation of the captured product on the surface of the filter material with partial liquid drainage. Once the pressure drop reaches 500 MPa, the filter is subjected to periodic washing (usually once every 15 - 30 days) using a portable nozzle inserted through the hatch.

The filter material is needle-punched felt, consisting of fibers with a diameter of 70 microns; layer thickness 4-5 mm.

Technical characteristics: temperature of purified air 5-90°C; vacuum in the apparatus is not more than 700 Pa; hydraulic resistance 150-500 Pa; the degree of air purification is not lower than 96-99%; optimal filtration speed 3-3.5 m/s; water consumption for one-time washing of 1 m2 of surface is 200-300 l; wash water pressure 100-200 kPa; washing time 10-15 minutes.

The connecting dimensions of the FVG-T-0.37-I fiber filter are given in Table 4.

Table 4 - Connecting dimensions of the FVG-T-0.37-I fiber filter

The main advantages of filters: ease of maintenance (easy replacement of filter material); small dimensions; presence of a built-in water seal; the ability to purify the air from aerosol particles of acids, alkalis, salts and their vapors.

The filter is installed in the air duct from the on-board exhausts of the chemical oxidation and degreasing baths, etching to the indoor fan to facilitate access to the filter, cleaning and changing the filter cassette.

Zconclusion

Having analyzed the environmental activities of the galvanic section of workshop No. 41 of OJSC PSZ "Yantar", it was revealed that special attention needs to be paid to cleaning the air emitted into the atmosphere. Emission treatment facilities have not been installed, since the enterprise is located in an industrial zone, and the concentration of harmful substances for residential buildings, due to dispersion, does not exceed the maximum permissible values.

But the presence of emissions of harmful substances, which in themselves are harmful to human health and the environment, and the possibility of their total accumulation in the atmospheric air due to the total emissions from other enterprises, leads to the idea that the installation of gas and dust cleaning equipment is necessary.

Based on the results of certification of workplaces, it was established that, first of all, it is necessary to clean up emissions of alkali and acid vapors, since their actual concentration in the emitted air exceeds the maximum permissible concentration for atmospheric air.

The FVG-T-0.37-I fiber filter selected during the work ensures emission purification by 96-99%. Thus, after installing the filter, the concentration of harmful substances in the emitted air will not exceed the maximum permissible values, which will help improve the environmental situation, both inside the enterprise itself and outside it.

Listusedsources

1. Industrial ecology N.V. Pogozheva: Textbook. - Kaliningrad: KSTU, 2003 - 93s

2. Handbook on dust and ash collection A.A. Rusanov - M, 1983

3. http://www.eco-technologes.ru 4 http://www.woodtechnology.ru

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