´EnviroMan´ Environmentally adapted metal manufacturing processes; chemical and waste material recyc

Project time: 2012 – 2015

Budget: 20 660 000 SEK

Funding: FFI – Strategic Vehicle Research and Innovation

A study “before and after” EnviroMan, indicates that the project has created increased understanding on specific topics and also useful results

The project EnviroMan, Environmentally adapted metal manufacturing processes, is part of the FFI Strategic Vehicle Research and Innovation collaboration program Sustainable Production, handled by VINNOVA. Within this program, the project EnviroMan is part of the Swedish Manufacturing R&D Clusters roadmap, area Component Manufacturing. The EnviroMan project lasted from Oct 2012 to Aug 2015, performed by 23 partners from industry and research. The project is followed by a technology transfer initiative.
The R&D work had a wide scope, covering innovative and sustainable process fluid cleaning methods, environmentally adapted heat treatment processes, minimized waste products from foundries, and a specific focus on methods for energy and environmental analyses. A summary from the studies and the results from them are:
Innovative and sustainable cleaning of process fluids. Industrial case studies are specifically made on sustainable cleaning of process fluids from bacteria, in one case by the use of ozon at SKF, and in another by the use of UV light at Volvo CE. The results prove, that both methods give effect, but needs to be optimized according to process control, system design and handling routines. The UV light system needs weekly cleaning of the lamps, high quality of both the process fluid circulation and the process water. The ozon system was used in a process fluid system supporting 7 machines. Ozone is very efficient against bacteria, in this case the (maybe too) large fluid system needed a mix of both biocide and ozon treatment, to deliver good results during the evaluation. The overall goal: Reduce or eliminate the use of chemicals related to heat treatment ope-rations. Two specific areas have been studied: Cleaning of surfaces and quenching for re-duced environmental impact. The cleaning studies have evaluated different process fluids applied on steel surfaces, which were heat treated and analyzed by advanced methods. The effects of different cleaning operations prior to heat treatment were analysed. A con-clusion is, that it seems to be possible to extend the service-life of those washing/cleaning baths. The study according to polymer quenchants resulted in a guide, on how to handle quenchants in workshops. A prestudy using UV light treatment of polymer quenchants were made, as an alternative to biocides. This study needs to be followed by more R&D.
The major long term focus is to reduce or eliminate waste to landfill, but also to increase internal reuse of sand and fine-grained particles in foundries. Recirculation of bentonite sand generates fine-grained residuals, which has a potential to be used in a number of applications: Added to landfill sand. Landfill sand having 20% fine-grained residuals will result in a leakage-proof combination. Added to foundry sand: Fine-grained residuals can be added into foundry sand from about 20% to 50%, which means a robust and easy to control process. Life cycle analyses are made for different use of the sand.

Participating researcher(s)



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