How to Achieve Optimum Productivity with Comprehensive Water Treatment

Related Vendors

cac-2023-poslogo-idea-ahead (CAC ENGINEERING GMBH)

The customer provided full support in flushing the water whenever it was requested. With the cooperation of the customer, a significant quantity of bad quality water was flushed out. The turbidity level was reduced from 450 NTU to 10 NTU, and the iron level from 25 ppm to 0.5 ppm in the weld guns. The water loss was checked and recorded. The 3D Trasar cooling water technology along with the filter aid solved the issues and met the customer’s requirements.

Environmental / Economic Results

With Nalco’s chemical treatment program; dosing filter aids N8105 at the sand filter and suggestions for maintaining the flow rated of the side stream filters, continuous monitoring through 3D Trasar Technology and regular service; the following results were achieved:

1. Avoid Production Loss and increase System Protection

As the turbidity and iron levels in the guns were reduced, the down time of the weld guns was significantly reduced from 600 hours to 180 hours per year due to the decreased flushing frequency of the guns from once every day to once every three months. This eliminated the choking issue of the guns which required significant cleaning. The welding shop has more than 400 guns, and this process avoided a major production loss. Compared with 2010, production increased by 150 per cent from 38,000 cars per year to 100,000 in 2011.

2. Reduce Chemical Consumption

Chemical consumption was reduced by around 50 per cent per year due to the stable dosing control of 3D Trasar cooling water technology, saving the customer $10,100 per year.

3. Reduce Water Consumption and Wastewater

Because of the decreased flushing frequency, the fresh water consumption was reduced from 1300 m3 in 2010 to 990 m3 in 2012. This was a reduction of nearly 30 per cent, saving $10,000 per year. The wastewater treatment cost in the Effluent Treatment Plant (ETP) system was also reduced by $ 20,000 annually due to reduced fresh water usage. Along with the lowered iron and turbidity levels, the particles in the weld water of the guns were reduced by 98 per cent in both volume and total number, improving the water quality and clarity.

(ID:43511924)