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Pollution Prevention and Control Technologies for Plating Operations

Section 4 - Chemical Solution Maintenance


4.5.5 Costs Capital Costs Operating Costs Capital Costs

The required size of an APU™ depends mainly on: (1) the volume of the acid bath; (2) the type and concentration of acid; (3) the dissolved metal buildup rate; and (4) the permissible operating concentration of dissolved metal. With regard to the fourth sizing criteria, most pickling applications are sized to operate at 40 g/l to 50 g/l of dissolved metal, most anodizing applications are sized to operate at 10 g/l of aluminum, and most nickel or copper stripping (nitric) applications are sized to operate at 70 g/l.

Exhibit 4-16 shows the capital costs (APU™) for the maintenance of sulfuric acid anodizing baths (based on a 10 g/l aluminum feed concentration. The equipment costs include the APU™, prefiltration, feed and product tanks, and a cooling system. Installation costs are estimated to range from 10% to 35% of equipment costs. Exhibit 4-16 covers the most common range of applications. A larger APUª unit is available that would provide 70 kg/hr of aluminum removal. Operating Costs

The primary operating cost elements for this technology include: O&M labor, parts replacement, resin replacement and electricity. Water use costs are negligible for most applications.

Estimated operating costs for the sulfuric acid anodizing application are $16.00/kg ($7.27/lb) of aluminum removed. Operating cost data and annual savings data provided by respondents to the Users Survey are presented graphically and compared to capital costs (estimated in 1993 dollars) in Exhibit 4-18.

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