Integrated Electroplating System Modeling and Simulation for Near Zero Discharge of Chemicals and Metals

Abstract

The optimality of design and operation of an electroplating system determines largely coating quality, productivity, and waste reduction efficiency. Industrial practice shows that, in a usual operation, the solution loss from an electroplating unit through drag-out can be as high as 30% of overall consumption. This has dramatically increased operating cost as well as waste treatment cost. On the other hand, plating quality in terms of coating thickness on workpieces is always a concern in plants. To improve the economic and environmental performance, a key step is to have a deep understanding of the system. Model-based simulation has proven to be a costeffective approach along this venue. This paper introduces a fundamental-based general modeling methodology for characterizing an integrated electroplating system that consists of a plating unit and a solution recovery subsystem. The methodology allows detailed system analysis and complete process information integration, which will be crucial for optimal design and operation of a closed-loop electroplating for prevention of plating solution loss and assurance of coating thickness on workpieces. A case study on an alkali zinc electroplating system will demonstrate the efficacy of the model-based design and operation approach.

Synergetic Modelling of Energy and Resource Efficiency as well as Occupational Safety and Health Risks of Plating Process Chains

“…In the same context, Despeisse et al were rather focusing on production systems aspects and their interaction with the factory system [27]. Xu et al model the resource flows in electroplating and rinsing systems for one specific product [28]. However, the approach neglects the energy demand and other systems of the plating line.…”

“…Cleaner production regulations in the electroplating industry System dynamics Heilala et al [22] Environmental impact of discrete manufacturing systems Discrete event model with a life cycle impact assessment Kurle [23] Planning heat flows in production systems Dynamic heat flow model Leiden [24] Energy and resource demand of plating process chains Dynamic energy and resource flow model Thiede [25] Energy flows in manufacturing processes and systems Dynamic energy flow model THERM [26,27] Energy flows in manufacturing systems and building Dynamic energy flow model Xu [28] Chemical/metal flows in electroplating and rinsing process Mass balance with stoichiometric equations…”

Model-based analysis, control and dosing of electroplating electrolytes

“…A validation by comparing the simulation results with analytical measurements is not available. Xu et al modelled an alkali zinc plating process in detail based on the chemicals reactions in the electrolyte [29]. Again, this approach lacks a validation with analytical measurements.…”

Agent-Based Simulation Approach for Occupational Safety and Health Planning: A Case of Electroplating Facilities

“…Kurle [16] partially included electroplating processes into his approach, but mainly focusses on the heat flows in the production system. Xu et al [17] model the resource flows in electroplating and rinsing systems in detail, but neglect the energy demand and further systems of the plating line. This detailed approach also allows for simulating only one specific product.…”