PREMISE/Collaborative Research: Integrated Drag-out and Dynamic Water Allocation for Maximum Reduction of Waste and Energy in the Electroplating Industry

在这个产品实现和环境制造创新系统（PREMISE）项目中，韦恩州立大学和拉马尔大学计划共同开发一种综合的可盈利的污染预防（P3）理论，重点是开发一种集成的反向拖出和动态水分配方法，以最大限度地减少电镀中的一般清洁、冲洗和电镀系统的浪费和能源。动态的废物和能源减少将捕捉整个生产系统中产品和环境质量以及经济的所有细节。这将其与通常实践的方法区别开来，这些方法侧重于：(i)减少废物的单一稳态结果，（ii）单个单元，以及（iii）工厂结束而不是生产线结束的废物。在这一发展中，pi将进行三种类型的整合：(i)清洁，冲洗和电镀的整合，（ii）设计（修改）和控制（操作）的整合，以及（iii）经济和环境问题的整合。在系统设计中，该方法的基本方法是将清洗、冲洗和电镀溶液泵回（看似风险很大），将部件上的污垢残留最大化到污垢的上限（看似不可接受），在某些操作中增加拖曳（看似违反惯例），并动态切换水分配（看似非常困难）。该方法将在实际工业环境中进行测试。初步结果将证明有理由展开该项目的第二阶段。这一合作也将有利于两所大学的研究生教育，因为学生不仅可以由不同优势的教授共同指导，而且还有机会与合作的工程师一起工作。作为环境监管第二严格的行业，电镀行业在实现日益严格的环境和能源目标、保持全球经济竞争力方面面临着巨大的挑战。该行业迫切需要的是一种方法，可以大大改善污染预防（P2）的做法，同时获得经济效益的电镀工厂。

In this Product Realization and Envrionmental Manufacturing Innovative Systems (PREMISE) project, Wayne State University and Lamar University plan to jointly develop a comprehensive profitable pollution prevention (P3) theory, with a specific focus on the development of an integrated reversed drag-out and dynamic water allocation methodology for maximum waste and energy reduction in general cleaning, rinsing, and plating systems in electroplating. The dynamic waste and energy reduction will capture all-time details of product and environmental quality and economics in the entire production system. This distinguishes it from commonly practiced approaches that focus on: (i) a solely steady-state result of waste reduction, (ii) individual units, and (iii) end-of-plant, rather than end-of-line waste. In this development, the PIs will conduct three types of integration: (i) the integration of cleaning, rinsing, and plating, (ii) the integration of design (modification) and control (operation), and (iii) the integration of economics and environmental concerns. In system design, the basic approach of the methodology is to pump cleaning, rinsing, and plating solutions back (seemingly very risky), to maximize the dirt residue on parts to the upper limits of dirtiness (seemingly not acceptable), to increase drag-out in certain operations (seemingly against convention), and to dynamically switch water allocation (seemingly very difficult). The methodology will be tested in a real industrial setting. The preliminary results will justify the initiation of the second phase of the project. The joint effort will also benefit the graduate education in the two universities as students will not only be co-advised by the professors with different strengths, but also have opportunities to work with collaborating engineers.As the second most environmentally regulated industry, the electroplating industry is facing tremendous challenges in achieving increasingly stringent environmental and energy goals and maintaining global economic competitiveness. An urgent need for the industry is the methodology that can substantially improve pollution prevention (P2) practice and gain economical benefits simultaneously in electroplating plants.