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个全面的有利可图的污染预防（P3）理论，特别侧重于开发一个综合的反向拖出和动态水分配方法，以最大限度地减少废物和能源，在一般的清洁，冲洗和电镀系统电镀。 动态的废物和能源减少将捕获整个生产系统中产品和环境质量以及经济性的所有时间细节。 这使其区别于通常实践的方法，这些方法侧重于：（一）废物减少的唯一稳态结果，（二）单个单元，以及（三）工厂末端，而不是生产线末端的废物。 在该开发中，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洁、冲洗和电镀溶液泵回（似乎非常危险），将部件上的污垢残留量最大化到污垢的上限（似乎不可接受），增加某些操作中的拖出（似乎违反惯例），以及动态切换水分配（似乎非常困难）。 该方法将在真实的工业环境中进行测试。 初步结果将证明有理由启动该项目的第二阶段。 此外，两所大学的研究生教育亦会受惠，因为学生不但可获得不同专长的教授共同指导，更有机会与工程师合作。电镀业作为全球第二大受环保规管的行业，在达致日益严格的环保及能源目标，以及维持全球经济竞争力方面，正面临巨大挑战。 该行业迫切需要的是能够在电镀厂中显著改善污染预防（P2）实践并同时获得经济效益的方法。

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.