Steel wheel manufacturing: Optimization of wastewater treatment

Customer Application and Activity

Hayes Lemmerz International is a world leader in the production of steel and aluminium wheels for the automotive industry. Its site in Königswinter, Germany, specializes in the manufacture of steel wheels and has a daily discharge of 150m3 of effluents containing zinc, iron and nickel, as well as phosphates.

Problem to be solved

The on-site treatment station was regularly disrupted by an excess of solids in suspension. Moreover, downtime in the plant resulted in unpleasant odours being produced. A solution was sought to:

1. 1- Optimize the elimination of phosphates and heavy metals in the effluents
2. 2- Avoid solids forming in suspension
3. 3- Eliminate odors

Key Achievements

Switching over to Neutralac® SLS45 has led to several benefits for Hayes Lemmerz:

1. 1- Faster removal and superior elimination of zinc, iron and nickel
2. 2- Optimum elimination of the solids held in suspension thanks to better sedimentation after neutralization
3. 3- A lower consumption of flocculants (FeCl3).
4. 4- A filter cake which is more easily detachable from the filter press
5. 5- A major increase in the percentage of dry matter in the sludges
6. 6- Elimination of phosphate build-up through the precipitation of an easily removable calcium phosphate
7. 7- A reduction in the frequency of reagent deliveries and associated transport costs

Conclusions

Since its switch to Neutralac® SLS45 several years ago, Hayes Lemmerz has been treating its effluents successfully. The use of Neutralac® SLS45 has targeted major requirements including:

1. 1- Optimized elimination of phosphates and heavy metals
2. 2- Improved filter cake quality
3. 3- Enhanced effluent treatment at a reduced cost through lower reagent consumption