Greening of production in metal processing industry through process modifications and improved management practices

• 5 Different sustainable production applications were realized in a metal processing company.
• Water consumption of the company was reduced by 18,831 m3/year (34.1%).
• Wastewater treatment sludge was reduced by 4656 kg/year (16.9%).
• Chemical consumption in zinc phosphating was decreased by 1401 kg/year (26.1%).
• Study was carried out as part of “National Eco-efficiency (Cleaner Production) Programme”.

Although it was indicated through various studies from around the world that resource efficiency can be adapted in metal processing plants, a very limited number of projects could be realized in Turkish metal processing industry so far. In this study it was aimed at investigating process modifications and management practices to increase water and chemical use efficiency thus increasing environmental and economic performance of a metal processing company. As a result of the applications in heat treatment and zinc phosphating processes total water consumption of the company was reduced by 34.1% corresponding to an annual water saving of 18,831 m3. Moreover, total chemical consumption in zinc phosphating as one of the most chemical intensive processes in the company, was decreased by 1401 kg/year (26.1%). Applications in zinc phosphating process led to a significant decrease in the amount of treated wastewater and wastewater treatment sludge which is labelled as hazardous waste according to national legislations. Total wastewater generation was decreased by 3255 m3/year (50.9%) while wastewater treatment sludge was reduced 4656 kg/year (16.9%). Moreover, energy consumption of the company was reduced by 32.647 kW h/year which corresponds to 36% energy saving in water pumping. Implementation cost of the applications were 34,233$ which is calculated to be paid back in 2.3 years. This study is expected to fill a gap in Turkey by demonstrating that environmental performance in metal processing industry could be improved by process modifications and improved management practices resulting in tangible economic gains.