Medium
Acids and alkalis
Container
VARIBOX and standard IBCs
Solution
5× SAFETEC pump kit
The Challenge
At the electroplating facility in Bad Laasphe, the process baths are regularly replenished with Sulphuric acid, nitric acid and caustic soda. Until now, dosing has been carried out manually from canisters and IBCs – involving direct contact between staff and corrosive substances, significant handling effort and increased disposal costs. The laboratory-monitored baths must be topped up with Sulphuric acid, nitric acid and caustic soda – until now, this has been done manually from canisters or single-use IBCs, involving direct contact with staff.
Direct Media Contact
When handling canisters and single-use IBCs, staff were exposed to splashes, vapours and the transport of heavy loads from the cellar — a safety risk despite the use of protective equipment.
Manual dosing errors
Manual top-ups of active baths monitored in the laboratory leave room for variations in concentration — and thus for fluctuations in coating quality.
High disposal costs
Disposable IBCs incur disposal and annual inspection costs for spill trays — a cost factor that continues to rise with every batch.
Gallery
Dosing process
From the sealed IBC in the basement to reproducible dosing in the electroplating bath, in four steps.
The filled VARIBOX IBC is connected to the SAFETEC via a hose line with a dry coupling. The coupling reliably prevents the medium from leaking during connection and disconnection. Depending on the container type, either a conventional IBC suction lance or the suction lance integrated into the VARIBOX is used.
Using the touch panel with a plain-text display, the operator selects a preset filling quantity or enters it directly. Alternatively, the pump runs until the IBC is completely emptied. Control stations are installed both in the basement near the IBC storage areas and on the ground floor near the electroplating tanks.
The MAGSON magnetic centrifugal pump conveys fluids at temperatures up to 60 °C through pipes from the basement to the electroplating baths. Solenoid valves in the pipes act as backflow preventers when the pump is shut down. The ultrasonic flow meter measures the flow rate noncontact and without any moving parts.
The built-in dry-run monitoring system indicates an empty IBC on the display and automatically shuts off the pump. The dry coupling allows the container to be replaced without coming into contact with the fluid—the supplied VARIBOX is returned to the chemical supplier via the circulation system.
0 %
Employee exposure to corrosive substances
5
SAFETEC units for different chemicals
100 %
Automated and reproducible dosing
Products Used
SAFETEC pump ket
For emptying enclosed IBCs and drums; compatible with CDS/QC couplings
MAGSON magnetic centrifugal pumps
Leaks are impossible; the pumps operate maintenance-free
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