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4. Electroless copper bath growth.
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Process chemistry substitution using palladium-based and/or graphite-based alternatives. Copper recovery. Autocatalytic copper removal onto a sponge.
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Eliminates formaldehyde.
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May produce excess organic wastes. May not be suitable for all applications. Expensive compared to other methods. Produces a waste to be transported. Continuous activation, heat, and monitoring are required. Produces sludge. Chelating agents are still present in the treated waste. May not be universally applicable. Solids handling could be a problem. Expensive proprietary chemicals. Minimal organic load reduction in treated waste. Requires segregation. Requires space to install dragout tanks. Requires more waste segregation and can be expensive as more recycling and recovery is required. Produces sludge. Increasing liability. Requires intensive effort for labor. Not universally applicable. Possible chemical treatment of bath VOC emission from semiaqueous baths.
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Reduces copper discharge. Effective removal of copper metal complexed with EDTA. Possible copper recovery. Least capital cost. Eliminates hauling solids. Reduces quantity of this material to be hauled for off-site disposal.
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Chemical treatment. 5. Develop/Resist Strip. Use resists which do not emit wastes. Chemical treatment to reduce volume compared to hauling spent process baths off-site for disposal or dumping waste to the sewer. 6. Other wastes including tin, tin/lead, nickel, and gold. Recover metal and chemistry from dragout tank.
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Bath and metal recovery and recycling are possible.
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Chemical treatment and membrane filtration. 7. Printed circuit assembly cleaning wastes. Use of water-soluble solder mask and flux. Use of semiaqueous or saponified cleaners for RMA fluxes.
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Least capital cost. Eliminates toxic chemicals. Allows rinse recycling. Eliminates use of CFCs.
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Settling Process Following the second-stage pH adjust, waste flows to the flocculation chamber in a clarifier where polyelectrolytes and recycled sludge are added and rapidly mixed. The waste then enters a second stage where a slow-speed mixer is used to enlarge the hydroxides to make settling more effective. Finally, the flocculated waste will flow down the clarifier. The precipitated solids settle to the bottom of the clarifier and the clarified liquid is discharged to a final pH adjust system or in some cases to a sand filter prior to final pH adjust if required to meet discharge standards. (See Fig. 60.6.)
Cross-Flow Microfiltration Cross-flow microfiltration systems are used in place of a clarifier and sand filter where the maximum discharge limit for copper is below 1.0 mg/l. Treated wastes are collected in a recirculation tank and pumped at turbulent flow and 10 to 35 psig through a series of capsules containing tubular filters. The majority of the recirculated wastewater plus all the suspended solids returns to the recirculation tank. The suspended solids free water will pass through the side walls of the tubular filter. Sludge is withdrawn near the discharge of the recirculation pump. The 3 percent (total suspended solids) sludge is pumped to a sludge holding tank and then pumped to a filter press. (See Fig. 60.7.)
Sludge Thickening and Dewatering The purpose of the sludge thickening tank is to increase the concentration of the 1 to 2 percent sludge from the clarifier to approximately 3 percent. This is accomplished by continuously decanting the water from the sludge thickening tank and directing it back to the rinse collection tank. The solids from the sludge thickening or holding tanks are then pumped to a filter press for dewatering to reduce sludge volume. The total suspended solids in the sludge can be increased to about 35 percent with a filter press. In addition, sludge dryers are available which increase the solids concentration to about 70 percent by adding heat to the sludge. This reduces the volume of sludge to be hauled away.
60.9 ADVANTAGES AND DISADVANTAGES OF VARIOUS TREATMENT ALTERNATIVES
All of the techniques described in this chapter have advantages and disadvantages. None of them are appropriate in all situations. Each potential application requires specific analysis and a thorough understanding of the technical and economic issues involved prior to implementation.Table 60.2 presents a summary of the advantages and disadvantages of some of the technologies discussed in this chapter.
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