Journal
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
Volume 142, Issue 7, Pages -Publisher
ASME
DOI: 10.1115/1.4046902
Keywords
electrochemical machining; heavy metal removal; selective ion exchange; natural zeolite; filter paper; Lewatit TP 207; electrical and electrochemical machining; nontraditional manufacturing processes; process engineering
Funding
- Republic of Turkey Ministry of Industry and Technology [621.TGSD.2010]
- Scientific and Technological Research Council of Turkey [111M226]
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During electrochemical machining (ECM) of metals, the electrolyte gets polluted by heavy metal ions and compounds. This creates crucial process control problems due to variation in electrical conductivity and is an environmental threat if the solution is discharged without treatment. In this study, an economical, simple multistep treatment system based on ion-exchange was developed to remove metal ions from the polluted electrolyte. We specifically looked at the electrolytic discharge from ECM of copper pieces, which is widely used in biomedical and electronic applications. Three different ion-exchange media were used: (1) a natural zeolite, (2) a special type of adsorbent quantitative filter paper, and (3) a polymer-based synthetic cation-holder resin (Lewatit TP 207) that works well with copper ions. Optimization studies for pH and contact time showed the following: (1) by using zeolite alone, and after 2 h of mixing, 43.2% of Cu2+ could be removed; (2) by using the filter paper alone, and after three times of filtration, 90% of Cu2+ could be removed; and (3) by using Lewatit TP 207 alone, 100% of Cu2+ could be removed. While Lewatit TP 207 allowed for 100% removal of Cu2+, its use alone is costly and troublesome due to constraints from service life and multistep regeneration and conditioning with strong acids and bases, respectively. The most simple and economical scheme for removal of Cu2+ and recycling the electrolyte for reuse was the three-step zeolite-filter-resin treatment system.
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