Galvano Hengelo is a specialised galvanisation company based in Hengelo, operating in surface treatment (silver plating, tin plating, Protalloy® (zinc-nickel) and electroless nickel) since 1996 for a wide client base across Western Europe. The company strives to stay ahead when it comes to sustainability and views innovation in this area as an opportunity rather than a burden.
Curious about a better method
The company has a long-standing partnership with Vivochem, and in 2022, it decided to trial Ferr-Tech’s sustainable innovation, FerSol®, as an alternative to conventional chemicals in its wastewater treatment process. They were curious about new methods to remove heavy metals, notably copper, from their wastestream. They were especially interested in ways to speed up the process while reducing their environmental footprint by lowering chemical consumption. Galvano Hengelo’s goal: to use a sustainable chemical capable of reliably achieving at least the current discharge requirements, take a significant step forward in process efficiency, and drastically reduce chemical consumption. The pilot with FerSol® is now well underway, and early results look promising.
About FerSol®
FerSol® is Ferrate (VI), the world’s most powerful oxidant, in liquid form. It is an innovative and green chemical that is up to 63% stronger than chlorine. FerSol® can be used in the purification of (waste)water and offers a sustainable alternative to traditional chemicals with a higher environmental impact. It simplifies the water treatment process, lowers energy consumption, and enables water reuse. Besides heavy metals, FerSol® removes various other pollutants from wastewater, such as phosphates, COD, organic contamination, ammonium, and hydrocarbons.
A more effective and sustainable way to remove heavy metals
Depending on the batch, Galvano Hengelo’s wastewater contains various heavy metals. In the past, they treated this wastewater using chemicals such as ferric chloride and sodium sulphide. This approach often required large amounts of chemicals and had a relatively long processing time. Copper removal, in particular, was the most challenging, frequently taking up to a day and a half per batch.
Beyond regulatory compliance, Galvano Hengelo was motivated by a desire to proactively reduce the use of conventional chemicals to minimise its environmental footprint.
The company, therefore, faced a clear challenge: finding a more effective and sustainable method for removing heavy metals from its wastewater. That’s precisely where FerSol® comes in.
“We aim to do things as smart as possible. If there is a way to use fewer chemicals, we want to explore it.”
Testing tailored to diverse conditions
Every day at Galvano Hengelo looks different, and the composition of the wastewater varies just as much. That meant integrating FerSol® required a custom approach tailored to their dynamic needs. Due to the broad range of wastewater batches, time and fine-tuning were needed to integrate FerSol® effectively, which was achieved through close collaboration with the technical specialists at Ferr-Tech. The process started with lab analysis of samples, followed by on-site testing. The pilot was launched in 2022, and a more extensive test has been running since the beginning of this year.
Integration into their existing process was straightforward: the only addition was a mix, condition, and dose unit (MCD) to ensure cooling and precise dosing of FerSol®. FerSol® is added during the water treatment process and effectively removes heavy metals from the water.
“Removing copper used to be a time-consuming task. In the past, we relied on large amounts of iron chloride and sulphide. Since switching to FerSol®, these problems have been solved. The process of eliminating copper is now much faster, and chemical consumption has been significantly reduced.”
Results so far
While the pilot is still ongoing, the positive impacts of FerSol® are already noticeable.
In some cases, sodium sulphide has already been completely phased out, and the complete replacement of ferric chloride is also being investigated. Such replacements simplify the process and make it more sustainable.
“We are already successfully removing one heavy metal, copper, with FerSol®. Our goal is to extend the use of FerSol® to as many other heavy metals as possible that need to be removed in our water treatment process.”
Reduced use of chemicals such as ferric chloride and sodium sulphide.
Easy integration into the existing process.
Significant improvement in copper removal, with processing times reduced from up to a day and a half to just a few hours.
Potential for broader application across different wastewater batches.
About the collaboration
The collaboration between Galvano, Ferr-Tech, and Vivochem has been positive. Given the variations in wastewater batches, the process demands coordination and flexibility from everyone involved.
“No two weeks are the same here. You need to adapt when a new batch comes in. That dynamic makes the testing phase more time-consuming.”
As it is a tailored process, continuous adjustments are part of the journey.
Looking ahead
Galvano Hengelo intends to expand the use of FerSol®, as long as the process remains straightforward and the benefits continue to prove themselves. The company aims to consistently meet discharge limits, and using FerSol® also aligns with their broader commitment to sustainability. This approach goes beyond compliance; it reflects their dedication to continuous improvement.
For Galvano Hengelo, sustainability is not an obligation. It is a conscious choice that shapes their strategy for the future.
“We don’t see sustainability as something we’re forced into. It’s an opportunity. Companies wanting to remain relevant in the coming decade need to start actively considering sustainable practices today. This project with Vivochem and Ferr-Tech shows it is a priority for us.”
