The first ion exchangers, as they are generally used today, were described just over 50 years ago. Among other things, they were a product of modern plastics chemistry and the production of plastics for every conceivable application. However, another 20 years or so passed before ion exchangers found their way into wet-chemical metal processing. Initially, it was used to purify water from natural substances and, in particular, to remove precious metals from the water. Such ion exchangers were often incinerated to release the metals. Other metals, on the other hand, were mainly precipitated using conventional methods. Ion exchangers also attracted great interest in technology for less precious metals, especially with the advent of the method of saving water to a considerable extent. The aim was to keep water in circulation for as long as possible. And this is where ion exchangers are the ideal aid. This is also demonstrated by the fact that the structure of the resins has hardly changed in the last 10 to 15 years. Already at this time mature ion exchange resins were available, providing the basis for successful use in chemical surface technology. In recent years, another aspect has boosted interest in ion exchanger technology: Ion exchangers can be used to remove dissolved metals from various industrial waters to such an extent that the low limits for the discharge of water into the public sewerage system are easily met. This means that companies that process metal and are subject to the associated requirements no longer necessarily have to have a wastewater treatment system or transport large quantities of metal-containing solutions to recyclers at high cost. Decker Verfahrenstechnik GmbH in Berg/Oberpfalz is a company that has been offering intensive pioneering work and good service in this area for 30 years now.
30 Jahre Entwicklungen und Veränderungen
In 1987, Erwin Fischer and Reinhard Naujoks decided to found a company, Decker Verfahrenstechnik GmbH, which was to focus primarily on the use of ion exchangers for the purification of water and wastewater. At that time, the use of ion exchangers in electroplating plants was still a new technology. Above all, the production of pure and ultrapure water was the preferred application. However, ion exchanger modules were also increasingly being used in the purification of rinsing water in the processing of precious metals. Extensive development work on this had been carried out in previous years in a number of research projects at the company Dornier in Friedrichshafen, among others.
Reinhard Naujoks and Erwin Fischer had set themselves the task of demonstrating the advantages of ion exchangers when working with metal-containing, aqueous solutions for industry, i.e. to make them attractive through correspondingly innovative technologies. The young entrepreneurs found support from the company Decker GmbH & Co KG, Berg i. d. OPf., which participated as a silent partner with the corresponding premises in their new building. In addition, the periphery with various production areas and workshops as well as the possibility of cooperation with the plant engineering division of the Decker group of companies represented an excellent starting opportunity for a young company. From the very beginning, the company philosophy of the two founders Fischer and Naujoks not only included the production and sale of ion exchanger systems, e.g. also demineralization systems, demineralization cartridges and selective exchanger systems, but also the operation of an own waste water system for ion exchanger regeneration services for the customer. Thus the construction of a chemical-physical wastewater treatment system was linked to the beginning of the company’s history.
The service of carrying out ion exchanger regeneration in addition to setting up an ion exchanger system was gladly accepted by customers. Around three quarters of the company’s customers make use of the service, preferably companies for which it is not practical or feasible to set up their own wastewater treatment system, or companies for which the realization of partial flows of rinsing and waste waters is problematic. The connection to Decker GmbH & Co KG helped to establish customer contacts in the initial phase and made it possible to carry out the orders quickly and thoroughly. The first large system was planned for the Maul & Belser print shop in Nuremberg in 1989. The company’s process technology grew rapidly and in 1991 it was possible to rent approx. 1000 square meters of operating space in the extended building of Decker Gmbh & Co. At the end of 1994, an important research project was completed for Decker Verfahrenstechnik, in which the reduction of contaminated waste water from chemical and electrolytic treatment baths and the development of a process for recycling valuable materials using ion exchangers were described. Using a modular exchanger system, it was shown that the amount of regeneration chemicals can be considerably reduced. The production of mono-sludge was rated positively, although external recycling should be sought in order to achieve reasonable quantities.
Angebot der Decker Verfahrenstechnik
The installation of an ion exchanger system usually begins with a thorough on-site analysis of the types of wastewater and waste produced and the existing disposal processes. The first step is to examine the extent to which a reduction in wastewater and waste or an improvement in processing options can be considered. In most cases, the focus is on minimizing the rinsing water from wet-chemical processes, but electrolytes are also taken into consideration. If the use of ion exchangers is recommended, the most suitable resins are selected. If it is not possible to fall back on proven types, the best possible variant is determined in the company’s own laboratory. The company is in close contact with numerous well-known resin manufacturers such as Lewatit (formerly Bayer) and Rohm & Haas.
However, not only ion exchanger systems are built, but also technologies and systems for neutralization, oxidation, reduction, filtration or sludge treatment are installed if required. The systems are manufactured in-house or – if components are purchased – are fitted and adapted. The more common variant is the installation of a so-called stationary demineralization system for production of demineralized water, where the customer often takes over the regeneration himself. When setting up new processes, Decker Verfahrenstechnik offers the mobile ion exchanger system as an interesting alternative. This allows the application to be tested, giving the customer experience in managing his new processes.
