Otimização do Uso de Hidróxido de Cálcio no Tratamento de Efluentes: Estudo de Caso em uma Indústria de Reciclagem de Chumbo

Abstract

The search for operational efficiency and sustainability has driven the industry to adopt structured methodologies for optimizing production processes. In the lead recycling sector, effluent treatment plays a fundamental role in environmental compliance, with calcium hydroxide being a critical input in the neutralization of acidic waste. However, excessive consumption of this substance can lead to significant financial impacts, such as increased operating costs, in addition to environmental problems such as excessive sludge formation and increased generation of solid waste. This study aims to apply quality management tools to reduce calcium hydroxide consumption in the effluent treatment plant (ETP) of a lead recycling industry. To this end, problem-solving methodologies were employed within the context of World Class Manufacturing (WCM), which integrates the Kaizen continuous improvement philosophy. The problem identified demonstrates the need to reduce consumption by 26.7% to achieve the target set by the company. This deviation from the target remained for more than five months, reinforcing the importance of a detailed investigation of the causes. Using the Ishikawa Diagram, the 5 Whys technique and brainstorming sessions with the team involved, the main root causes of the problem were identified as the lack of regularity in cleaning the formulation tank, the inadequate concentration of the calcium hydroxide solution and the lack of strict control of the dosing process. In view of this, an action plan was drawn up including the review of the allocation of calcium hydroxide consumption, the performance of laboratory tests to adjust the ideal dosage and the standardization of new operational procedures. The results obtained demonstrated a significant reduction in calcium hydroxide consumption, reaching the established target within just one month of implementing the corrective actions. In addition to reducing operational costs, the optimization of the process allowed for the minimization of waste generation, promoting a more sustainable operation aligned with good environmental practices. Thus, this study reinforces the importance of the structured application of quality management tools such as the cause and effect diagram and continuous improvement methodologies in the industry, demonstrating that the adoption of systematic approaches can result in significant gains in both economic and environmental terms. Thus, the results achieved can serve as a reference for future process optimization initiatives in different industrial sectors, contributing to the consolidation of sustainable and efficient practices.