This master’s thesis addresses the safety, health, and environmental challenges associated with electroplating processes. The work examines the feasibility of replacing carcinogenic hexavalent chromium (Cr(VI)) with the less harmful trivalent chromium (Cr(III)), the application of the HAZOP method for risk management, and potential improvements to reduce environmental impact. Hexavalent chromium is known to cause severe health problems, including lung cancer, as well as damage to the respiratory and digestive systems, skin, and eyes. In the environment, it contaminates water, soil, and air, negatively affecting plants, animals, and aquatic ecosystems.
Based on the physical and chemical characteristics of chromium, a study was conducted to assess whether the substitution of Cr(VI) with Cr(III) is technically feasible. Two risk assessment methods were applied: the AUVA method, which is quantitative, and the ZVD method, which is more descriptive and qualitative. The HAZOP analysis revealed that the greatest risks are associated with toxic vapors and electrolyte spills. Consequently, technical and organizational measures were proposed and implemented to mitigate these risks, including personnel training and the development of evacuation protocols.
From an environmental perspective, the thesis discusses closed systems and pulse electrodeposition, which reduce electrolyte consumption by 20–30% and emissions by 15–25%. The study is aligned with European legislation, such as Directive 2010/75/EU, and emphasizes the need for further development of Cr(III)-based technologies and the investigation of alternative chemicals. Overall, the thesis presents a comprehensive approach to safer and more sustainable electroplating processes, aiming to protect worker health, ensure process safety, and minimize environmental impacts.
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