Transcript Slide 1

In Situ Recycling of Cleaning and
Rinsing Fluids to Meet Lean and
Green Cleaning Process Targets
By
Steve Stach
President
Austin American Technology
Outline
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Setting recycling targets?
Paying for recycling?
What can be recycled?
Review of the 4 basic types of fluid recycling
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Absorption
Distillation
Filtration
Replenishment
• Estimating the cost and saving
– Estimating system life
– Cost Model review
Setting Cleaner
Recycling Targets
• Government Regulations
– Few direct mandates
– Significant cost/liability regarding waste;
i.e. generation, storage, transportation, disposal
• Corporate Directives
– Avoid liability by not generating
– Cut manufacturing expenses
– Marketing
Potential Savings
•
•
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Water Saving – up to 99% reduction
Chemical Savings – 50-99% reduction
Energy Saving – 10-50% reduction
Waste Disposal – 50-90% reduction
What Cleaning Fluids Can be
Recycled?
Just about everything!
• Water
– Tap, DI
• Water Mixtures, Neutral pH
– Buffered aqueous mixtures
• Water Mixtures, Alkaline
– Emulsions, Homogenous mixtures
• Organic, nonflammable
– Halogenated solvents
• Organic, combustible
– Glycols, oils, esters
• Organic, Flammable
– Alcohols, light hydrocarbons
Choosing the Right Recycling
Technology
1. It depends on the Solvent
2. It depends on what is happening in the solvent?
Alkaline/Saponifier
Water/Emulsion
Organic Solvent
Reacting w/Soils
Accumulating Soils
Evaporation
Getting Started
Look at your “Mass Balance”
• Mass Balance analysis
looks at all materials
entering and leaving the
cleaning process.
• Shows where you are
loosing or gaining
fluids/ingredients
Cleaning Mass Balance Diagram
Fluid Feed,
Make-up
Parts
Mist-Evaporative
And Drag-Out
Losses
w/soils
Fluid
Tank
Recycling
System
Cleaning
System
Waste
Cleaning Fluid
With Soils
Sewer or Disposal
Identify & Understand Your Recycling Method
Recycle
Method
Type
Used with
Waste stream
Waste disposal
handler
System
Complexity
level
Safety concern
Chemical
addition
Additive
Key Ingredient
1) Reactive
Aqueous
Mixtures
(saponifiers)
Soil loaded
tank dump
Company
Technician
Medium
Ion Exchange
Subtractive
Adsorption
Rinse water
Alcohols
Glycols
Esters
Depleted DI
resins
Third party
Operator
Low
Carbon
Adsorption
Subtractive
Adsorption
Rinse water
Carbon media
with organics
Third party
Operator
Low
Zeolite
Absorption
Subtractive
Adsorption
NPB
CFC’s
HCFC’s
Zeolite with
adsorbed
contaminate
Third party
Operator
Low
Chelation
Subtractive
Adsorption
Water with
heavy metals
Chelation media
with heavy
metals
Third party
Operator
Low
Distillation
Subtractive
Distillation
NPB
CFC’s
HCFC’s
Non volatile
residues
Company
Technician
High
Filtration
Subtractive
Filtration
All fluids
Filters with
contaminate
Company
Technician
Medium
Reverse
Osmosis
Subtractive
Filtration
Rinse water
Reject fluid
stream
Company
Technician
Medium
Cleaning Fluid Recycling Choices
Cleaning/Rinsing Agent
Adsorption
Distillation
Filtration
Replenish
Ingredient
Water Only
Recommend
Not Used
Used
Not Used
Water Neutral
Not Used
Not Used
Used
Recommend
Water Alkaline
Not Used
Not Used
Used
Organic Non-flammable
Used
Recommend
Used
Not Used
H2O
IPA
Cool
Prec.
Recommend
NPB
Organic Combustible
Recommend
Used
Used
Not Used
Organic Flammable
Recommend
Used
Used
Not Used
Additive Recycling Technologies
• Key Ingredient Replacement
– Common in aqueous mixture to replace
drag out or reactive losses
• Saponifing agents
• Degreasing stabilizers
Subtractive Recycling
Technologies
• Filtration
– Use of filters to remove soils
• Distillation
– Removes contaminates with higher
boiling points
• Absorption
– Use of Carbon, DI resins, Zeolites
and other Media to Adsorb
contaminates
Fluid Filtration
• One of the oldest recycling methods
• Configuration
– Cartridge, Bag, Plate, Cake
• Filter Size
– 1to10 micron typical
• Design Type
– Mono or Multi-Filament
– Absolute vs Standard
• Recommended uses
– Used in most closed or open loop cleaning systems
Fluid Distillation
• Boiling fluid is vaporized and
condensed
• High boiling soils are left
behind for disposal
• Recommended for nonflammable, single solvents or
azeotropic solvent blends
• Not usually recommended for
water or flammable solvents
Ion Exchange
• Ionic soils are captured by ion exchange resins
• Cations (Na+, K+,NH3+) are removed by cationic
exchange resins
• Anions (OA-, Br-,CO3-) are removed by anionic
exchange resins
• Mixed Beds remove both Anions and Cations
• Recommended for purifying water and most organic
solvents
• Not recommended for solutions containing amines
Carbon Absorption
• Organic soils are captured by
Granular Activated Carbon
(GAC)
• Works on basis that “Like
attracts Like”
• Capacity depends on the
molecule
• Often used in conjunction
with DI closed loop systems
Carbon Exhaustion Foams Rinse
Carbon Absorption
• GAC is made by anaerobic
heating organic material to
drive off all volatiles
• Most GAC is acid washed to
remove acid soluble impurities
• Coconut shell and anthracite
coal are two type that product
low powdering
• GAC can be partially
regenerated by steam
stripping – not recommended
Carbon Absorption
VS Compound
Compound
Mole Weight
Water
Solubility %
Adsorption g
soil/ g GAC
Adsorption %
reduction
2-ethyl butanol
102.2
0.43
.170
85.5%
Mono-ethanol
amine
61.1
∞
.015
7.2%
Di-ethanol
amine
105.1
95.4
.057
27.5%
Nitro-benzene
123.1
0.19
.196
95.6%
Butyric acid
88.1
∞
.119
59.5%
Ethylene glycol
mono butyl
ether
118.2
∞
0.112
55.9%
Test solution1g/liter
Closed Loop Inline Cleaning System
FilterMΏ
GAC
Mixed
Carbon
Turbine
1g/m
1g/m
Reverse Osmosis (RO)
• RO is most commonly used for feed
water generation to closed loop
cleaners
• RO typical removed ~90% of dissolved
solids from tap water
Reverse Osmosis
• Molecular sized microscopic pores block large
molecules and allow smaller molecules to pass
Incoming Tap/RO water
Feed to fill tanks
Initial and Make-up
Operational .Flow @120F=
3gal/hr estimated
Dryer
DI Rinse
Power Rinse
Chem
Isolation
Wash
Chem
pump
Filter MΏ
GAC
Carbon
Mixed
Turbine
High Alarm
High Alarm
Add
Add
Low Alarm
Low Alarm
1g/m
1g/m
~25gallons
~40gallons
Gravity Drain
Inline Cleaner - closed loop wash and Rinse
Back View - Plumbing diagram
Problem Heavy Metals in
DI/GAC media
• Absorptive medias capture metal ions
• Cations (Pb+2, Ag+2,Cu+2) are captured
by cationic exchange resins
• GAC can do the same
• Use new GAC and DI media or find
regenerator with metal cheatlation
system
Molecular Sieve Absorption
• A molecular sieve traps molecular soils in
microscopic pores.
• Naturally occurring materials are referred to
as zeolites
• Man made materials are called molecular
sieve.
• Molecular sieve comes in different pore sizes
ranging from 3 to 12 angstrom
• Commonly used as a desiccant
• Available in round or extruded pellets
Molecular Sieve Absorption
• Useful in removing water, flux residues, and
most ions from organic cleaning solvents
35X
700X
4,500X
Use of Molecular Sieve
• Molecular Sieve
filters to remove
contamination
from
– Degreasing
Solvents
– Organic solvents
The impact of the recycling location
The impact of the recycling location
Here, There or Anywhere?
Chem
pump
MΏ
GAC Filter
Mixed Turbine
Carbon
~25gallons
1g/m
1g/m
In Situ
(in the cleaner)
Plant System
(in the factory)
Third party
(bonded & licensed)
Off-site Treatment of
Cleaning Materials
• The Local Sewer Plant
– Check with local water authorities
– A permit may be requires
• The DI Guy
– What materials do they use?
• Source, new or regenerated?
– How do they dispose of the waste?
• Solvent Recycler/Disposal
– Use EPA licensed & bonded company
– Cradle to grave responsibility
In-plant Recycling of Cleaning Fluids
• Distillation and Evaporation
– Check with local air quality
authorities
– A permit may be required
• Central DI Plant
– What materials are use?
• Source, new or regenerated?
In Situ Recycling of Cleaning Fluids
• Built in, or Next to the Cleaner
– No transfer logistics
– Minimizes heat loss
– Fewer Parts
• Local Control
– Requires training
• Operator
• Maintenance
• Costs less to Operate
– Equipment costs less than stand
alone
– Lowest operating costs
The Cost of Cleaning
Building the Cost Model
Indep
Process Data
Inline Open Loop
Closed Loop
Central
System
Varib
Equipment cost
$200,000
$200,000
$200,000
DI system system cost
$25,000
$35,000
$5,000
Shipping
$5,000
$5,000
$4,000
Water consumption rate gph (operating)
300
10
10
Cost of water $'s/gal
$0.01
$0.01
$0.01
Cost to regenerate DI (1.5Ft3)
$300.00
$500.00
$500.00
Water purity (dissolved solids) mg/gal
250
20
20
Final rinse rate GPM
5
5
5
Power cost $s/Khr
$0.10
$0.10
$0.10
Operating KW (KV*A)
100
110
75
Inline Cleaner Cost Model
7
year equipment amortization
6
Run time per Shift
300
In Situ Closed
Loop
Shifts per year
Process Costs ($'s/hr)
Absorbtive capacity (mg CaCO3 or Succinate)
Bed Life (hrs of operation)
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Capacity of Close Loop Absorptive
Beds
•
Depends on the Ion
– Molecular weight & valance
•
Tank Absorptive Capacity (Abtotal)
– Bed Volume (Vab)
– Absorptive Capacity (Abcap)
(Abtotal) = (Abcap) X (Vab)
Estimating the Life of Absorptive Beds
US map showing
water hardness
• Contamination Feed Rate
– Mass Flow Rate (MFrate)
Bedlife = (Abtotal / MFrate)x %factor*
* %factor is % available in begining + % remaining at exhaustion
Building the Cost Model
Indep
Process Data
Inline Open Loop
Closed Loop
Central
System
Varib
Equipment cost
$200,000
$200,000
$200,000
DI system system cost
$25,000
$35,000
$5,000
Shipping
$5,000
$5,000
$4,000
Water consumption rate gph (operating)
300
10
10
Cost of water $'s/gal
$0.01
$0.01
$0.01
Cost to regenerate DI (1.5Ft3)
$300.00
$500.00
$500.00
Water purity (dissolved solids) mg/gal
250
20
20
Final rinse rate GPM
5
5
5
Power cost $s/Khr
$0.10
$0.10
$0.10
Operating KW (KV*A)
100
110
75
Inline Cleaner Cost Model
7
year equipment amortization
6
Run time per Shift
300
In Situ Closed
Loop
Shifts per year
Process Costs ($'s/hr)
Absorbtive capacity (mg CaCO3 or Succinate)
Bed Life (hrs of operation)
1,680,000
7,900,000
7,900,000
3.7
219.4
219.4
Cleaning Cost Estimates
Inline Open
Loop
Annual Cost of beds OL DI, CL DI+GAC
Closed
Loop
Central
System
In Situ
Closed Loop
$144,642.86
$4,101.27
$4,101.27
$80.36
$2.28
$2.28
$3.00
$0.10
$0.10
Power costs/hr
$15.00
$16.50
$11.25
Total Power and water cost $/hr
$98.36
$18.88
$13.63
Equipment Amortization cost per hr
$16.43
$17.14
$14.93
$114.79
$36.02
$28.56
Hourly Cost of beds
Hourly cost of tap water
Total Equipment + Water + Power ($/hr)
Summary
• Government and industry are driving
recycling
• Cost and environmental benefits provide
the rewards for conversion
• Cleaning mass balance analysis provides
data to start
Summary
• All cleaning solvents can be
recycled
• There are many methods of
recycling
• Your clean solvent guides you
recycling method
Summary
• Recycling reduces process costs
• The location of the recycling system
can affect cost.
• In situ recycling is the most cost
effective
Conclusions
• If you are not recycling your
cleaning fluids, you should be!
“In Situ Recycling of Cleaning and Rinsing Fluids to
Meet Lean and Green Cleaning Process Targets”
by
Steve Stach
Thank You for Attending
Questions
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