metalvoc layman report - european commission |...

Layman report METALVOC/LIFE-Project

METALVOC

LAYMAN REPORT

Reduction of VOC emissions by using fatty acid esters

for metal cleaning processes

(LIFE97 ENV/D/000465)

LIFE-Program of the European Union, Directorate General Environment

Project Coordinator: Kooperationsstelle Hamburg Besenbinderhof 60 D – 20097 Hamburg

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REDUCTION OF VOC EMISSIONS BY USING FATTY ACID ESTERS FOR METAL CLEANING PROCESSES SUMMARY 1. VOC-emissions from metal surface cleaning operations contribute significantly to the pollution of the atmosphere. The solvent-using industry is aware that alternatives are present and that the use of volatile solvents will be restricted in future. 2. Guided by the project team around 130 practical industrial tests have been conducted to show the applicability of emission-free fatty acid esters as possible alternatives for solvents. 3. It could be shown that esters can replace solvents in many typical metal surface cleaning operations, as open manual cleaning, repair activities and special applica-tions. 4. Guidance and information for the industry was provided by a large number of dissemination activities and the final publication of a comprehensive manual. 5. Initiated by the project team, important stakeholders have agreed on guides to promote the use of emission-free cleaning technologies. The sustainability of the pro-ject results is strongly supported by such agreements and other follow-up activities. 1. BACKGROUND Volatile Organic Compounds (VOC) are used in a large scale in many industrial processes. Due to high volatility many of these compounds are emitted directly into the air. For a long time organic solvents have been known as hazardous substances for both the environment and human beings. For these reasons, industrial users have looked for substitutes for volatile solvents since many years. Environmental hazards associated with organic solvent emission include the build up of atmospheric ozone by photochemical oxidation (Summer Smog) and ozone depletion in the stratosphere. Solvent use is also linked to water and soil pollution - the biodegradability of most mineral oil based solvents is inferior to products based on vegetable oils. In order to promote the reduction of VOC-emissions, the European Commission has adopted a directive with the aim that industry should reduce non-methane VOC-emission from industrial solvent use in Member States by 57 % from 1990 emissions levelsi. Solvents, their vapours and mists also have various negative effects on human health. Solvents enter the body by inhalation, swallowing and through the skin. Many of them have a neurotoxic effect, causing fatigue, dizziness and intoxication. Solvents degrease the skin. In addition, most organic solvents are flammable causing a fire risk. The metal industry is one of the largest consumers and emitters of solvents. Within the European Community, 2.2 million tonnes of solvents are consumed per year in industrial processes. Metal degreasing is calculated to be more than 1/10 of this figure (see figure 1). Currently, the typical cleaning agents in the metal sector are mainly petrochemicals of fossil origin. They are more or less volatile and often contain additives, e.g. corrosion inhibitors.

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Figure 1: Industrial Organic Solvents Use in the EU 2. THE PROJECT APPROACH - TESTS AND PROMOTION OF THE ESTER TECHNOLOGY This project set out to demonstrate that volatile organic solvents commonly used for cleaning purposes in the metal industry could be replaced by products on the basis of vegetable oil esters. Fatty acid esters represent an environmentally friendly alternative to typical industrial cleaners in the metal branch. They are emission-free, non-toxic, easily biodegradable and based on renewable resources. Figure 2: Production of esters from vegetable oils. Two examples: a) rape seed oil b) coconut oil

The project METALVOC was accepted for funding by the Life-Programme of Directorate Ge-neral XI (Environment) in 1997 for a three years period. Co-financing was provided by the German Industrial Professional Association for the Metal Industries, the State of Hamburg (Dept. of Environmental and Dept. of Finance) and the project partners’ own resources.

The overall goal of the project was to demonstrate successfully the substitution of organic solvents as cleaning and degreasing agents for with vegetable oil esters in pilot companies of the metal sector. The project was structured in a pilot, optimisation and dissemination phase. The demonstration tests in companies took place in Germany, the Netherlands and Austria. 3. PROJECT STRATEGY AND MAIN RESULTS

The main emphasis was put on four areas: • practical industrial tests • dissemination of information, • improvement of products, cleaning processes and recycling

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• as well as work on scientific questions which resulted from the industrial tests.


Practical industrial tests During the project more than 130 metal companies tested the fatty acid esters as new cleaning agents for their purposes. More than 300 times information packages were send out. In 50% of the companies the esters showed such good results that they replaced the cleaning agent used before. The practical industrial tests with alternative cleaners were a main factor in convincing the users of the efficiency and in determining their advantages for environment and worker protection.

Most successes were achieved in the areas of maintenance and repair. In most cases the cleaning process was just as good or better than with conventional products.

The companies accrue a variety of advantages from the use of vegetable oil esters: no solvent emission, less fire and explosion risks, better skin tolerance, simplification of cleaning processes, high efficiency for specific kinds of dirt and layers (e.g. molybdenum disulfide, bitumen, conservation layers), a temporary corrosion protection by a thin layer of remaining vegetable oil ester and possibly a cost reduction from longer operating life and less work time. For some follow-up processes the thin layer has to be removed by washing with water or with small amounts of other solvents before the next steps can follow. The following table summarises the results of the cleaning tests.

Better cleaning capacity than conventional cleaning agents with the following kinds of dirt/layers:

Equivalent cleaning capacity with the following kinds of dirt:

Table 1: Useful applications of esters long-term conservation layers (e.g. Tectyl:

Valvoline 506-EH. 506-33 tar and bitumen, colophony writing on metal, felt pencil markings lubricants containing

Molybdenum disulfide (MoS2)

Typical dirt like • cuttings fluids • oil, lubricating grease and fat • dusts, sand, metal particles and

similar dirt

The photos below show some cleaning workplaces where esters were tested successfully:

Photo 1: Cleaning of wheel bearings from Photo 2: Cleaning of newly manufactured trains, open application gear drive in an open cleaning bath

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Photo 3a+b: Finishing cleaning of a newly manufactured fire engine before delivery for the airport fire brigade

Photo 4a+b: Removal of lubricating grease containing molybdenum disulfide (MoS2) from parts of drive shafts (cars) with an ester based micro-emulsion

Photo 5a+b: Typical maintenance work in a cleaning bath and at a cleaning table

Photo 6: Removal of a Tectyl-layer from Photo 7: Manual cleaning of stainless steel a drive shaft (ship engine) at a shipyard plates, removal of bitumen and lacquer

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Dissemination of information Many interested companies, associations and experts were informed about the new cleaning method in different ways, as publication of information material (project folder, newsletter, handbook, workshop documentation), publication of technical articles, media and internet, fair booths, diverse workshops with professional associations, employers’ associations and trade unions. Articles in journals and the presentation at fairs brought the biggest response.

Photo 8: Presentation of the project at a Photo 9: Cleaning tests with participants of trade union congress in Hamburg a workshop for safety & health instructors

Product development, cleaning processes and recycling The activities of the project have supported the new and continued development of products. Meanwhile about 10 different products are available on the market. Apart from the typical liquid vegetable oil ester products there are also products for special tasks: A paste for tasks with a longer cleaning time (e.g. thick cohesive layers), emulsified products and a stable micro emulsion as an alternative for water-based cleaners and the use in ultrasonic baths.

Two companies producing automatic cleaning machines have successfully tested esters, one has modified a washing machine for the use of esters. This machine was installed in a work-shop of a big automobile producer. There MoS2-containing lubricants have to be removed from the joints of drive shafts (see photo 4a+b). A recycling unit is integrated.

In the project a number of methods for recycling were tested. Vacuum distillation was found to be best for the recycling of used cleaners.

Scientific support activities

Studies and technical tests were done on following subjects:

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Subject Description / results

Cleaning ability The cleaning capability of vegetable oil esters was partly better than that of mineral oil-based conventional cleaners that were used as comparison.

Corrosion protection

The temporary protection of the remaining layer from different ester products was tested using climatic tests. Temporary corrosion protection is higher than that of cold cleaners, which are generally used in the metal branch.

Penetration tension

The tested oils showed a comparable penetration tension to commonly used insulation oils.

Emissions by welding

Characterization of the emissions during welding of plates cleaned with esters: no additional air pollution from the use of vegetable oil esters as cleaning agents.

Skin tolerance Laboratory study on skin tolerance: the results show a considerably increased skin tolerance of vegetable oil-based cleaning agents in comparison to conventional carbohydrate-based products.


4. ENVIRONMENTAL BENEFITS OF USING ESTERS FROM VEGETABLE OILS

The main environmental benefits from the project are related to the reduction of VOC-emis-sions into the atmosphere by the metal industry. The project has proved and demonstrated, that metal cleaning agents based on vegetable oils are suitable substitutes for commonly used solvents in the metal branch.

Normally companies do not assess their diffuse emissions of VOC from cleaning units. Therefore the potential rate of VOC-reduction could not be calculated exactly. However, we believe that volatile organic solvents can be replaced by esters in approximately 50% of the cleaning activities.

The raw materials for the ester-products, in particular the vegetable oils are derived from renewable resources. The alcohol part could be technical or biological origin. The ester-products are easily biodegradable and the risk of soil and water pollution is low. Used amounts can be recycled with filtration or vacuum-distillation. Overall advantages and disadvantages of cleaning with fatty acid esters

Environmental Protection • No VOC-emissions to the atmosphere • Contribution to decrease the risk of summer smog • Easily biodegradable, thereby reducing water and soil pollution risks • The cleaning agents are made from renewable resources

Occupational Safety and Health • Workers are no longer exposed to solvent emissions • No odour emissions occur at the workplace • Cleaning agents no longer need to be labelled • Better skin tolerance

Mechanical Engineering • Parts are cleaned more effectively depending on the type of contamination or dirt • The cleaning agents feature excellent emulsion properties • No special devices to exhaust contaminated air at the washing places necessary • No fire precautions and explosion proofing is required • The residual oil film provides temporary corrosion protection

Chemical Engineering • Mixtures are replaced by individual substances (one to three fatty acid esters) • Several esters may be mixed to handle specific cleaning operations

Cost Effectiveness • The operating life of a cleaning agent is often increased substantially (no evaporation, high

capacity for dissolving oil and grease and taking up particular dirt) • The quantity of cleaning agent required is reduced by up to 80 % • Reduced working time for special cleaning tasks • Storage expenses are reduced (no hazardous substance) • Working expenses like costs for insurance, fire protection and explosion proofing decrease. • Reduction of personnel costs because of less occupational related diseases

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Diverse disadvantages • Spilling creates danger of slipping. The spilled cleaner has to be absorbed with sawdust or

other suitable materials. • The price per litre is higher. This can be balanced through a lower loss by evaporation and

a longer operating time. • In some cases the remaining thin film on surfaces of cleaned parts must be removed in a

second cleaning step.

5 .SUSTAINABLE RESULTS

The project has shown that substitution of volatile organic solvents by non volatile cleaning agents based on vegetable oil is feasible for metal surface cleaning. The pro and cons have been identified. For many cleaning tasks in different branches of the metal industry it is worth while thinking about this alternative cleaning technology.

The experiences of METALVOC have been used for a number of follow-up activities.

In results of the Life-project were:

1. A follow-up project (LIFE2), financed by professional associations, other authorities, suppliers and trade unions was started in Germany in 2001. The focus lies on new branches and new applications for non volatile metal cleaners.

2. Branch initiative: In July 2000 the union of metal industries and the employers association ‘Nordmetall’, together with the North German metal professional association all signed a branch initiative on worker and environmental protection. Vegetable oil esters are classified as products to be given preference. Generally, volatile cleaners of the danger class AI, AII and AIII (related to vapour pressure) should not be used anymore in typical manual cleaning processes.

3. For the federal safety and health executive a guide “Substitutes for metal cleaning” has been initiated. It is based on results and experience of the MetalVOC Life-project and leans on the branch agreement. This guide is a tool for labour inspector’s and enterprises looking for less hazardous cleaning agents.

4. The development of a good-practice-database for metal surface cleaning financed by the EU-Innovation-Programme.

5. In the Netherlands new research projects were started: a) on the occurrence of OPS (“Organic Psycho Syndrome”) in the metal industry, and b) research on the ‘state of the art’ in the shipbuilding and repair industry. This study encompasses the possibilities to reduce exposure to organic solvents in the shipbuilding and repair sector.

6. In Austria a follow up project has been initiated based on the work of the Life-project METALVOC. It is a national project in collaboration with the federal office of agriculture technique. The focal point is the technical application of rape seed oil in the areas of maintenance of agricultural machines and for road works.

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Contacts / further information The project was managed and co-ordinated by the Kooperationsstelle Hamburg. Professional partners were the metal employers association ‘Nordmetall e.V.’, the trade union ‘IG-Metall Küste’ and the Professional Association of the Metal Industries. Two companies were directly involved as partners: firstly Haltermann GmbH, a manufacturer of esters and developer of products and secondly B+V Industrietechnik as pilot user company. The partner in the Netherlands was Chemiewinkel, a consultancy and research centre active on chemistry, occupational health and environment. It is part of the University of Amsterdam. For Austria, the independent research and consulting office ppm in Linz participated. Ppm is a multi-disciplinary research and training association focusing on occupational health and safety issues and on the working environment. Information and results are available too by Internet:

http://www.uni-hamburg.de/kooperationsstelle-hh

Kooperationsstelle Hamburg; Besenbinderhof 60, D-20097 Hamburg, ++49 - 40/2858-640

You can get more information about other projects from LIFE-Environment:

http://europa.euint/comm/life/envir/index.htm

i In March of 1999, the EC adopted the Solvent Emissions Directive (Council Directive 1999/13/EC ‘On the limitation of emissions of volatile organic compounds due to the use of organic solvents in certain activities and installations’ )

http://www.uni-hamburg.de/kooperationsstelle-hh

http://europa.euint/comm/life/envir/index.htm

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