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Recycling of Cleaning Fluids to Meet Green Cleaning Process Targets By Steve Stach Austin American Technology

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Recycling of Cleaning Fluids to Meet

Green Cleaning Process Targets

By

Steve Stach

Austin American Technology

Setting recycling targets? Paying for recycling? What can be recycled? Review of the 4 basic types of fluid recycling

Absorption

Distillation

Filtration

Replenishment Estimating the cost and saving

Estimating system life

Cost Model review

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 “Green Manufacturing” sells product

Water Saving – up to 99% reduction Chemical Savings – 50-99% reduction Energy Saving – 10-50% reduction Waste Disposal – 50-90% reduction

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

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

Recycle

Method

Used with Waste stream Waste disposal

handler

System

Complexity

level

Safety concern

Chemical

addition

Reactive

Aqueous

Mixtures

(saponifiers)

Soil loaded

tank dump

Company Technician Medium

Ion Exchange Rinse water

Alcohols

Glycols

Esters

Depleted DI

resins

Third party Operator Low

Carbon

Adsorption

Rinse water

Carbon media

with organics

Third party

Operator Low

Zeolite

Absorption

NPB

CFC’s

HCFC’s

Zeolite with

adsorbed

contaminate

Third party

Operator Low

Chelation Water with

heavy metals

Chelation media

with heavy

metals

Third party

Operator

Low

Distillation NPB

CFC’s

HCFC’s

Non volatile

residues

Company Technician High

Filtration All fluids Filters with

contaminate

Company Technician

Medium

Reverse

Osmosis

Rinse water Reject fluid

stream

Company Technician

Medium

Identify & Understand Your Recycling Method Recycling System Choices

Cleaning/Rinsing Agent Adsorption

Distillation Filtration Replenish

Ingredient

Water Only Recommend for

high purity

Rarely Used Recommended for

General use

Not Used

Water + additive, Neutral pH Not Used Not Used Recommended for

General use

Recommend

Water Alkaline Not Used Not Used

Recommended for

General use

Recommend

Organic Non-flammable Used Recommend Recommended for

General use

Not Used

Organic Combustible Recommend

Used

Recommended for

General use

Not Used

Organic Flammable Recommend

Used

Recommended for

General use

Not Used

H2O

IPA

NPB

Key Ingredient Replacement

Common in aqueous mixture to replace drag out or reactive losses

▪ Saponifing agents

▪ Degreasing stabilizers

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

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

Boiling fluid is vaporized and condensed

High boiling soils are left

behind for disposal Recommended for non-

flammable, single solvents or azeotropic solvent blends

Not usually recommended for

water or flammable solvents

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

RO is most commonly used for feed water generation to closed loop cleaners

RO typical removed ~90% of dissolved solids from tap water

Molecular sized microscopic pores block large molecules and allow smaller molecules to pass

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

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

Useful in removing water, flux residues, and most ions from organic cleaning solvents

35X 700X 4,500X

Molecular Sieve filters to remove contamination from Degreasing Solvents

Organic solvents

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

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

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

Mass Balance analysis looks at all materials entering and leaving the cleaning process.

Shows where you are loosing or gaining fluids/ingredients

Fluid Tank

Recycling

System

Cleaning

System Waste

Fluid Feed,

Make-up Mist-Evaporative

And Drag-Out

Losses

w/soils

Parts

Cleaning Fluid

With Soils

Sewer or Disposal

Turbine Mixed

GAC

Carbon

1g/m 1g/m

Filter MΏ

Vent

Rinse Wash

Dry

The impact of the recycling location

The impact of the recycling location

Turbine Mixed GAC

Carbon

Chem

pump

1g/m 1g/m

Filter MΏ

~25gallons

In Situ

(in the cleaner)

Plant System

(in the factory)

Third party

(bonded & licensed)

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

Indep

Inline Cleaner Cost Model Process Data Inline Open Loop

Closed Loop

Central

System

In Situ Closed

Loop

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

7 year equipment amortization

6 Run time per Shift

300 Shifts per year

Process Costs ($'s/hr)

Absorbtive capacity (mg CaCO3 or Succinate) 1,680,000 7,900,000 7,900,000

Bed Life (hrs of operation) 3.7 219.4 219.4

Depends on the Ion Molecular weight & valance

Tank Absorptive Capacity (Abtotal)

Bed Volume (Vab) Absorptive Capacity (Abcap)

(Abtotal) = (Abcap) X (Vab)

Contamination Feed Rate

Mass Flow Rate (MFrate) Bedlife = (Abtotal / MFrate)x %factor* * %factor is % available in begining + % remaining at exhaustion

US map showing

water hardness

Inline Open

Loop

Closed

Loop

Central

System

In Situ

Closed Loop

Annual Cost of beds OL DI, CL DI+GAC $144,642.86 $4,101.27 $4,101.27

Hourly Cost of beds $80.36 $2.28 $2.28

Hourly cost of tap water $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

Total Equipment + Water + Power ($/hr) $114.79 $36.02 $28.56

Saves

$85/hr

All cleaning solvents can be recycled

There are many methods of recycling

Your clean solvent guides you recycling method

Government and industry are driving recycling

Cost and environmental benefits provide the rewards for conversion

The savings are easy to estimate with a good mass and energy balance diagram

The location of the recycling system can affect cost.

In situ recycling is the most cost effective

If you are not recycling your cleaning fluids, you should be!

"Cleaning Fluid Recycling Options for Green

Manufacturing” by

Steve Stach

Thank You for Attending

Questions

?