Today we are providing operating advice for vapor degreasing equipment to help you save solvent and by extension, money!
In order to reduce solvent loss when starting up the operating machine, activate the cooling system, followed by checking the controls. Next, adjust solvent levels and activate heaters.
When a stable vapor blanket has been established, activate spray pumps and introduce work into the unit.
To shut down the unit, use the following procedure:
- Stop work processing and clear the machine of all work.
- Deactivate the heaters.
- Activate sump cooling coils, if available, and allow vapor blanket to collapse completely.
- Keep the condenser cooling system ON and close cover on open-top units.
FluoSolv Operatory Guidelines
In order for the vapor degreaser to be used effectively with our Fluosolv products, good work practices must be implemented.
Ventilation
Airflow across the vapor degreaser is the most common cause of extraordinary solvent losses. In no way, shape, or form should the vapor degreaser be ventilated, including the solvent product. When the system is not in use, the lid should always be kept on the degreaser.
Workload
There are two common effects that can expel solvent vapors from a cleaning system if the processing of workloads exceeds the capabilities of the vapor degreaser:
The piston effect is when a basket too large in physical size on the degreaser displaces vapor from the cleaning unit. Solvent will in turn be ejected from the machine as the mass of cleaning materials descends into the cleaning vapors. To avoid losses by this process, the area of the workload should not be greater than 75% of the horizontal cross-sectional area of the sump into which it is being introduced.
The second effect, work shock, occurs when the load of the degreaser becomes too heavy and the vapor blanket collapses. Until the vapor blanket is re-established, infiltration of air into the cleaning unit will increase solvent losses.
Work Positioning
Drag-out losses occur when baskets are not positioned correctly, causing excess parts to be removed during cleaning. Cleanout procedures must be followed for the vapor degreaser in order to prevent this scenario. Drag-out prevention is extremely essential to the effectiveness of the operating device. A good vendor should be able to document incremental operating costs and drag-out losses on a feature-by-feature basis. Additionally, they should be able to highlight specific environments (e.g., types of contamination, cycle times) which will reduce solvent losses.
Vapor Linger Time
The workload should remain in the vapor zone after the final cleaning step until its temperature equals that of the vapor zone and vapor condensation on the part stops. Work withdrawn earlier will emerge wet with solvent condensate. Insufficient dwell times are encountered most commonly in open-top units where work is manually moved into and out of the unit. Use of a programmed work transporter, like an automated hoist, can help eliminate excessive drag-out due to insufficient dwell time.
Work Scheduling
The expulsion of air from a vapor degreaser during start-up always results in carryout solvent vapor. Emissions caused by frequent activation and deactivation of the cleaning system can be minimized by deferring cleaning until all of a day’s production is compiled for processing with only one start-up of the cleaning equipment.
Changing the Cleaning Fluids in the System
Fluorinated cleaning fluid blends are extremely stable can function for extended periods of time in the vapor degreaser. Since the solvent is constantly being distilled and recycled, it remains clean and pure for an indefinite time period. While the BromothaneTM products have a requirement to perform acid acceptance tests on a weekly basis, overall the maintenance is reasonably minimal.
The real issue is the compilation of debris at the bottom of the sump. After a while the debris accumulates and the machine becomes too dirty to operate effectively. This is when a system clean-out becomes necessary. In a busy machine, this might occur twice to four times a year.
In a standard degreaser, the contamination accumulates in the boil sump. This is the first chamber in the cleaning cycle and is the location into which the dirty parts are placed when they first go into the machine. It is here where the worst contamination will aggregate. In general, make sure the rinse sump fluid will always be clear and colorless. It will be time to change the solvent in the boil sump when it accumulates a high concentration of dissolved contamination, to the point of tinting the solvent yellow or beige. Additionally, at the bottom of the boil sump will be a large collection waste. This junk will need to be removed. It’s time to clean the machine.
Cleaning a degreaser normally involves a process called a boil-down. This process simply involves distilling, or boiling, all the solvent out of the system, rather than returning it to the rinse sump and recapturing it in a pail or a drum for re-use. The heat must be turned off when the last few liters of solvent remain at the bottom of the boil sump. Any residual waste solvent and the solid contamination is cleaned out by hand and disposed of as a hazardous waste. The entire cleaning process may take a day on a large and especially dirty operating machine.
In more sophisticated machines, a recirculating pump is installed on the boil sump to refresh the solvent and to remove particulate. This will extend the periods between boil-downs. Once the machine is ready to be returned into service, the old, cleaned solvent that was recaptured during the boil-down process is dumped back into the machine.
The recovery procedure described here should be conducted on a regularly scheduled basis, typically quarterly or semi-annually.
For even more accurate thoughts and recommendations, check with the machine manufacturer.
Detailed Solvent Boil-Down Process:
The recovery procedure described here should be conducted on a regularly scheduled basis, typically quarterly or semi-annually. Be advised that the machine must be taken out of production during the boil-down process; cleaning cannot be performed while the reclamation process is underway.
Here are the steps to follow:
- When the solvent in the boil sump is too dirty for normal operations to continue, turn the ultrasonics off. Empty the condensate (and the “rinse” sump in a multi-chamber system) into a clean, solvent-safe container.
- Continue to operate the boil sump. As the dirty solvent boils in the boil sump the solvent vapors will be captured and distilled by the cooling coils. The clean, nearly-pure distillate should be reclaimed into the solvent-safe container.
- Gradually the solvent and contamination remaining in the boil sump will concentrate and become viscous and syrupy.
- Before the residues become too thick, the high-temperature safety controls in the boil sump will detect the rising temperature and shut off the heaters. At this point, about 50% of the material in the sump will be solvent.
- Manually raise the boil sump temperature by another ten degrees and continue to boil the system until the safety controls shut off the system again.
- The “bottoms” are collected for disposal by draining the boil sump. The boil sump should then be cleaned with wipes and elbow grease. Wear gloves and take precautions to avoid exposures to high concentrations of the vapors.
- Once the boil sump is clean and dry, close all the drain valves and add fresh solvent to the clean solvent collected during the boil-down. Add enough solvent that the normal operational levels are re-established.
- Return the temperature controls on the boil sump back to their original and correct settings. If the facility has collected contaminated cleaning fluids over a period of time and would like to reclaim it all at once, this procedure can be extended simply by adding more of the dirty solvent to the boiling chamber during the boil down process.
Solvent Handling:
Crucial tips for minimizing solvent loss during normal operation of the machine:
- Ideally, the solvent should be pumped into the degreaser through a liquid-submerged fill connection.
- Make-up solvent (topping off the machine to replace lost solvent) should be added to the rinse sump.
- Cold solvent should not be added to operating degreaser, for it can collapse the vapor blanket.
- The addition of solvent to an open-top degreaser by pouring from drums or buckets should be avoided. The turbulence of such pouring destabilizes the vapor/air interface.
- Drums should be stored with the bung end up to eliminate the possibility of a major spillage of solvent through a leaky bung. Drums filled with solvent and not in current usage should have tightly sealed lids. Take great care when moving drums of solvent. Do not pressurize the drums of solvent in an attempt to expedite unloading.
The cooling coil defrost setting should be set to periodically de-ice the coils. The vapor-degreaser’s boiling temperature setting should be increased by 10 to 15 °C when separate distillation for reclaiming spent solvent, due to the elevated boiling point of the contaminated solvent. The refrigeration/chiller should be set to its lowest temperature possible for best distillation efficiency. This is caused by an elevated boiling point of the contaminated solvent.
End of Lesson!
We hope these tips will help you reduce your solvent losses and save you money. If you have further questions about vapor degreasing or would like to know about the solvent products we sell for use with vapor degreasing, give us a call at 800-563-1305 or email us at vapordegreasing@ecolink.com
Is Your Company Aware of the TURA Chemical List?
/in Worker Safety/by Industrial DegreasersWhen we talk about the deleterious effects that toxic industrial cleaners can have on humans and the environment, we often reference the Environmental Protection Agency’s List of Lists — a list of chemicals whose regulation or ban is enforced by the federal government. But state governments haven’t been sitting idly by while the EPA does all the work. As Massachusetts’ Toxic Use Reduction Act (TURA) shows, the fight for better human and environmental safety through the use of non-toxic cleaners is alive and well at the state level, too.
History of the TURA Chemical List
On July 24, 1989, Massachusetts Governor Michael Dukakis signed the TURA into law, which immediately affected the Eastern Seaboard state in several ways. Initially, the TURA set out to achieve the following five goals:
Helping the state achieve the goals are four partner organization: the Department of Environmental Protection (MassDEP), the Office of Technical Assistance and Technology (OTA), The Toxics Use Reduction Institute (TURI), and Administrative Council on Toxics Use Reduction. As described below, with the support of these entities, the TURA Act has been successful since its implementation over 25 years ago.
Effects of the TURA Act
The advent of the TURA Act set in motion several important accomplishments related to the reduction of toxics throughout Massachusetts. Highly notable have been a 50 percent reduction in the generation of toxic waste (accomplished in 1998), and the following achievements (accomplished by 2005) of the “Core Group” of industries that the TURA requires to report on their use of toxics:
The act is designed to benefit businesses while goals are pursued, providing the following advantages, regardless of business’ size or Core Group status: modernization of production practices, improvement of operation and maintenance, reformulation of products with non-toxic components, and recycling of leftover raw materials during production.
Most Recent List of Chemicals on TURA
Like the EPA’s List of Lists, Massachusetts’ TURA Act has grown to include more substances than it originally listed in 1989. View the current list in its entirety by accessing the link. If any of the chemicals your company or organization uses appear on the list, contact the team of chemists at Ecolink about implementing an environmentally preferred replacement.
Are Your Chemicals on the TURA List?
Is so, now is the time to start the process of replacing them for four reasons: to protect the health of workers, better protect the environment, avoid government fines for usage violations, and avoid the financial fallout of chemical injuries in the workplace, especially: increased number of sick days taken, workers compensation claims, and chemical injury lawsuits.
Ecolink specializes in providing industrial, eco friendly cleaning solutions in a variety of categories. With our solutions in place, you can rest easier, knowing that you use the best products for the safety of your workers and the environment. Call us today at (800) 563-1305, or complete the contact form on our website. We look forward to assisting you!
How To Minimize Solvent Loss When Cleaning a Vapor Degreaser
/in Chemical waste, Vapor Degreasing/by Industrial DegreasersToday we are providing operating advice for vapor degreasing equipment to help you save solvent and by extension, money!
In order to reduce solvent loss when starting up the operating machine, activate the cooling system, followed by checking the controls. Next, adjust solvent levels and activate heaters.
When a stable vapor blanket has been established, activate spray pumps and introduce work into the unit.
To shut down the unit, use the following procedure:
FluoSolv Operatory Guidelines
In order for the vapor degreaser to be used effectively with our Fluosolv products, good work practices must be implemented.
Ventilation
Airflow across the vapor degreaser is the most common cause of extraordinary solvent losses. In no way, shape, or form should the vapor degreaser be ventilated, including the solvent product. When the system is not in use, the lid should always be kept on the degreaser.
Workload
There are two common effects that can expel solvent vapors from a cleaning system if the processing of workloads exceeds the capabilities of the vapor degreaser:
The piston effect is when a basket too large in physical size on the degreaser displaces vapor from the cleaning unit. Solvent will in turn be ejected from the machine as the mass of cleaning materials descends into the cleaning vapors. To avoid losses by this process, the area of the workload should not be greater than 75% of the horizontal cross-sectional area of the sump into which it is being introduced.
The second effect, work shock, occurs when the load of the degreaser becomes too heavy and the vapor blanket collapses. Until the vapor blanket is re-established, infiltration of air into the cleaning unit will increase solvent losses.
Work Positioning
Drag-out losses occur when baskets are not positioned correctly, causing excess parts to be removed during cleaning. Cleanout procedures must be followed for the vapor degreaser in order to prevent this scenario. Drag-out prevention is extremely essential to the effectiveness of the operating device. A good vendor should be able to document incremental operating costs and drag-out losses on a feature-by-feature basis. Additionally, they should be able to highlight specific environments (e.g., types of contamination, cycle times) which will reduce solvent losses.
Vapor Linger Time
The workload should remain in the vapor zone after the final cleaning step until its temperature equals that of the vapor zone and vapor condensation on the part stops. Work withdrawn earlier will emerge wet with solvent condensate. Insufficient dwell times are encountered most commonly in open-top units where work is manually moved into and out of the unit. Use of a programmed work transporter, like an automated hoist, can help eliminate excessive drag-out due to insufficient dwell time.
Work Scheduling
The expulsion of air from a vapor degreaser during start-up always results in carryout solvent vapor. Emissions caused by frequent activation and deactivation of the cleaning system can be minimized by deferring cleaning until all of a day’s production is compiled for processing with only one start-up of the cleaning equipment.
Changing the Cleaning Fluids in the System
Fluorinated cleaning fluid blends are extremely stable can function for extended periods of time in the vapor degreaser. Since the solvent is constantly being distilled and recycled, it remains clean and pure for an indefinite time period. While the BromothaneTM products have a requirement to perform acid acceptance tests on a weekly basis, overall the maintenance is reasonably minimal.
The real issue is the compilation of debris at the bottom of the sump. After a while the debris accumulates and the machine becomes too dirty to operate effectively. This is when a system clean-out becomes necessary. In a busy machine, this might occur twice to four times a year.
In a standard degreaser, the contamination accumulates in the boil sump. This is the first chamber in the cleaning cycle and is the location into which the dirty parts are placed when they first go into the machine. It is here where the worst contamination will aggregate. In general, make sure the rinse sump fluid will always be clear and colorless. It will be time to change the solvent in the boil sump when it accumulates a high concentration of dissolved contamination, to the point of tinting the solvent yellow or beige. Additionally, at the bottom of the boil sump will be a large collection waste. This junk will need to be removed. It’s time to clean the machine.
Cleaning a degreaser normally involves a process called a boil-down. This process simply involves distilling, or boiling, all the solvent out of the system, rather than returning it to the rinse sump and recapturing it in a pail or a drum for re-use. The heat must be turned off when the last few liters of solvent remain at the bottom of the boil sump. Any residual waste solvent and the solid contamination is cleaned out by hand and disposed of as a hazardous waste. The entire cleaning process may take a day on a large and especially dirty operating machine.
In more sophisticated machines, a recirculating pump is installed on the boil sump to refresh the solvent and to remove particulate. This will extend the periods between boil-downs. Once the machine is ready to be returned into service, the old, cleaned solvent that was recaptured during the boil-down process is dumped back into the machine.
The recovery procedure described here should be conducted on a regularly scheduled basis, typically quarterly or semi-annually.
For even more accurate thoughts and recommendations, check with the machine manufacturer.
Detailed Solvent Boil-Down Process:
The recovery procedure described here should be conducted on a regularly scheduled basis, typically quarterly or semi-annually. Be advised that the machine must be taken out of production during the boil-down process; cleaning cannot be performed while the reclamation process is underway.
Here are the steps to follow:
Solvent Handling:
Crucial tips for minimizing solvent loss during normal operation of the machine:
The cooling coil defrost setting should be set to periodically de-ice the coils. The vapor-degreaser’s boiling temperature setting should be increased by 10 to 15 °C when separate distillation for reclaiming spent solvent, due to the elevated boiling point of the contaminated solvent. The refrigeration/chiller should be set to its lowest temperature possible for best distillation efficiency. This is caused by an elevated boiling point of the contaminated solvent.
End of Lesson!
We hope these tips will help you reduce your solvent losses and save you money. If you have further questions about vapor degreasing or would like to know about the solvent products we sell for use with vapor degreasing, give us a call at 800-563-1305 or email us at vapordegreasing@ecolink.com
Using Zero VOC Cleaning Solvents: An Overview
/in Volatile Organic Compounds/by Industrial DegreasersIf you enter an industrial work environment where chemical solvents are in use, you might get a strong whiff of something that smells like a cross between manmade chemicals and highly odoriferous natural substances. There’s a good chance that what you smell is a mixture of volatile organic compounds (VOCs), which are naturally occurring or manmade organic compounds whose volatility frequently makes them gasify quite quickly at room temperature.
Dangers of VOC Exposure
When it comes to the effects of VOC exposure in humans, VOCs are similar to hazardous air pollutants (HAPs) that don’t have an organic formulation. Short-term exposure can cause symptoms such as upset stomach, difficulty breathing, and watery eyes. Long-term exposure can potentially cause permanent nerve damage, neurological problems, and even cancer.
The dangers of VOC exposure hold negative consequences for companies as well as their workers. Short-term exposure to VOCs can lead to an increase in sick days taken, which hampers productivity; and long-term VOC exposure commonly results in workers compensation claims chemical injury lawsuits. For companies and their workers, using zero VOC cleaning solvents to replace solvents that contain hazardous VOCs is win-win situation.
Buying Zero VOC Solvents
In terms of sheer product selection, industrial solvents that have low VOC content are generally easier to find than ones that contain no VOCs. However, zero VOC cleaning solvents have become more popular in recent years, as the EPA and OSHA have taken an increasingly firm stance on regulating the use of dangerous chemicals in the workplace, and businesses have taken cost cutting to a new level to help offset losses from the recession.
One of our own products, Eco-Spray ZV-2 – Zero VOC Cleaner Degreaser, is a good example of a flexible, zero VOC solvent that can be used for various applications. In addition to purchasing readymade solvents, there’s also the option of having zero VOC cleaning solvents made from scratch to address your unique requirements. Regardless of which type of product you choose, one thing is certain: Your operation stands to benefit from improved workplace safety.
Low VOC Cost Saving Benefits
Even when a zero VOC cleaning solvent costs more than a VOC solvent it could replace, there are still some important cost saving benefits to be had from making the switch. In addition to helping decrease sick days taken and avoid workers compensation claims and injury lawsuits, using zero VOC solvents can help companies avoid fines for emission cap violations, avoid using the highest level of personal protective equipment (PPE) for workers, and operate the air filtration system that removes airborne contaminants more efficiently.
Who We Are
At Ecolink, we specialize in developing industrial cleaning solvents that are environmentally safe and environmentally preferred. In addition to providing readymade solutions, we also formulate custom blends that can be supplied for as long as you need them. If your company or organization is in the market for zero VOC cleaning solvents, we can provide them. To start exploring your options, please call us today at (800) 563-1305, or use our contact form.
Sustainable Chemical Management: The Rise of Green Chemistry
/in Chemical Management Services/by Industrial DegreasersGreen chemistry, also known as sustainable chemistry, is a discipline of chemistry that focuses on reducing the usage and production of environmentally dangerous substances in order to decrease the chemical industry’s impact on the environment.
Green Chemistry and Solvents
When green chemistry is applied to the formulation and utilization of industrial solvents, sustainable chemical management is one of the primary areas of emphasis, as this helps to accomplish two goals of green chemistry: curtailing chemical pollution and minimizing the use of nonrenewable resources. For companies that implement green solvents, three important benefits can emerge: lower waste disposal costs, reduced solvent purchases, and the promotion of a good business image.
Benefits of Using Eco-Friendly Solvents for Sustainable Chemical Management
Chemicals that are renewable inherently lead to a lower waste disposal cost, as instead of immediately entering the waste trap, they can be recycled. The trap will eventually fill up and need to be emptied, of course, but reusable chemicals help to reduce the frequency with which this occurs.
Reusable chemicals also reduce solvent expenses. For example, if a parts washing system is able to recycle a degreasing agent, it will be used at least twice. Thus, implementing this type of solvent can decrease solvent expenses by roughly 50 percent.
Finally, at a time when many companies have a goal of reducing their environmental impact and improving workplace safety, and consumers like to support organizations that have decided to “go green”, following sustainable chemical management practices is a great idea for any company that works with chemicals. Organizations that use sustainable solvents can put the feather of sustainable chemical management in their cap and use it to improve public relations or for marketing purposes.
How Ecolink Can Help
Ecolink is a long-time supporter of green chemistry, as our team of chemists works to create solvents that support sustainable chemical management solutions.
Moreover, we design industrial cleaners that maximize the number of parts you can clean while minimizing the amount of solvent you use to perform the cleaning. The majority of our products are environmentally safe and environmentally preferred, which makes them an excellent choice for companies looking to go green.
Take advantage of our specialty in green chemistry to enhance your operation’s sustainable chemical management. To get started, call us at 800-563-1305 or email us at info@ecolink.com. We look forward to supplying you with eco-friendly solvents that will benefit both your business and the planet!
Professional Degreasers Vs. Consumer Degreasers: What’s The Difference?
/in Degreasing Agents/by Industrial DegreasersAll types of chemical degreasers have one thing in common: They are chemically formulated to break up accumulations of grease and similar substances. Beyond this central commonality, however, degreasers can differ widely, especially when it comes to comparing professional degreasers that are designed for commercial and industrial use to consumer degreasers that are designed for residential use and light, occasional cleaning jobs in non-industrial buildings.
Professional Grade Vs. Consumer Grade
It seems obvious that a company or an organization that has professional degreasing needs would shop for professional degreasers, but there are plenty of entities that try to use consumer grade degreasers because the solutions tend to cost less per volume than professional grade solutions. Using a consumer degreaser instead of a professional degreaser may cost less up front, but there are four crucial sacrifices the customer makes to achieve the initial cost saving.
Professional degreasers almost always deliver more cleaning power by volume than consumer grade degreasers — and there are some types of greasy, convoluted substances that the latter type of degreasers simply won’t remove efficiently, no matter how much of the solution you apply. Part of what makes professional grade degreasers “professional” is that they do the job quickly.
Consumer grade degreaser may have a lower price tag than professional degreaser, but the price difference doesn’t mean as much when you consider that you typically have to use more of the former than the latter for any given cleaning operation. In addition, professional degreasers are frequently offered in bulk orders at wholesale prices, whereas consumer grade solutions are typically sold in single units or small packs that aren’t intended for long-term storage or big degreasing jobs.
As a solvent category, professional degreaser is created for a wider range of applications than consumer degreaser. For example, if you need to clean large, energized motors that have complex geometries, you can order a large cylinder of aerosol that’s dispersed with a spray gun, has a dielectric formulation, and evaporates almost instantly while leaving behind no residue. Such options — especially in combination — are hard to come by in consumer degreasers.
Providers of professional degreasers that have their own team of chemists often present the option of custom solvent formulation. That is, they can create a custom solvent that’s designed to meet the unique requirements of a single user. Consumer grade degreasers don’t come with this option. They are readymade products that are designed to hit store shelves and sell fast.
Need Professional Degreasers?
If so, Ecolink is great place to get them, especially if you’re looking for degreasers that have the characteristic of being environmentally safe or environmentally preferred. If you need help selecting the right degreaser for your professional degreasing operations, our team of chemists and product specialists are here to help. Give us a call today at (800) 563-1305, or complete the contact form on our website. We look forward to supplying best in class, eco friendly degreaser.