ENVIRONMENTAL
, PROTECTION
\
DALLAS, TEXAS
United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park, NC 27711
Research and Development
EPA/600/SR-94/131 November 1994
EPA Project Summary
Replacing Solvent Cleaning with
Aqueous Cleaning
Kenneth R. Monroe
The report documents actions taken
by Robert Bosch Corporation, Charles-
ton, SC, in replacing the cleaning sol-
vents 1,1-2trichloro-1,2,2-trifluoroethane
(CFC-113) and trichloroethylene fTCE)
with aqueous solutions. Bosch has suc-
ceeded in eliminating all their CFC-113
use and, so far, has eliminated two-
thirds of their TCE use. Their goal is to
completely free of chlorinated cleaning
solvents by the end of 1995.
This Project Summary was developed
by EPA's Air and Energy Engineering
Research Laboratory, Research Tri-
angle Park, NC, to announce key find-
ings of the research project that is fully
documented in a separate report of the
same title (see Project Report ordering
information at back).
Overview
Experience of the Bosch Company at
Charleston, SC, indicates that, with inno-
vative engineering, it is possible to re-
duce, even eliminate, the use of solvents
for a range of cleaning applications.
These changes in cleaning have not
only responded to the environmental goals
of the Montreal Protocol and EPA's 33/50
program, but have also resulted in im-
proved cleaning at dramatically reduced
costs. An early key decision was to re-
place their aging, large, central degreasing
stations with several small cleaning units,
each designed and dedicated for cleaning
just one part, at one step, in the product
assembly process. This strategy de-
manded reassessment of each cleaning
step and the identification of apparatus
and chemistry for optimizing each aque-
ous replacement. The report summarizes
the actions taken to achieve aqueous
cleaning of four typical components, pre-
viously cleaned with chlorinated solvents.
The report provides quantitative compari-
sons of cleaning performance and costs
of the old chlorinated (1988) and the new
aqueous (1992) cleaning methods. For
each of these components, the new aque-
ous cleaning step matched or exceeded
the cleanliness levels of the old chlori-
nated cleaning methods, and did so at
similar or lower costs.
The solvent replacement program, which
was carried out, resulted in a major reduc-
tion in the use of chlorinated solvents.
The facility totally eliminated the use of
CFC-113 by 1993, from 544,000 Ib
(250,000 kg) in 1988. It reduced the use
of TCE from 133,00 Ib (60,00 kg) in 1988
to 43,000 Ib (20,000 kg) in 1992. This
conversion to aqueous cleaning also re-
sulted in major solvent and utility cost
reductions. The total non-labor annual cost
reduction for these categories was greater
than 90% of the 1988 solvent and utilities
costs.
Printed on Recycled Paper
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K. Monroe is with Research Triangle Institute, P.O. Box 12194, Research
Triangle Park, NC 27709.
Charles H. Darvin is the EPA Project Officer (see below).
The complete report, entitled "Replacing Solvent Cleaning with Aqueous
Cleaning,"(OrderNo.PB95-129128/AS;Cost:$17.50;subjecttochange)will
be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH 45268
Official Business
Penalty for Private Use
$300
EPA/600/SR-94/131
BULK RATE
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
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