ULTRASONIC CLEANING AS A REPLACEMENT FOR A
CHLOROFLUOROCARBON-BASED SYSTEM |
by
Paul B. Kranz
Erie County Department of Environment and Planning
Division of Environmental Compliance
Buffalo, NY 14202
T. Gardner-Clayson, K.C. Malinowski, T.D. Schaab, and J.E. Stadelmaier
Recra Environmental, Inc.
Amherst, NY 14228 ''
CR-816763
Project Officer
Paul M. Randall
USEPA Pollution Prevention Research Branch
Risk Reduction Engineering Laboratory
Cincinnati, OH 45268
RISK REDUCTION ENGINEERING LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OH 45268
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NOTICE
This project has been funded wholly or in part by the U.S. Environmental Protection Agency (EPA) under
Contract No. CR-816762 to the Erie County Department of Environment and Planning. It has been subjected to
the Agency's peer and administrative review and approved for publication as an EPA document. Approval does
not signify that the content necessarily reflect the views and policies of the U.S. Environmental Protection Agency,
the County of Erie, or Recra Environmental, Inc.; nor does mention of trade names or commercial products
constitute endorsement or recommendation for use. This document is intended as advisory guidance only to assist
in developing approaches to waste reduction. Compliance with environmental and occupational safety and health
laws is the responsibility of each individual business and is not the focus of this document, j
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FOREWORD
i'
Today's rapidly developing and changing technologies and industrial products and practices frequently carry
with them the increased generation of materials that, if improperly dealt with, can threaten both public health and
the environment. The U.S. Environmental Protection Agency (EPA) is charged by Congress with protecting the
Nation's land, air and water resources. Under a mandate of national environmental laws, the agency strives to
formulate and implement actions leading to a compatible balance between human activities and the ability of natural
systems to support and nurture life. These laws direct the EPA to perform research to define our environmental
problems, measure the impacts, and search for solutions.
The Risk Reduction Engineering Laboratory is responsible for planning, implementing, and managing
research, development and demonstration programs to provide an authoritative, defensible engineering basis in
support of the policies, programs and regulations of the EPA with respect to drinking water, wastewater, pesticides,
toxic substances, solid and hazardous waste, Superfund-related activities, and pollution prevention. This publication
is one of the products of that research and provides a vital communication link between the researcher and the user
community.
This report describes the results of field testing of an ultrasonic cleaning device utilizing aqueous-based
cleaners. This project supports the reduction of hazardpus waste generation through the use of alternatives to
chlorofluorcarbon (CFC) compounds for parts degreasing.
E. Timothy Oppelt, Director
Risk Reduction .Engineering Laboratory
' U.S. Environmental Protection Agency
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ABSTRACT
The study summarized here evaluated, on a technical and economic basis, the replacement of a solvent
vapor degreasing system using chlorofluorocarbons (CFC-113) with an ultrasonic cleaning system using a heated
water-based cleaning fluid for cleaning stainless steel parts. ;
The intent of the substitution was to reduce fugitive volatile emissions while eliminating the use and
handling of hazardous materials at the facility. The ultrasonic cleaning system was custom fabricated to meet the
dimensions requirements of the parts fabricated on site. Cleaning standards for the new system were to remain
consistent with the criteria used for vapor degreasing. I
Through the utilization of an ultrasonic cleaning system, fugitive emissions have been significantly curtailed.
Volatile emissions are estimated to be reduced 68% (3,450 Ibs./yr. versus 10,876 Ibs./yr.) over the period 1990
to 1992. This reduction was in addition to the elimination of bench top freon cleaning units |at the facility which
reduced emissions from 25,215 Ibs./yr. to 10,876 Ibs./yr. from 1987 to 1990. The elimination of 26 drums/yr. of
stillbottoms generated through solvent reclamation was also realized. i
To complete the economic evaluation, the costs of raw material* (cleaners), utilities and labor was
considered along with waste disposal. An annual savings, utilizing the ultrasonic cleaning system was projected to
be $27,875 with the most significant savings realized with the cost differential in raw materials due to the high cost
of chlorofluorocarbon cleaning solvents. A payback period of 1.6 years was calculated for the project.
Additional benefits from the emission reduction includes improved working environment, reduced indoor
air pollutants and better community relations. ' ;
r
This report was submitted in fulfillment of CR-816762 by Erie County Department ;of Environment and
Planning, Environmental Compliance Services, under the sponsorship of the U. S. Environmental Protection Agency.
This report covers a period from October 1991 to September 1993, and work was completed as of January 1992.
IV
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CONTENTS
Page
Notice ii
Foreword iii
Abstract . iv
Tables v
vi
vii
viii
Figures
Appendices ....
Acknowledgement
1. Introduction
Appendices
Program Overview .
Project Objective . .
Industrial Participant
1
1
1
1
Background > 1
2. Technology Description 3
Vapor Degreasing Technology 3
Aqueous Ultrasonic Cleaning Technology .' 3
Conax's Miraclean System . '..... 4
3. Methodology ; 10
Description of Technical and Economic Approach 10
Sampling and Analysis Plan . 10
4. Results and Discussion ; 11
Discussion of Results 11
Discussion of Analytical Data j 27
5. Economic evaluation ..' 29
Major Operating Costs 29
Capital Costs ; 29
Economic Analysis 29
Economic Assessment ' 30
6. Conclusions ; 31
7. References 32
A. Ultrasonic Cleaning Demonstration Log Sheet 33
B. Analytical Data 35
C. Correspondence Date May 21, 1992 from Conax Buffalo Corporation 61
D. Material Safety Data Sheets 64
E. Conax Buffalo Corporation: General Cleaning Procedures 80
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TABLES ;
Number ....!... Page
1 Fugitive Emissions - "R" Form • j 13
2 Initial Cost of Aqueous Ultrasonic Cleaning System : 14
3 Conax Buffalo Corporation: Ultrasonic Cleaning System Evaluation-Cleaning Demonstration Log 1 . . 15
4 Conax Buffalo Corporation: Ultrasonic Cleaning System Evaluation-Cleaning Demonstration Log 2 . . 18
5 Annual Chemical Costs . i 21
i
6 Summary of Raw Materials Used for Cleaning Technology ' - - • • 22
7 Aqueous Ultrasonic Cleaning System Annual Power Cost ,••••, 23
8 Summary of Waste Generation for Cleaning Technologies l 24
9 Summary of Operating Procedures and Costs for Cleaning Technologies 25
10 Summary of Cleaning Technology Evaluation 1 26
11 Summary of Design and Operating Characteristics for Cleaning Technologies '. .j 26
12 Conax Analyses Results ' 28
13 Operating Costs Summary i 29
VI
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FIGURES
Number £sge
1 Conax Miraclean System Schematic J ••••;• 6
l -7
2 Conax Miraclean System Dimensions '
3 Conax Miraclean System Plan View 8
4 Sample Flow Diagram Using Ultrasonic Cleaning with Two Cascade Rinses 9
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ACKNOWLEDGEMENT
The U.S. Environmental Protection Agency, Erie County, and Recra Environmental, Inc. acknowledge
Cona'x Buffalo Corporation for its assistance and cooperation during the evaluation and for providing the site for
this study. . j
Ronald Benz and Joseph Frysz of Conax arranged the use of the equipment for testing. William Sonntag
of the National Association of Metal Finishers and John Sparks of the U.S. Environmental Protection Agency
reviewed the draft report. !
Vlll
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SECTION 1
INTRODUCTION
PROGRAM OVERVIEW
This is a final report for the second of five innovative waste minimization technology evaluations which
are to be conducted under the cooperative agreement program between USEPA and Erie County entitled "Waste
Reduction Innovative Technology Evaluation" (WRITE) Program Contract No. CR-816762. The project entailed
the technical and economic review of ultrasonic cleaning using a heated aqueous-based cleaning fluid in lieu of freon
vapor degreasing to clean stainless steel components. The program was completed in conformance with the work
plan previously submitted and approved by the USEPA.
The project was completed under the terms of the Erie County /WRITE Program as a joint effort by Conax
Buffalo Corporation; Erie County Environmental Compliance Services, Buffalo, New York; Recra Environmental,
Inc., Amherst, New York; and the EPA Office of Research and Development, Cincinnati, Ohio.
PROJECT OBJECTIVE
The objective of this project was to evaluate, oh a technical and economic basis, the use of ultrasonic
cleaning, utilizing aqueous-based cleaners, as a substitute to chlorofluorocarbon vapor degreasing.
The intent of the aqueous ultrasonic cleaning system waste reduction evaluation are as follows:
To determine the economics associated with cleaning oil and dirt from stainless steel components
using an ultrasonic cleaning system employing a water-based cleaning fluid, in comparison to a
vapor degreasing process
To determine the use and generation of hazardous materials from an ultrasonic cleaning system
To evaluate the treatment performance of an aqueous ultrasonic cleaning system in phase
separating the surface contamination removed from the stainless steel components.
INDUSTRIAL PARTICIPANT .
The industrial participant for this program was Cpnax Buffalo Corporation (Conax). Conax was originally
founded in Buffalo, New York, in 1950 and in 1983 formed a separate subsidiary, Conax Florida. Conax Buffalo
has been engaged in the design and manufacture of highly-engineered, precision products for industrial, aerospace,
nuclear, fiber optic and military applications. In July, 1988, Conax Buffalo Corporation was acquired for cash by
IMI Americas, a wholly-owned subsidiary of IMI pic, a publicly traded corporation located in England.
BACKGROUND
Since 1980, chlorinated solvents and chlorofluorocarbons (CFC-113), including trichloroethylene, 1,1,1-
trichloroethane, trichlorotrifluoroethane (freon) and a freon/acetone mixture have been used at Conax. The CFC's
are used for both degreasing parts after machining, and cleaning parts prior to assembly, shipment or stock. Until
recently, four operations within Conax utilized chlorinated solvents and CFC's:
Machining centers parts cleaning
Machine shop vapor degreasing
Assembly vapor degreasing
Assembly final cleaning
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j '
Although the use of .CFC's results in extremely clean parts that meet quality control criteria, there are
several disadvantages to their use. These include: j
The physical properties of CFC's and the methods of handling/processing result in the production
of fugitive emissions. ;
Fugitive emissions require reporting on "Form R" to comply with the Environmental Protection
Agency's (EPA's) reporting requirements under SARA Title III. As of May 15, 1993, products
containing or manufactured with ozone depleting chemicals, must be labeled with a warning
statement. ;
The cost of CFC's is increasing.
CFC's are targeted for eventual elimination per the 1987 Montreal Protocol and Clean Air Act
due to their ozone depleting characteristics. i
The use of CFC's is going to be taxed. I
Reclamation of freon is possible, however hazardous wastes are still generated (i.e., F002
stillbottoms). ' !
After examining their operations and reviewing the disadvantages to CFC use, Conax decided to investigate
alternative cleaning/degreasing processes and cleaning agents. |
In 1989, Conax initiated the first step in their program to eliminate the use of all CFCj"s plantwide. Within
their machining centers, freon was being used in one and one-half gallon cans for degreasing metal parts. Conax
successfully replaced these units with ten-gallon, hot aqueous cleaning systems. These systems, which utilize an
alkali (soap) based cleaning agent, have substantially reduced freon usage, fugitive emissions iand hazardous waste
generation within Conax. [
i
The next step in their CFC elimination program was the removal of CFC's within the machine shop vapor
degreasing operation. Conax undertook an intensive investigation into various equipment and processes on the
market to replace their 110-gallon freon vapor degreasing unit. Based on their research, Conax decided to replace
their existing cleaning unit with a hot aqueous cleaning system utilizing ultrasonics. i
Conax and Chautauqua Metal Finishing Supply (CMFS), manufacturer of the Miraclean ultrasonic cleaning
system, agreed to participate in the Erie County /WRITE Program in June, 1991. The ultrasonic cleaning technology
purchased by Conax was the subject of this technical and economical waste reduction evaluation. This system was
compared to Conax's existing freon vapor degreasing unit employed to clean various stainless steel components.
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SECTION 2
TECHNOLOGY DESCRIPTION
VAPOR DECREASING TECHNOLOGY :
The vapor degreasing units consisted basically of a tank split in two sections. The solvent was heated by
electric elements in the bottom of one section where the parts were cleaned. Higher in the unit were copper cooling.
coils that recondensed the vapor which then collected in the other section of the tank and overflowed into the heated
section. The condensing coils were cooled by a constant flow of cool tapwater which went to a drain. Parts were
introduced through the top of these units. Two problems with using the vapor degreaser were (1) tendency for
entrained freon to be removed from the degreaser with the cleaned parts and (2) the necessity to clean long tubes
(length >_ S'/t feet), one end at a time due to the physical size constraints of the degreasing units. The Branson
unit was the larger, containing 100 gallons of solvent and having physical dimensions of 2V4 x 5Vi feet floor space
and ~5'/i feet in height. The Blakslee was a 25 gallon unit having physical dimensions of 4 x 2 x 4l/i feet.
AQUEOUS ULTRASONIC CLEANING TECHNOLOGY
Ultrasonic cleaning is one of a number of methods which can be used for removing microparticulates from
hard surfaces. Ultrasonic cleaning consists of immersing a part in a liquid medium, agitating that medium with high
' frequency (24-26 kHz) sound for a brief interval of time (usually a few minutes), rinsing with clean solvent or water
and drying.
The underlying mechanism behind this process involves microscopic bubbles in the liquid medium
imploding or collapsing under the pressure of agitation, producing shock waves. These shock waves impinge on
the surface of the part and, through a scrubbing action, displace or loosen particulate matter from that surface. The
process by which these bubbles collapse or implode is known as cavitation.
There are no physical means by which actual cavitation action can be measured. Thus, operators seeking
to assess the performance of an ultrasonic cleaning system must rely almost exclusively on the evaluation of actual
cleanliness levels achieved.
The cavitation intensity in a sonic field is largely determined by three factors:
I. The frequency and amplitude of the radiating wave
2. The colligative properties of the medium (vapor pressure, surface tension, density, viscosity), and
3. The Theological properties of the liquid (static condition, turbulent flow, laminar flow).
In order for cavitation to be produced in a liquid medium, the amplitude of the radiating wave must have
a certain minimum value, usually rated in terms of electrical input power to the transducer. Cavitation intensity and,
hence, cleaning effectiveness is greatly affected by the characteristics of the cleaning fluid. Flow characteristics,
or rheological properties, also play an important role in ultrasonic cleaning performance.
The design of an ultrasonic cleaning process must take into consideration the size, configuration and
capacity of the ultrasonic tank to accommodate the parts to be cleaned in an efficient manner. Certain basic rules
which serve as guidelines in making design-related determinations are as follows:
Tank Loading: The sum of the surface areas of the parts to be cleaned measured in square inches
should not be much greater than the tank volume, measured in cubic inches.
- • Work Baskets and Fixtures: Work baskets or fixtures should have as little mass as possible, be
made of metal (preferably stainless steel or some other hard, sound-reflecting material), and be
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of open construction so that there will be minimal interference' with the free passage of both sound
waves and cleaning fluids. ;
Work Orientation: Parts to be cleaned should be evenly spaced throughout the tank volume and
oriented with their narrowest dimensions toward the transducer radiating surfaces.
Location of Transducers: Sonic transducers should be placed on the largest sides of the tank to
allow for maximum distribution of sonic energy throughout the cleaning solution.
Power Requirements: The ultrasonic power requirements, expressed in terms of electrical-input
wattage to the transducers, lie in the range of 50-100 watts per gallon of cleaning fluid, or 2.8-3.6
watts per square inch of transducer radiating surface (for piezoelectric transducers, most
commonly used in ultrasonic cleaning systems). i
Cleaning Fluid: Cleaning fluids should be carefully selected on the basis jof (1) chemical and
physical nature of the contaminants to be removed, and (2) identity of the substrate material.
The operation of the ultrasonic cleaning system is also critical for the proper removal ,of particulate matter
and other contaminants from substrate surfaces. Operating parameters include: I
Use of Clean Solvents and Detergent Solutions: The importance of using clean solvents cannot
be overemphasized, since exposure to dirty solutions could easily result in the deposition of soils
that are more difficult to remove than the original contaminants. i
Wetting of Substrates and Contaminants: Wetting should usually be accomplished not more than
a few seconds following introduction of the sonic fluid. •
Prevention of Redeposition: Continuous filtration or overflow, or both, are required to remove
all contaminated cleaning solutions. This can be accomplished through either spraying or vapor
misting techniques, or ultrasonic immersion rinsing in heated water in;order to maximize
cavitation activity. >
CONAX'S MIRACLEAN SYSTEM j
[
The Miraclean System is an ultrasonic cleaning system designed by Chautauqua Metal Finishing Supply
(CMFS) of Jamestown, New York. It is a modular design of cleaning and rinsing tanks, employing an aqueous
cleaning agent within the ultrasonic tank to accelerate the cleaning action (i.e., cavitation). Miraclean systems have
a variety of available options, such as additional rinse tanks and dryer station, to meet individual customer cleaning
requirements. For example, in the Conax case, the system was designed to handle long tubes.
i
After reviewing Conax's needs for a replacement of their solvent-based cleaning system, CMFS suggested
the Miraclean aqueous ultrasonic cleaning system as an alternative method of cleaning. ; To determine the
applicability of the system, preliminary trial tests were conducted. i
Sample tests were run on representative parts sent to CMFS from Conax. The parts were made of stainless
steel, aluminum, copper and/or plastic. These parts were covered with the typical contalninants that Conax
removed, including standard screw machine oils, water-based coolants, in-house shop dirt and metal shavings.
Conax had several criteria for the cleaner to be selected. The cleaner must:
Be multi-metal safe
Not etch aluminum '
Be compatible with plastic/nylon
Be biodegradable i
Clean the above contaminants
Be free-rinsing
Be non-hazardous '-,
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CMFS used a protective cleaning system to clean the parts in-house. After reviewing the criteria for
cleaner and the types of contaminants to be removed, a powder silicated cleaner (Metex Cleaner TS-40A) was
selected as the best cleaning agent for Conax of the four tested. The three others tested include two other alkaline
cleaners called GP Ultra and GP Special, provided by Miraclean, and ND1 which is a terpene-based cleaner. The
clean parts which were sent to Conax for inspection met Ithe Quality Department's product quality standards.
A second trial run was done with Conax representatives present. A 72" stainless steel pipe was cleaned
using the powder silicated cleaner in an ultrasonic cleaning tank. The oils, chips and dirt particles were removed.
Conax was satisfied that the Miraclean System would meet their quality standards for the variety of parts they
needed cleaned.
Based on the results of the preliminary trial tests conducted for Conax, a Miraclean System was designed
for their specific requirements. A description of the system, shown schematically in Figure 1 and 4, is provided
below:
LOADING (Station (I))-- where the parts are placed in a basket for cleaning.
CLEANING TANK (Station (2)) - Six (6) ultrasonic (24-26 kHz) transducers are mounted on the side of
the tank. The ultrasonic energy provides a mechanical scrubbing action. The action, in conjunction with
the cleaning agent, quickly and effectively cleans the parts.
The cleaning tank is designed with an interior grease trap/overflow weir. A sparger system is used to
gently move insoluble oils and surface debris over the grease trap/overflow weir. These oils are contained
in this area and are removed via phase separation.
A pump and filter system is installed in the cleaning tank to remove suspended solids, chips and files. This
extends the life of the cleaning solution.
COUNTERFLOW RINSE TANKS (Stations (3 and 4)) - The purpose of a rinse tank is to dilute the
concentration of cleaner that remains on the part to a level that is acceptable to Conax. A counterflow
rinse system was designed to minimize fresh water use (see Figure 1). In a counterflow system, fresh
water flows into the second counterflow rinse tank (4). This tank is designed with an overflow weir that
empties into the first counterflow rinse tank (3). This first counterflow rinse tank has an overflow weir
that collects insoluble solution that remains on the part after leaving the cleaning tank. By counterflowing
a single stream of water through two rinse tanks, the same water can be used twice. This greatly reduces
the amount of fresh water needed to maintain acceptable rinse dilution.
FINAL HOT RINSE (Station (5)) - At this time, Conax will use the final tank for rinsing. Heat has been
added to this tank to elevate the temperature of the part to help expedite drying.
UNLOAD SYSTEM (Station (6)) - After leaving the final hot rinse, parts are cooled and removed from
the baskets.
The dimensions of Conax's Miraclean System are depicted in Figure 2. Overall, the system measures
approximately 10' x 6.5' x 3' high. The work area, the area within the system where substrates are ultrasonically
cleaned, measures approximately 9' x 1' x 1.5' deep. The system was designed to accommodate Conax's long
stainless steel tubes.
A plan view of the Conax Miraclean System is shown in Figure 3. This diagram shows the location and
relative size of the ultrasonic cleaning equipment, including the transducers, heaters, temperature and other system
controls, and the pump and filter systems. The heating elements are positioned close to the bottom of the ultrasonic
cleaning tank and hot water rinse tank. The six (6) transducers are lined side-by-side along the largest side of the
tank. A cover will be utilized for conservation of energy on the two (2) heated tanks.
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SECTION 3
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METHODOLOGY ,
DESCRIPTION OF TECHNICAL AND ECONOMIC APPROACH j
A fundamental difference in the technical features of a vapor degreasing system and an ultrasonic cleaning
system is that the vapor degreaser utilizes the vapor of a highly volatile solvent to remove dirt, oil and debris from
small and limited access areas of the part being cleaned. An ultrasonic system uses the sound vibrations to loosen
and a.gitate the liquid surrounding the immersed part to accomplish the same objective. j
The salient points of comparison are the composition of the cleaning agents, the relative costs of operation,
and hazardous waste generation. |
i
Waste generation for the ultrasonic unit was evaluated through a sampling program'described in Section
3.2, Sampling and Analysis Plan. In order to perform a comparative economic evaluation1 of the two systems,
several factors required consideration including capital costs, power requirements, waste disposal costs and labor
costs. This information has been collected and tabulated by Conax engineers and is presented in Section 4.0,
. Results and Discussion.
SAMPLING AND ANALYSIS PLAN ;
As part of the evaluation of the Miraclean system, samples from the wash tank (Station 2), rinse tank
(Station 4) and final hot dip tank (Station 5) were taken to be analyzed for oil and grease (O4;G) and total organic
carbon (TOC). These samples were taken (1) just before changeout of the wash tank, (2) of the wash solution after
neutralization, and (3) early in the use of the fresh solution. The purpose of this sampling was to track the
increasing concentrations of organic contaminants hi the system and the effect of increased contamination on transfer
of contaminants to the rinsewater and subsequently to the sewer. Analytical results are presented in Table 12 and
in Appendix B. i
i
The Miraclean system is operated as follows relative to determining when tank changeout is required:
a. The fresh water solution is mixed at a ratio of 10 ounce powdered Metex TS-40A per gallon of
tap water, which results in a cleaning solution of pH ~ 12. As cleaning continues, the alkalinity
of the solution is consumed and diluted, and the solution becomes more; buffered, requiring
periodic addition of alkaline cleaner powder in increasing amounts to maintain a pH of ~ 12. The
alkaline cleaner powder is added when the pH drops below 11 in the wash tank.
b. The periodic addition of alkaline cleaner powder continues until the concentration is again 10
ounces per gallon (OPG). This concentration is monitored weekly using a simple filtration
procedure and a kit supplied by the manufacturer. At 10 OPG, the cleaning solution is once again
at a pH of ~ 12 (see Appendix E, page 4).
c. Alkaline cleaner powder is added to the bath as described hi b, until the amount added equals the
amount initially used for the bath formulation at startup. When this final cleaner addition is
consumed, the wash tank is allowed to cool, and is neutralized with H2SO4 to promote separation
of the oil and grease concentrate which is collected for disposal. The neutralized aqueous phase
is sewered. The average time span between changeouts is approximately 4 'months.
Samples of the system were taken on April 13, 1992. This batch of cleaning solution was made up on
January 7, 1992 and separated on April 21, 1992. The separation took 2 days to complete and samples were taken
each day to monitor the separation efficiency. A new solution was made up on April 23, 1992, and another set of
samples was collected on May 5, 1992, to test a relatively "clean" system. All sampling and analysis procedures
were performed according to SW-846 3rd Edition protocols (Method 9060 - Total Organic Carbpn and Method 9070
-Total Recoverable Oil and Grease). i
10 i
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SECTION 4
RESULTS AND DISCUSSION
DISCUSSION OF RESULTS
Prior to 1989, parts cleaning activities conducted at Conax involved the use of two types of freon-based
cleaning solvents, Genesolv D and Genesolv 5535, which are HCFC compounds manufactured by Allied Signal.
Fugitive emission data reported by Conax shows a release of 10,876 pounds of freon solvent annually for the
previous several years, with a high of 32,990 pounds in [1988 (see Table 1). This solvent loss occurred in four
stations: (1-2) from solvent cans at the work benches and machining centers, (3) at the Blakslee Vapor degreaser
in the Nuclear electric Penetrations Assembly department (N.P. Assembly), and (4) at the Branson degreaser in the
deburring department. It can be seen from inspection of Table 1 that initial efforts in changing from freon to
alkaline cleaning at the machining center substantially reduced emissions at these stations in 1989, and eliminated
these emissions in subsequent years.
In August, 1991, Conax had the Miraclean Ultrasonic System installed at a total cost of $44,411 (see Table
2). The purpose of this system was to clean parts previously cleaned with freon in the Blakslee and Branson vapor
degreasers. A log of cleaning activity at the Ultrasound unit was kept for two weeks during January, 1992 (1/13/92-
1/24/92) (Appendix A). The log described the types and number of parts being cleaned as well as the time each
"batch" of parts spent hi the various stations of the Miraclean systems. Engineers at Conax described this two week
period as typical of production so that one could extrapolate this loading on the wash system to an annual basis.
During this two week period, 131 "batches" of parts were cleaned.
As summarized hi Tables 3 and 4, an average time per batch spent in the Miraclean unit is approximately
8 minutes (Stations 2 through 5). The size and number of parts cleaned per batch ranged from large tubes to phis,
and from one to several thousand units as summarized in Log #2 (Table 4). Since the exact number of parts cleaned
was not tabulated, the data was averaged to derive an estimated 186 parts cleaned per batch or cycle.
There is no objective test procedure used by Coniax to determine cleaning effectiveness, instead, the parts
are subject to visual and tactile inspection after cleaning. One difference reported between parts cleaned with the
alkaline/ultrasound process as compared to freon degreasing is that the freon cleaned products would, at times, have
a slight powder residue deposition after drying which is not found with the Miraclean washed parts. This is due
to the inability of solvents to dissolve inorganic salts that; accumulate on the parts. The use of an aqueous-based
cleaner solves this. No parts have been rejected for cleanliness by customers from either cleaning system and there
have been no consumer complaints.
Based on correspondence with Conax (Appendix C) for freon degreasing, parts were placed in freon vapors
for approximately 3 to 5 minutes and then air dried for approximately 1 to 2 minute. Conax further indicated that
throughput in terms of parts/batches or cycles for the freon system was comparable to the ultrasonic cleaning
system.
Referring again to Table 1, the fugitive emissions from the vapor degreaser were eliminated with the use
of the Miraclean system as seen in the projected 1992 year report. The amount of oil and grease cleaned from the
parts cannot be accurately approximated hi this case from interpretation of analytical data collected from the
Miraclean system. The analyses can be used to estimate the contaminant loading and transport within the system
and to help understand general operation. A discussion of these analyses is included in Section 5.2. After the
separation, approximately 20 gallons of oily concentrate were separated from the approximate 180 gallon waste tank
for disposal. The remainder was sewered. It should be noted that just prior to changing the cleaning solution, the
contaminant loading was suspected of affecting the cleaning efficiency of the Miraclean system by increasing the
average cleaning time required by an estimated 10-15%. This is not reflected in the averages from Logs 1 and 2,
11
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(Tables 3 and 4), however, the batches tabulated do not include non-production parts such as the machine fixture
in Batch #130 which was given inordinately long cleaning times. These tend to give a positive; skew to the average
clean time. Another important consideration is that the actual operation of this system does not reflect the
theoretical optimum or maximum operation in this case. Conax engineers found in the operation of this system that
the filter used for removing contaminants from the wash tank (Station #2) tended to readily plug and also remove
the cleaning solution. They found that the filter could be removed without any adverse effect on cleaning efficiency.
This is in direct contradiction to the generalized theory of operation as stated in the technology description and
should not be considered as typical of optimum operation. '
i
A breakdown of comparative waste generation and costs of operation for the ultrasonic cleaning versus
vapor degreasing systems is included in Tables 5 through 11. In preparing these tables, many of the numbers are
derived from best estimates from Conax's engineers where recorded data was not available.; Where data is not
possible, the tables will contain N/A for these data points. j
Table 5 provides information on annual chemical costs for both the ultrasonic cleaning System and the freon
vapor degreasing process. For the freon systems, data is provided for a three (3) year period. As the freon
degreasers have been replaced, obvious cost-savings have resulted. Table 6 provides comparative information
including costs for raw materials used in both types of cleaning technologies. Raw material cost savings are
substantial for ultrasonic cleaning system ($32,735.70 per year, assuming Conax would have continued to use both
freon degreasing units). \
i
Table 7, using information supplied by Conax, provides a comparison of the annual power costs between
the ultrasonic cleaner and the freon degreasers. Annual power costs are substantially higher ($6,528.00) for the
ultrasonic cleaning system, assuming current power costs and equipment operating times. A significant portion of
the increased utility costs result from the need for a heated rinse tank to facilitate drying subsequent to aqueous
cleaning.
i
Table 8 provides a summary of waste generation for both types of cleaning technologies. Waste
management costs for the two (2) freon degreasers are based on 1990 data. Current costs would be substantially
higher. I
I
t
Table 9 summarizes data from Table 1 and Tables 5 through 8, and provides comparative information in
regards to operating costs of the ultrasonic cleaning system versus the freon degreasing system.
The average length of cleaning cycle includes cleaning only. Additional time for drying is difficult to
determine because it is a function of the part configuration. Long tubes or parts with dead ended taps for set screws
require longer drying times. An air gun was made available for drying of parts subsequent to aqueous cleaning for
such difficult areas, or for parts which were required in a more expedient fashion.
Although the cleaning using the ultrasonic unit required more steps, the custom sizing of the unit to
accommodate all Conax part configurations eliminated redundant cleaning steps for parts which could not be
immersed in the freon degreaser in a single dip. :
As confirmed by Conax, production rates for parts cleaning are assumed to be constant for comparison of
historical information. Cost comparisons are provided for utilities, labor and raw material. Annual operating costs
for the vapor degreaser was determined to be $51,683, while costs for the aqueous ultrasonic unit was found to be
$24,675. ' i
A second iterative evaluation was completed appraising the cost of each system on a per batch basis (Table
1). Raw material costs for the vapor degreaser per batch ($9.98) versus the aqueous ultrasonic system provided
the most significant cost savings. This savings more than offset increases in operational costs,1 $5.21 for the vapor
degreaser versus $6.90 for the aqueous ultrasonic system. The net result, on a per batch basis, was approximately
12 !
-------
50% costs savings, $15.20 for vapor degreasing versus $7.26 for ultrasonics. The information presented in Tables
9 and 10 are further discussed in Section 5.0, Economic Evaluation.
I
Table 11 provides further operating characteristic [comparisons for the two systems such as system capacity,
mobility, logistical operating requirements and labor requirements. System capacity for the aqueous ultrasonic
system was greater (75 batches per hour versus 17 batches per hour). This was due to the increased surface areas
of the aqueous ultrasonic unit (63 square feet versus 14 square feet/8 square feet) as compared to either vapor
degreasing unit. The size, however, has impacted system mobility where the vapor degreasers are somewhat
portable relative to the fixed ultrasonic unit.
TABLE 1
FUGITIVE EMISSIONS
"R" FORM
REPORTING YEAR
Emission type and source
Freon (Gencsolv D)
Machining Centers (Ibs)
N.P. Assembly Tables (Ibs)
N.P. Vapor Degreaser (Ibs)
Freon/ Acetone
(Genesolv 5535)
Deburr Vapor Degreaser (Ibs)
Total
1987
14,500
5,135
1,033
4,547
25,215
1988
20,614
7,301
1,033
4,042
32,990
1989
1,369
6,000
500
!
4,950
12,819
1990
0
6,086
500
4,290
10,876
APPROX.
NOT
COMPLETE
1991
0
6.400
500
0
6,900
PROJECTED
1992
0
3,450
0
0
3,450
Hazardous Waste Disposal
Genesolv D and Genesolv 5535
REPORTING YEAR
Amount Genesolv D (Ibs)
Amount Genesolv 5535 (Ibs)
Cost of Disposal
1987
2,070
600
$660
1988
690
600
$280
1989
2,750
1,650
$1,030
1990
690
905
$370
1991
690
1,200
$705
PROJECTED
1992
1,380
zO
$470
13
-------
TABLE 2 ;
INITIAL COST OF AQUEOUS ULTRASONIC CLEANING SYSTEM
A) Ultrasonic Equipment
B) NEMA Enclosure
C) Three Tank System
D) Pumps/Filter
E) Sparger Pump
F) Tank Covers
G) Crane
L) Supplies & Labor to Install
TOTAL
$18,300.00
2,769.00
11,034.00
960.00
625.00
2,000.00
2,000.00
6,723.00
$44,411.00
14
-------
TABLE 3
CONAX BUFFALO CORPORATION
ULTRASONIC CLEANING SYSTEM EVALUATION
CLEANING DEMONSTRATION LOG
1/13/92-1/24/92
Batch #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Time (min)
Station #2
2
1
4
1
2
3
6
3
3
3
' 4
5
4
5
3
5
5
5
5
5
5
5
5
5
5
5
5
5
1
5
5
5
5
2
5
5
5
5
5
14
5
15
5
15
10
#3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
#4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
I
#5
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
: 1
1
1
1
1
1
1
1
1
2
1
[ 1
1
1
1
PH
#2
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
#3
7
7
7
7-
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
#4
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
Temp (F)
#2
140
140
145
145
145
160
160
145
165
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
#5
160
160
160
160
145
145
160
145
145
145
145
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
140
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
[AVERAGE 5.02 1.07 1.04 1.04 12.00 7.00 7.00 157.39 157.38
(continued)
15
-------
TABLE 3 (continued)
Batch #
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
Time (min)
Station #2
5
5
5
15
5
1
5
2
6
5
2
5
5
5
3
3
1
1
5
3
2
3
3
1
5
2
1
20
5
25
15
1
2
30
5
5
3
20
5
3
3
5
2
2
2
2
#3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
10
1
1
1
3
1
1
1
1
1
1
1
1
,
#4
1
1
1
1
1
,1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
1
1
1
1
1
1
1
1
1
1
1
1
#5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
1
1
1
1
1
1
1
1
1
1
pH
#2
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
#3
7
7
7
7
7
7
7
7
7
7
7
7
#4
7
7
7
7
7
7
7
7
7
7
7
7
Temp (F)
#2
160
155
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
140
150
150
155
155
160
160
160
160
160
160
160
160
160
160
160
160
160
#5
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
145
155
155
155
155
160
160
160
160
160
160
160
160
160
160
160
160
AVERAGE
5.63 1.30 1.20 1.09 12.00 7.00 7.00 158.80; 159.22
(continued)
16
-------
TABLE 3 (continued)
Batch iC
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
Time (min)
Station #2
1
2
2
2
1
2
1
1
1
3
3
3
5
2
2
2
1
2
2
1
2
1
2
1
5
1
1
• 1
1
2
5
5
5
5
3
5
5
1
30
5
#3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
#4
1
1
1
I
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
, 1
#5
1
1
1
1
1
! 1
1
1
1
1
1
1
2
1
.1
1
1
1
1
1
1
1
1
1
1
t 1
1
1
r 1
1
1
1
i 1
1
1
1
1
1
5
1
PH
#2
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
11
11
11
11
11
#3
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
#4
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
Temp (F)
#2
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
150
150
158
160
160
tfS
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160
160'
160
160
160
150
155
159
160
160
160 160
AVERAGE
3.13 1.10 1.10 1.13 11.85 7.00 7.00 159.45 159.58
OVERALL
AVERAGE
4
.66
BASED
1.16
ON 131
1.11
BATCHES
1.08
11
.94
7.00
7.00
158.69
158.71
17
-------
TABLE 4
CONAX BUFFALO CORPORATION
ULTRASONIC CLEANING SYSTEM EVALUATION
CLEANING DEMONSTRATION LOG
, .1 1/13/92-1/24/92
Batch #
1
2
3
4
' t
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
NUMBER OF PARTS TO BE CLEANED
1-15
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
15-100
X
X
X
X
X
X
X
X
X
X
100-100
X
X
X
X
X
X
X
X
X
X
X
1000 +
X
CONFIGURATION
TUBE
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
OTHEF
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X-
X
X
X
X
X
X
X
X
X
DESCRIPTION
SHORT TUBES 304SS
STOCK
PINS 303SS
SEATS 303SS
SEALANTS
SEALANTS '.
PINS 303SS :
304SS
304SS
304SS
304SS
304SS
304SS
304SS :
304SS
304SS
304SS
304SS
304SS :
304SS
304SS ;
304SS
304SS :
304SS
304SS
I04SS
SEALANTS TEFLON
SEALANTS TEFLON
;04SS
SEALANTS VITON
WELD LIP
BODIES 303SS
SPRING STOPS 303SS
SEALANTS TEFLON
BODIES 303SS
'LUGS
PINS
SEALANTS
GUARD ALUM
LATE(ADPT)CAST ALUM
LATES CAST ALUM
HORT TUBES 304SS
HORT TUBES 304SS
HORT TUBES 304SS
HORT TUBES 304SS
TOTALS
23
10
11
20
24
(continued);
18
-------
TABLE 4 (contined)
BATCH #
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
NUMBER OF PARTS TO BE CLEANED CONFIGURATION
1-15
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
15-100
X
X
X
X
X
X
X
X
X
X
X
100-1000
X
X
X
X
X
X
X
X
X
X
X
X
1000 +
X
TUBES
X
X
X
X
X
X
OTHER
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
DESCRIPTION
SPRING STOP 303SS
MHM BODY304SS
LNG. HEXNIPP. 316SS
RODS 303SS
MHM BODY 31 6SS
SEALANTS TEFLON
MHM BODY 303SS
SEALANTS
CAPS316SS
INSERTS
SEALANTS TEFLON
BODY 303SS
PACKING GLANDS 303SS
ADPT PLATES CST ALUM
SM. FLANGE 303SS
EG+GLANDS 303SS
304SS
PINS
RODS
GLANDS 31 6SS
SEALANTS TEFLON
SEALANTS POLY.
304SS
CUTTER
SEALANTS TEFLON
304SS
BAR STOCK
MON DISC 6061 ALUM
BUSHING POLY.
BUSHINGS POLY.
SEATS 303SS
HEADER 304SS
ADPT PLATES CST ALUM
PLATES
MIDLOCK CAPS 303SS
CHIK BLOCK FOR MAINT DEP
304SS
PLATES
304SS
304SS
SHORT 2' 5/16 DIA 304SS
SEALANT VITON
SEALANT TEFLON
SEALANT TEFLON
TOTALS
12
39 | (continued)
19
-------
TABLE 4 (continued)
-' ; "f
(NUMBER OF PARTS TO BE CLEANED |CONFIGURATION ;
BATCH* 1-15 15-100 100-1000 1000-1- TUBESOTHER
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
DISC !
SEALANT TEFLON
SEAT 303SS
FOLLOWER 303SS
RODS 303SS i
FOLLOWER 303S
SEALANT TEFLQN
PIPE 304SS ;
FOLLOW 303SS !
303SS ADAPTER .25" DIA
ALUM
ALUM
26* DIA HEADER 304SS
FIXTURE SS
FERRULES 303SS
BODY
GLANDS CAP :
GLANDS !
THREADED ROQ 303SS
BODY 304SS
MONARY DISC (ALUM)
BUSHINGS POLY.
304SS i
SPLIT SEATS 303SS
COPPER !
CONNECTING HOUSINGS
FLANGES j
SEALANTS TEFLON
PG 5 SEALANTS ITEFLON
NUCLEAR SERV.i CONNECTORS
FOLLOWERS 303SS
FOLLOWERS 303SS
SEATS 303SS !
METAL SEATS 303SS
PIPE 304SS
SLEEVES ALUM '
SLEEVES ALUM :
MHM BODY316SS
MACHINE FIXTURE 303SS
PIPES 304SS ;
TOTALS 21 | 7 | 10 |
2 | 0 |
39
OVERALL
TOTALS | 65 | 28 | 33 |
4 | 26 |
102
20
-------
TABLE 5
ANNUAL CHEMICAL COSTS
AQUEOUS ULTRASONIC CLEANING SYSTEM (Projected 1992):
Costs based on 3.5 changeovers/year
Metex TS-40A cleaning compound 1050 Ibs/year
Sulfuric acid 10.5 gal/year
$940.80/year
$262.50/year
BRANSON VAPOR DEGREASER/BLAKSLEE VAPOR DEGREASER/ r
NP ASSEMBLY BENCH CLEANING
COSTS OF GENESOLV D & GEl^fESOLV 5535 FOR 1990-1992
USAGE BY PROCESS AREA
Genesolv 5535
(Branson Degreaser in Deburring
Department)
Genesolv D
(Blakslee Degreaser in NP
Assembly)
Genesolv D
(NP Assembly Cleaning at Work
Benches)
TOTALS
YEAR
Cost
Tax
Cost
Tax
Cost
Tax
1990
$14,280
$ 7,753
(14 drums')
$22,033
$ 7,369
$ 4,537
$11,906
$ 7,369
$ 4,537
(6 drums')
$11,906
$45,845
(26 drums)
1991
0
$ 5,851
$ 3,024
(4 drums')
$ 8,875
$ 8,777
$ 4,536
(6 drums')
$13,313
$22,188
(10 drums)
Projected
1992
0
0
$10,512
$ 5,531
(6 drums')
• $16,043
$16,043
(6 drums)
21
-------
TABLE 6
SUMMARY OF RAW MATERIALS USED FOR CLEANING TECHNOLOGIES
,
Raw Material Used
Product Type
Usage Rate
Delivery Mode
Transfer Mode
Empty Container Mgt
Raw Material Cost:
Purchase Price (total)
Taxes (if applicable)
Total Cost
Storage Requirements:
Area (ft2)
Special Precautions
BRANSON
DEGREASER
Genesolv 5535
Freon/acetone
14 drums
Drums
By Hand
Return drums
$14,280
7,753
$22,033
25 ft2 .
Avoid excess
heat
BLAKSLEE
DEGREASER
Genesolv D
Freon
6 drums
Drums
By Hand
Return drums
$ 7,369
4,537
$11,906
-25 ft2
'Avoid excess
heat
AQUEOUS ULTRASONIC
CLEANING SYSTEM
Metex TS-40A
Alk. cleaner
1050 Ibs
Drums
By Hand
Disposal
$940.80
$940.80
-25 ft2
Corrosive
mat' Is
H2S04
lyfineral acid
10V$ gal (~1501b)
Drums
By Hand
Disposal
$262.50
$262.50
f25ft2
Corrosive mat' Is
22
-------
TABLE 7
AQUEOUS ULTRASONIC CLEANING SYSTEM
ANNUAL POWER COST
AQUEOUS ULTRASONIC CLEANING SYSTEM LOADS/MONTH
Ultrasonics 4.52 KW
Pumps 2.98 KW
Heaters (wash) 18.00 KW
Heaters (rinse) 18.00 KW
TOTAL 43.50 KW
Annual Demand Charge ' = $4,437.00
Annual KWH Charge "ON PEAK"2 = $3,008.00 (40,494 KWH)
Annual KWH Charge "OFF PEAK"2 = $ 642.00 (13.519 KWH)
TOTAL = $8,087.00
BRANSON & BLAKSLEE VAPOR DEGREASER
ANNUAL POWER COST
Annual Demand Charge1 = $ 714.00
Annual KWH Charge "ON PEAK"2 = $ 739.00 (9948 KWH)
Annual KWH Charge "OFF PEAK"2 = $ 106.00 (2232 KWH)
TOTAL = $1,559.00
Demand charge based on $8.50/kw per month
KWH charge based on $.074283 KWH "ON PEAK"
$.047488 KWH "OFF PEAK"
23
-------
TABLE 8
SUMMARY OF WASTE GENERATION FOR CLEANING TECHNOLOGIES
Waste Type
Cleaning Medium
Cooling Water
Rinse Water
Oil/Aqueous Concentrate
Filters
Air Emissions: VOCs
Waste Type
Freon
Concentrated Cleaner
Rinse Water
Cooling Water
Oil
Filters
Off-Site Waste Mgt Cost
($/yr)
FREON VAPOR
DEGREASERS
26 drums/year - stillbottoms &
fugitive emissions (Table 1)
1,134,000 gpy (2 units)
Filters not used
See "R" Form - Table 1
Waste Management Practice
Stillbtms disposed as haz waste
Sewered
No filters
$370 (1990 data)3
AQUEOUS ULTRASONIC
CLEANING SYSTEM
1050 Ib/yr either neutralized w/acid
& disposed w/oil waste or sewered
567,000 gpy <
-55 gal/year (-450 Ibs)
Filters not used ;
i
Waste Management; Practice
Neutralized; shipped w/waste oil1
Sewered
Trucked out of state - fuel blending
Filters not used j
~$2002
!
' Most of the cleaner is sewered over the course of the year.
2 $100 transportation/drum; $100 disposal/drum.
3 1990 data, costs for other years is presented in Table 1.
24
-------
TABLE 9
SUMMARY OF OPERATING PROCEDURES AND COSTS
FOR CLEANING TECHNOLOGIES
OPERATION
Avg Length of Cleaning Cycle
(min/cycle)
Throughput Production (parts/year)
Avg No. of Cleaning Cycles/Year
Avg No. of Parts/Cleaning Cycle
Utility Requirements:
Energy (KWH/year)
Water (gal/year)
Labor Requirements:'1
System operation (manhours/year)
Maintenance (manhours/year)
Raw Material Usage:
Freon (Ib/year)
Silicate Cleaner (Ib/year)
Sulfuric acid (gal/year)
Operating Costs:
Utility Costs ($/year)
2Labor Costs ($/year)
Raw Material Costs ($/year)
Water Costs ($/year)s
Sewer Costs ($/year)*
Total Operating Costs ($/year)
BOTH FREON VAPOR
DEGREASERS
7 minutes
-3400 batches
; -3400
-186
12.180KWH
1,134,000 gal/year'
397 hours/year
150 hours/year
12,^40 Ibs/year
I
$ 1,559
$ 8,205
$33,9393
$1,780
i $6,200
$51,683
AQUEOUS ULTRASONIC
CLEANING SYSTEM
8 minutes
-3400 batches
-3400
-186
54,013 KWH/year
567,000 gal/year4
453 hours/year
100 hours/year
1050 Ibs/year
10.5 gal/year
$ 8,087
$ 8,295
$ 1,203
$ 890
$6,200
$24,675
1 Based on 18 hrs/day, 350 days/year; data provided by Conax; Data is for both vapor degreasers
2 Average labor cost is assumed to be $15/hour (wages and benefits)
3 Based on 1990 costs ;
* Information supplied by Conax
5 $0.00157/gallon; Data supplied by Conax
* Data provided by Conax
25
-------
TABLE 10
SUMMARY OF CLEANING TECHNOLOGY EVALUATION
Raw Material Cost/Batch of
Parts Cleaned ($/part)
Operating Cost/Batch of
Parts Cleaned2
Waste Generation/Batch
of Parts Cleaned
Waste Disposal Cost/Part
Cleaned ($/part)
Total Operating Cost/Batch
of Parts Cleaned4
FREON VAPOR
DEGREASER
$ 9.98'
$ 5.21
0.47 Ib.
(See Table 1,
1990 data)
See Table 1 1990 data
$0.109
$15.20
AQUEOUS ULTRASONIC
CLEANING SYSTEM
$0.35
$6.90
0.016 gal waste oil
(55 gal/year)
$0.0593
$7.26
!
| REDUCTION
i $ 9.63
; ($1.69)
i
I
$0.05
$7.94
Data is based on annual costs divided by 3400 batches. •
1 Based on 1990 data ;
2 Operating Cost = Utility Costs + Labor Costs + Water Costs + Sewer Costs
3 Disposal Cost = $100/drum Transportation; $100/drum Disposal >
4 Total Operating Cost = Operating Costs + Raw Material Cost + Disposal Cost ;
TABLE 11
SUMMARY OF DESIGN AND OPERATING CHARACTERISTICS
FOR CLEANING TECHNOLOGIES •
CHARACTERISTIC
System Capacity (batches/hour)
System Mobility (portable, fixed)
Logistical Operating Requirements:
Space (area) (ft2)
Water (gals/hour)
Electrical Power (amps/volts)
Sewer Access (yes/no)
Labor Requirements (manhours/batch
cycle)
FREON VAPOR DEGREASER
BRANSON/BLAKSLEE
17 batches/hour1
Portable / Portable
14 ft2 / 8 ft2
-180 gal/hr
240V/50A
Yes
0. 1 17 manhours/batch
AQUEOUS
ULTRASONIC
CLEANING SYSTEM
75 batches per hour2
fixed
63 ft2
180 gal/hr
240V/50A
lYes
i
0. 134 manhours/batch
1 Assumes 7 minute cleaning time and 50% of maximum capacity. ;
60 min./hour x 1 batch/7 minutes = 8.57 batches/hour x 2 vapor degreasing systems = 17.14
batches/hour " i
2 Assumes 8 minute cleaning time and 10% of maximum capacity.
60 min./hour x 1 batch/8 minutes = 7.5 batches/hour x 10 = 75 batches/hour.
26
-------
DISCUSSION OF ANALYTICAL DATA
The oil and grease (O+G) analyses conducted in testing the ultrasonic cleaning system were subject to
severe matrix interference from both the water soluble lubricants on the parts being cleaned and from the alkaline
cleaner (Metex TS-40A) used in the system. Although primarily an inorganic cleaner containing principally sodium
metasilicates and ortho-phosphates, Metex TS-40A also contains an appreciable amount of non-ionic and anonic
surfactants as well as alkylsulfonates. These compounds are reported to total less than 10 % of the cleaners make-
up; however, concentrations of a few percent can have dramatic effects on both the oil and grease and total organic
carbon (TOC) analyses. The non-ionic surfactants in conjunction with the glycols in the soluble lubricants can have
& dramatic effect on the partition coefficients and subsequent efficiency of oil and grease extractions. The organic
fraction of the cleaners can also contribute appreciably to TOC. TOC values up to 5000 mg/1 could be reasonably
attributed to organic contributions from the cleaner, although 1000 to 2000 mg/1 TOC would be a better estimate
from the data. Analytical data is included in Appendix C.
Other complications in interpreting the analytical data are the dynamic nature of the system and the fact
that operational experimentation was being conducted by Conax to optimize the system. Conax operators found that
there was no loss in cleaning efficiency by operating the system at a pH closer to 11 than to pH 12 and began
experimenting with adding a decreased level of cleaner. This practice impacts on the projected chemical use and
the observation that longer cleaning times were required later in the life of the wash solution.
Bearing these factors in mind, certain observations can be made from the analytical data (Table 12).
Because occasionally three shifts have been used in Conax cleaning activities, an approximation of 18 hours per day,
350 days per year, has been used in calculating annual r^tes. Using TOC data, we can calculate a "maximum"
discharge to sewer of approximately 311 pounds of TOC per year. This is based on the April 13, 1992 data (Table
12) and breaks down to approximately 299.7 Ibs being sewered by the 3 gpm rinsewater (32 mg/1 TOC) and 11.3
Ibs being sewered by the 3.5 dumps of split washwater (TOC 2150 mg/1, 180 gal each). The remaining TOC of
approximately 30 Ibs would be removed for disposal. This of course reflects an analytical worst case from the data
collected at the time just prior to changeout for the wash tank. A good correlation can be drawn between the ratios
of TOC in the wash and rinse tanks sampled late in the batch cycle on April 13, 1992 and early in the new batch
on May 5, 1992. These approximate a 300:1 ratio on average (respectively 245:1 and 346:1). The bulk of TOC
remains in the wash tank and is not transferred to the rinse tank which is subsequently discharged to the sewer.
As can be seen from a comparison of the oil and grease readings from the wash tank, "new" batch on May
5, 1992, TOC and O+G numbers compare favorably indicating good extraction efficiency. The "old" batch sample
taken from the wash tank on April 13, 1992 shows a large discrepancy in TOC versus O+G. This is probably due
to a build-up of soluble lubricants in the wash tank that adversely affects the extraction efficiency for O+G analysis
as explained previously. Another possible cause for the discrepancy is the fact that metallic surfaces are oleophilic
and may tend to preferentially extract non-polar substances as surface film especially as the cleaner is consumed
and loses some "wetting" ability. These possibilities are only speculation and have not been proven to be the cause
of the analytical discrepancies, however, it appears that TOC data should be considered the most reliable of the
analytical characterizations. There are two reasons for this: first, because it is more consistent with observed and
expected contaminant concentrations, and second, because it is a more reliable indicator of biochemical oxygen
demand which would be the principal contaminant strength determinant for this type of waste.
27
-------
TABLE 12
CONAX ANALYSES RESULTS
SAMPLE
4/13/92 Wash Tank
5/5/92 Wash Tank
4/13/92 Rinse Tank
5/5/92 Rinse Tank
4/20/92 Wash Tank Split (Day 1)
4/21/92 Wash Tank Split (Day 2)
4/13/92 Final Hot Dip Tank
O+G (mg/I)
54
1500
*
14.2
105
9.0
*
TOC(mg/I)
7840
1420
32
4.1
3090
2150
14
O+G = Oil and Grease; TOC = Total Organic Carbon
* Less than method detection limit of 5.0 mg/1
28
-------
SECTION 5
ECONOMIC EVALUATION
MAJOR OPERATING COSTS
i
The major operating costs for both the vapor degreasing process and the ultrasonic cleaning process consists
of: (1) raw materials utilized for cleaning (Tables 5 and 6); (2) power utilization (Table 7); (3) waste disposal costs
(Tables 8 and 9); (4) water utilization (Table 9); and (5) labor costs (Table 9). This information is summarized
below:
TABLE 13
OPERATING COSTS SUMMARY
Major Degreasing Cost
Raw Materials ($/yr)
Power Costs ($/yr)
Sewer Costs ($/yr)
Off-Site Disposal ($/yr)
Water Costs ($/yr)
Labor Costs ($/yr)
Total ($/yr)
Vapor Degreasing
$33,939
$ 1,559
$ 6,200
$ 370
$ 1,780
$ 8.205
$52,053
Ultrasonic Cleaning
$ 1,203
$ 8,087
$ 6,200
$ 200
$ 890
$ 8.295
$24,875
Based upon the operating costs presented above, an annual savings of $27,178 can be realized. Cost
savings are primarily reflective of significantly lower raw materials costs for the ultrasonic cleaning system. As
would be anticipated, power costs are significantly higher for the ultrasonic cleaning system. Other operating costs
for this analysis were fairly comparable.
CAPITAL COSTS
Table 2 provides information relative to the capital cost for the installation of the ultrasonic cleaning
system. Capital costs were $44,411 including equipment and installation charges.
ECONOMIC ANALYSIS !
The economic evaluation for this project utilized a standard measure of profitability, namely the payback
period. For small facilities with only a few processes, the economic assessment need not be cumbersome or overly
sophisticate. In these situation, obvious cost savings options may be implemented with little or no economic
evaluation. A balance needs to be maintained relative to the magnitude of cost savings versus the amount of time
required to perform detailed technical and economic analyses.
project.
The payback period for a project is the amount of time it takes to recover the capital investment in the
Payback Period (years) = Capital Investment
Annual Operating Cost Savings
Payback Period (years) - $44.411
$27,178
Payback Period (years) - 1.6
For this project, a payback period of 1.6 years is anticipated.
29
-------
ECONOMIC ASSESSMENT j
A payback period of 1.6 years represents an excellent return on Conax's investment. This is particularly
true, considering the fact that if the company had continued to utilize a solvent-based process, raw material costs
and disposal costs would have continued to escalate making the investment even more attractive.
30
-------
SECTION 6
CONCLUSIONS
In conclusion, there are clear benefits in terms of waste and cost reductions evident from the change to
ultrasonic aqueous cleaning from solvent degreasing by Conax Buffalo. Listed in bullet form, they can be
summarized as follows:
Freon use cut by ~20 drums/year. ;
Waste reduction of over 12,000 lbs/year,when fugitive emissions are considered in the total.
Annual costs (based on 1990 costs for Ereon Systems) for cleaning parts are cut by 48 % from
$52,053 to $24,875 based on 1990 costs and estimates.
Although utility costs were seen as higher for the ultrasonic cleaning system than for the vapor
degreaser, when considering the fact that the ultrasonic cleaning system was operated at —10%
capacity compared to 50% capacity for the degreasers, an increase in efficiency of use could easily
offset this disadvantage.
Transport and fate of wastes are changed from predominantly uncontrolled air emissions of freon
to predominantly sewered cutting and cleaning fluids. In terms of concentration at ~300 ibs/year
TOG, an approximate BOD loading of 600 Ibs could be estimated. In the flow of rinsewater used,
this would contribute a concentration of ~70 mg/1 BOD, which is lower than typical
concentrations of 250 mg/1 over which a;POTW will generally access a surcharge. However, if
this were considered on a total basis, th'e cost for this loading might be on the order of $200
annually (assume 35C/lb surcharge for BOD).
Although all of the information requested was not available (i.e., capital cost of degreasers, reliable
comparative labor costs for administration and management ,of different systems, etc.), it is safe to conclude that
this change produced substantial savings in financial and environmental costs for Conax.
31
-------
SECTION 7
REFERENCES ;
1. Options for Minimizing Chlorinated Solvent Losses .from Cleaning Operations., Hazardous Waste
Consultant, May/June 1992. j
!
2. Waste Minimization Opportunity Assessments Manual. EPA/625/7-88-003, U.S Environmental Protection
Agency, Hazardous Waste Engineering Research Laboratory, Cincinnati, Ohio, April 1988.
3. Waste Minimization in Metal Parts Cleaning. EPA/530-SW-89-049, U.S. Environmental Protection
Agency, Office of Solid Waste and Emergency Response, Washington, DC, August 1989.
4. Alternatives for CFC-113 and Chloroform in Metal Cleaning. EPA/400/1-91/019, U.S. Environmental
Protection Agency, Air and Radiation (ANR-445), June 1991. .
5. McQueen, D.H. Ultrasonically Enhanced Chemical Dissociation from Solid Surfaces. Ultrasonics,
November 1990. j
i
6. Harding, W.B. The Application of Ultrasonics to Metal Finishing. Plating Surface Finishers, 77:40,
March 1990.
7. Cleaner Kegs and Drums with Ultrasonic Washer. Process Engineer, 71:25, January; 1990.
8. Cleaning: Life Without VOC's, Heavy Metals. Modern Metallurgy, 46:112 + , August 1990.
9. SIC has New Range of Ultrasonic Cleaners. Ultrasonics, 28:60, January ,1990.
10. Ultrasonic Cleaner Replaces Vapor Degreaser. (Illustration). Tool Production, 55:110-11, October 1989.
i
11. Ultrasonic Cleaning and Degreasing. Ultrasonics, 27:124, March 1989. i
12. Ultrasonic Cleaning Replaces Solvents. (Illustration). American Machine, 133:99-l6o, June 1989.
13. Ultrasonic Cleaning: Tiny Bubbles Do the Work. (Illustration). Modern Metals, 44:96 + , October 1988.
14. Fitch, A. Aqueous Ultrasonic Cleaning Systems. Metal Finishing, 86:9-10, April 1988.
15. Fuchs, F.J. Multi-tank Ultrasonic Cleaning Systems. Metal Finishing, 90:7-10, May 1992.
16. Maltby, P. The Effluent Use of Ultrasonic Cleaning for Precision Components. Metal Finishing, 90:17-
20, August 1992. \
32
-------
APPENDIX A
ULTRASONIC CLEANING DEMONSTRATION LOG SHEET
33
-------
ULTRASONIC CLEANING SYSTEM EVALUATION
CLEANING DEMONSTRATION LOG SHEET
Date: = — Operator:
STRTTON 1 - LOAHTNG STATION
Description
_ 100-1000 type)
_ 1000+
Parts Configuration: _ tubes - other
STATION 2 - ULTRASONIC rT.KANING TANK :
Start time: Stop time: Elapsed time:
pH: Temperature (°F): Flow Rate (gpm):
i
CITATTON 3 - couNTERFLQW RINSF TANK NO. 2
Start time: Stop time: Elapsed time:
H. Temperature (°F) : _j
STATION 4 - COUNTERFLOW RTNSE TANK NO. 1 ,
Start time: Stop time: Elapsed time:
H: Temperature (°F): _
i
• STATION 5 - FINAT. HOT RINSE TANK I
Start time: Stop time: Elapsed time:
i
Temperature ( F): _ '
STATION fi - UNLOAniNG STA^TON ( COOLING)
Stop time:
inspection: __ Clean _ Not Clean - Return to Station 1
34
-------
APPENDIX B
ANALYTICAL DATA
35
-------
MEMORANDUM
RECRA ENVIRONMENTAL, INC.
Tom Clayson
TO:
FROM- Deborah J. Kinecki
DATE: May 18, 1992
RE: Analytical Results - County of Erie
Deborah J. Kinecki
Vice President
AH/DJK/ah
I.D.#92-1357
i NY2C4051
36
-------
ANALYTICAL RESULTS
i
\
Prepared For
Tom Clayson
Prepared By
Recra Environmental, Inc.
10 Hazelwood Drive, Suite 106
Amherst, New York 14228-2298
METHODOLOGIES
The specific methodologies employed in obtaining the enclosed analytical results are
indicated on the specific data table. The method numbers presented refer to the following
U.S. Environmental Protection Agency reference.
* 40 CFR Part 136 "Guidelines Establishing Test Procedures for the Analysis of
Pollutants Under the Clean Water Act" October 26, 1984 (Federal Register) U.S.
Environmental Protection Agency.
Comments pertain to data on one or all pages of this report.
The enclosed data has been reported utilizing data qualifiers (Q) as defined below.
U-The compound was analyzed for, but not detected.
Quality control analysis was performed on a batch basis. All results were within
acceptable limits.
The samples were received unpreserved. The results accurately reflect the analytes of
interest at the time of sample preservation and analysis.
Sample Wash Tank could not be preserved to a pH less than two (2).
After extraction for Total Oil and Grease sample Wash Tank was a yellow liquid with
a precipitate. This contributed to matrix interference during the analysis.
RECRA
ENVIRONMENTAL |
INC.
-------
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-------
MEMORANDUM
RECRA ENVIRONMENTAL, INC.
Tom Clayson
Kenneth C. Malinowski, PhD !
May 8, 1992
Analytical Results - County of Erie; Write Program
FROM:
DATE:
RE:
AH/KCM/rms
41
Kenneth C. Malinowski, PhD
Vice President
I.D. #92-1214
8NY2C4051
-------
ANALYTICAL RESULTS
Prepared For
County of Erie
Prepared By
Recra Environmental, Inc.
10 Hazelwood Drive, Suite 106
Amherst, New York 14228-2298
METHODOLOGIES '.
The specific methodologies employed in obtaining' the
enclosed analytical results are indicated on the specific data
table. The method numbers presented refer to the following U.S.
Environmental Protection Agency reference. '•.
\
* 40 CFR Part 136 "Guidelines Establishing Test Procedures for
the Analysis of Pollutants Under the Clean Water!Act"
October 26, 1984 (Federal Register) U.S. Environmental
Protection Agency. '
COMMENTS i .
Comments pertain to data on one or all pages of this report.
The enclosed data has been reported utilizing data
qucilifiers (Q) as defined on the Inorganic Data Comment Page.
i
Quality control analysis was performed on a batch basis.
All results were within acceptable limits.
r
Sample Wash Tank Split 2nd Day could not be preserved upon
reciept by Recra Environmental, Inc. i
Total Organic Carbon results may not include volatile
constituents since the sample was purged with an inert gas prior
to analysis. j
42
RECRA
ENVIRONMENTAL
INC,.
-------
ERIE COUNTY ENVIRONMENTAL PLANNING DEPT.
AQUEOUS! MATRIX
WATER QUALITY TESTING
LAB NAME RECRA ENVIRONMENTAL INC.
JOB NO. 92-1214
DESC AS010196
SAMPLE NO. WASH TANK *
SAMPLE DATE 04/21/92
COMPOUND
Total Organic Carbon
Total Recoverable Oil & Grease
UNIT OF
MEASURE
mg/1
mg/1
; METHOD
NUMBER
415.1
413.1
ANALYSIS
DATE
04/28/92
04/23/92
RESULT
2,150
9.0
Q
* SAMPLE NO. WASH TANK SPLIT 2ND DAY
273
43
-------
ERIE COUNTY ENVIRONMENTAL PLANNING DEPT.
AQUEOUS MATRIX
WATER QUALITY TESTING
LAB NAME RECRA ENVIRONMENTAL INC.
JOB NO. 92-1214
DESC AR002300
SAMPLE NO. METHOD BLANK
COMPOUND
Total Organic Carbon
Total Recoverable Oil & Grease
UNIT OF
MEASURE
mg/1
mg/1
METHOD
NUMBER
415.1
413.1
ANALYSIS
DATE
04/28/92
04/23/92
RESULT
1.0
5.0
Q
u
u
* SAMPLE NO. WASH TANK SPLIT 2ND DAY
273
44
-------
CUSTODY RECORD
REMARKS
F-
UJ
O
CC
LJLJ
DC
O
Ul
DC
PROJEC
i\
\
^
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45
-------
MEMORANDUM
RECRA ENVIRONMENTAL, INC.
TO: Tom Clayson
FROM: Kenneth C. Malinowski
DATE: May 6/ 1992
RE:
Aneilytical Results - County of Erie; Write Program
Kenneth C. Malinowski, PhD
Vice President
AH/KCM/ah
I.D.
46
#92-1207
#NY2C4051
-------
ANALYTICAL RESULTS
Prepared For
County of Erie
Prepared By
Recra Environmental, Inc.
10 Hazelwood Drive, Suite 106
Amherst, New York 14228-2298
METHODOLOGIES
The specific methodologies employed in obtaining the
enclosed analytical results are indicated on the specific data
table. The method numbers presented refer to the following U.S.
Environmental Protection Agency reference.
* 40 CFR Part 136 "Guidelines Establishing Test Procedures for
the Analysis of Pollutants Under the Clean Water Act"
October 26, 1984 (Federal Register) U.S. Environmental
Protection Agency.
COMMENTS
Comments pertain to data on one or all pages of this report.
The enclosed data .has been reported utilizing data
qualifiers (Q) as defined on the Inorganic Data Comment Pages.
Quality control analysis was performed on a batch basis.
All results were within acceptable limits.
Total Organic Carbon results may not include volatile
constituents since the sample was purged with an inert gas prior
to analysis.
RECRA
ENVIRONMENTAL
INC.
-------
I
INORGANIC DATA COMMENT PAGE
Laboratory Name RECRA ENVIRONMENTAL. INC.
USEPA Defined Inorganic Data Qualifiers:
B -• Indicates a value greater than or equal to thte instrument
detection limit but less than the contract required detection
limit.
U -• Indicates element was analyzed for but not detected. Report
with the detection limit value (e.g., 100). ;
E - Indicates a value estimated or not reported due to the presence
of.interference. i
S - Indicates value determined by Method of Standard Addition.
i
N - Indicates spike sample recovery is not within control limits.
i
i
* - Indicates duplicate analysis is not within control limits.
+ - Indicates the correlation coefficient for method of standard
addition is less than 0.995. |
M -• Indicates duplicate injection results exceeded control limits.
W - Post digestion spike for Furnace AA analysis is out of control
limits (85-115%) , while sample absorbance is less than 50% of
spike absorbance. i
G - The TCLP Matrix Spike recovery was greater than the upper limit
of the analytical method. i
i
L - The TCLP Matrix Spike recovery was lower than the lower limit
of the analytical method. •
48
RECRA
ENVIRONMENTAL
INC.
-------
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-------
MEMORANDUM
RECRA ENVIRONMENTAL, INC.
TO: Tom Clayson
FROM: Kenneth C. Malinowski
DATE: May 6, 1992
RE: Analytical Results - County of Erie; Write Program
AH/KCM/mec
-6ltf£
Kenneth C. Malinowski, PhD
Vice President
I.D. #92-1139
8NY2C4051
52
-------
ANALYTICAL RESULTS
Prepared For
County of Erie
Prepared By
Recra Environmental, Inc.
10 Hazelwood Drive, Suite 106
Amherst, New York 14228-2298
METHODOLOGIES
The specific methodologies employed in obtaining the
enclosed analytical results are indicated on the specific data
table. The method numbers presented refer to the following U.S.
Environmental Protection Agency reference.
* 40 CFR Part 136 "Guidelines Establishing Test Procedures for
the Analysis of Pollutants Under the Clean Water Act"
October 26, 1984 (Federal Register) U.S. Environmental
Protection Agency.
COMMENTS
Comments pertain to data on one or all pages of this report.
The enclosed data has been reported utilizing data
qualifiers (Q) as defined on the Inorganic Data Comment Page.
Quality control analysis was performed on a batch basis.
All results were within acceptable limits.
Total Organic Carbon results may not include volatile
constituents since the sample was purged with an inert gas prior
to analysis.
Sample WASH TANK could not be preserved to a pH of <2.
53
RECRA
ENVIRONMENTAL
INC.
-------
INORGANIC DATA COMMENT PAGE
Laboratory Name RECRA ENVIRONMENTAL. INC. :
USEPA Defined Inorganic Data Qualifiers: j
B - Indicates a value greater than or equal to the instrument
detection limit but less than the contract required detection
limit. •
U - Indicates element was analyzed for but not detected. Report
with the detection limit value (e.g., 100).
!
I
E - Indicates a value estimated or not reported due to the presence
of interference.
S - Indicates value determined by Method of Standard Addition.
N - Indicates spike sample recovery is not within control limits.
* - Indicates duplicate analysis is not within control' limits.
+ - Indicates the correlation coef f icient. f or method of standard
addition is less than 0.995. :
j
M - Indicates duplicate injection results exceeded control limits.
W - Post digestion spike for Furnace AA analysis is put of control
limits (85-115%) , while sample absorbance is less; than 50% of
spike absorbance. . . |
!
G - The TCLP Matrix Spike recovery was greater than the upper limit
of the analytical method. i
L - The TCLP Matrix Spike recovery was lower than the lower limit
of the analytical method. i
RECRA
ENVIRONMENTAL
INC.
-------
COUNTY OF ERIE
AQUEOUS MATRIX
WATER QUALITY TESTING
LAB NAME RECRA ENVIRONMENTAL INC.
JOB NO. 92-1139
DESC AS009883
SAMPLE NO. WASH TANK
SAMPLE DATE 04/13/92
COMPOUND
Total Organic Carbon
Total Recoverable Oil & Grease
UNIT OF
MEASURE
mg/1
mg/1
METHOD
NUMBER
415.1
413.1
ANALYSIS
DATE
05/06/92
04/17/92
RESULT
7,840
54
Q
273
• 55
-------
COUNTY OF ERIE
AQUEOUS MATRIX
WATER QUALITY TESTING
LAB NAME
JOB NO.
DESC
SAMPLE NO.
RECRA ENVIRONMENTAL INC.
92-1139 '
AS009884
RINSE TANK
SAMPLE DATE 04/13/92
COMPOUND
Total Organic Carbon
Total Recoverable Oil & Grease
UNIT OF
MEASURE
mg/1
mg/1
METHOD
NUMBER
415.1
413.1
ANALYSIS
DATE
04/17/92
04/17/92
RESULT
i
: 32
i 5.0
Q
U
273
56
-------
COUNTY OF ERIE
AQUEOUS MATRIX
WATER QUALITY TESTING
LAB NAME RECRA ENVIRONMENTAL INC.
JOB NO. 92-1139
DESC AS009885
SAMPLE NO. DIP TANK
SAMPLE DATE 04/13/92
! COMPOUND
[Total Organic Carbon
'Total Recoverable Oil & Grease
UNIT OF
MEASURE
rag/1
rag/1
1METHOD
NUMBER
415.1
413.1
ANALYSIS
DATE
04/17/92
04/17/92
RESULT
14
5.0
Q
U
273
57
-------
COUNTY OF ERIE
AQUEOUS MATRIX
WATER QUALITY TESTING
LAB NAME RECRA ENVIRONMENTAL INC.
JOB NO. 92-1139
DESC AR002271
SAMPLE NO. MB-1
, COMPOUND
Total Organic Carbon
(Total Recoverable Oil & Grease
UNIT OF
MEASURE
mg/1
mg/1
METHOD
NUMBER
415.1
413.1
ANALYSIS
DATE
04/17/92
04/17/92
; RESULT
[
j 1.0
; 5-°
Q
U
u
SAMPLE NUMBER = METHOD BLANK - 1
273
58
-------
COUNTY OF ERIE
AQUEOUS MATRIX
WATER QUALITY TESTING
LAB NAME RECRA ENVIRONMENTAL INC.
JOB NO. 92-1139
DESC AR002272
SAMPLE NO. MB-2
COMPOUND
Total Organic Carbon
UNIT OF
MEASURE
mg/1
METHOD
NUMBER
415.1
ANALYSIS
DATE
05/06/92
RESULT
1.0
Q
U
SAMPLE NUMBER = METHOD BLANK - 2
273
59
-------
-------
APPENDIX C
CORRESPONDENCE DATED MAY 21, 1992
FROM CONAX BUFFALO CORPORATION
61
-------
CONAX BUFFALO CORPORATION • 2300 WALDEN AVENUE, BUFFALO. NEW YORK 14225
716-684-4500 • 1-800-223-2389 • FAX: 716-684-7433 • TELEX: 91-275
May 21, 1992 !
Mr. Thomas Gardner-Clayson j
Incubator Laboratory Director j
RECRA ENVIRONMENTAL, INC. ;
Audubon Business Centre '
10 Hazelwood Drive, Suite No. 106 j
Amherst, NY 14228 j
Dear Mr. Gardner-Clayson:
In response to your questions compa'ring Freon to Ultrasonic Aqueous
cleaning: !
i
Freon Cleaning - Pieces lowered into vapors for approximately 3 to
5 minutes. When removed into air, parts immediately dry
(approximately 1-2 minutes). Process was dictated by cleaning time
in vapor. Handling, load and unload is the same for both systems.
i
Aquesous Cleaning - Pieces lowered into cleaner, ultrasonic cleaned
1 to 5 minutes, rinsed 1 to 2 minutes, rinsed 1 to 2 minutes, hot
rinsed to help drying 1 minute. Pieces may have to be air blasted
to remove excess water. Handling, load and unload is the same for
both units. j
l
To estimate actual cost for Freon cleaning, a basket would take 6
to 7 minutes to complete cycle. Estimate for the same;basket of
parts using Aqueous Ultrasonic cleaning is 8 to 9 minutes a cycle.
We feel the clean condition of the pieces degreased and the
reduction of Freon solvent more than offsets the cost of the extra
3 minutes per basket we spend. This method of cleaning has all but
eliminated our hazardous waste emissions. We have also decreased
our dependence on precleaning products used .before degreasing
operation. We have realized a payback on our cleaning unit in one
year. i
We have not had any product returned by customers because of
deeming method. We are able to weld pieces without any other
deeming process. We can do die penetrant after cleaning in new
system. No extra cleaning of surface is required. We;have
eliminated white coating left on pieces after old cleaning process.
62
"Excellence By Choice Not By Chance"
-------
Mr. Thomas Gardner-Clayson Page 2
RECRA ENVIRONMENTAL, INC.
We are using the Aqueous System in the following manner (16 hours
per day): Ultrasonic generators are used 10% of the time. Heaters
are used approximately 35% of the time. Water usage is approxi-
mately the same between both cooling and rinse cycles. Energy has
been addressed in past letters.
Wages and skill of operators are comparative between each system
and no appreciable difference occurs.
If I can be of any other help in your project please call on me.
Very truly yours,
CONAX BUFFALO CORPORATION
Ronald A. Benz
Methods Project Manager
/sm
cc: J., A. Frysz
63
-------
APPENDIX D
MATERIAL SAFETY DATA SHEETS
64
-------
t^J-jsurc or reproduction without \
ff JLThor&xnonrfOASl-MAT
PRODUCTS. INC. ti prchibVAjT1!
U S. DEPARTMENT OF LABOR
Occupational Safety and Health Administration
Form Approv«d
OMB No. 4*-R1387
itout n 1 T 1 CU FTT
MATERIAL SAFjETY DATA SHEET
iiJc! i , . •
B^^OSDL ^-JH-* *•--•:f" f; "t"08'
__ - -
EMERGENCY TELEPHONE NO.
_____ _ _ _
MANUFACTURER'S NAME
. ._
/._«,4«._ 9CI7
CHEMICAL NAME AND'SYNONYMS
SECTION II • HAZARDOUS INGREDIENTS
IT— r^~~~*^^^^^^^^^^*^—"""^""^^^^^^^
._.
ALLOYS AND METALLIC COATINGS
PAINTS. PRESERVATIVES. & SOLVENTS
THERS
•
HAZARDOUS
^ ™..^•-
Sodium metasilicate
OTHER LIQUIDS. SOUPS. OR GASES
SECTION III - PHYSICAL DATA
SPECIFIC GRAVITY
-------
Oakite 202
SECTION V - HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE Hixture: unknown. See Section..II.
"EFFECTS OF OVEREXPOSURE
Direct contact with eyes causes irritation. Prolonged skin
contact causes irritation.
EMERGENCY AND FIRST AID PROCEDURES For eyes ^ fiush with plenty of vater for at least
15 minutes: set medical attention.For skin, flush with plenty of water.
STABILITY
HAZARDOUS
i .._, SECTION
1 c
1 UNSTABLE
STABLE X I
BILITY (Materials to avoid) Tjiehly
VI - REACTIVITY DATA
:ONDITIONS TO AVOID ^ i^
v
acidic materials affect performance.
S DECOMPOSITION PRODUCTS Unknown.
MAY OCCUR
ATION
WILL NOT OCCUR
1- • •
CONDITIONS TO AVOID •
N/A
X
SECTION VII - SPILL OR LEAK PROCEDURES
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED
area with plenty of water.
WASTE DISPOSAL METHOD Neutraijze vith acidic material, dilute and discharge in
"accordance with federal, state, and local regulations.
SECTION VIII - SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (Specify type) j^A
II I ••-» I •« I -
VENTILATION
MECHANICAL (General)
PROTECTIVE GLOVES
Rubber for prolonRed contact.
OTHER PROTECTIVE EQUIPMENT
v«.nt;ilation5especially at elevated
[OTHER~Ttemperatures,
if subject to splash.
SECTION IX - SPECIAL PRECAUTIONS
^^ f*™*™*™-. Kee
-. — -- -
. 0°C (32^.) (restores when thawed and agitated). Keep container,
^^V^CeTnotSin use. Do not get in ey~- Avoid prolonged sk
thoroughly after handling.
PAGE (2)
CPO »B-t*3
_.__ information herein IB. given
in good faith, "but no warranty.
expressed or implied is made.
Form OSHA-20
R«». May '2
-------
Material Safety Data Sheet
May be used to comply with .
OSHA's Hazard Commun.cat.on Standard.
29 CFR 1910.1200. Standard must be
consuHed for specific requirements.
Ill I IT I——-—^^
U S Department of Labor
Occupational Safety and Health Administration
(Non-W*ndJtofY Form)
Form Approved
OMB No. 1218-0072
r Biar*. souces m not pamnttwl
'•' SfomjatoTS «v«iafate. tfx» apaoa
^^^^
IDENTITY (As Us»d on U£>* *** U*9
T«tephona Numbor *x tnfoftnation
Me
Siontlure o( Prepa/ef
, Strwf. C*y. »»«,
Dciv N.W
Section II - Hazardous IngredlentsAdentlty Information
to Common N«ma(S)) OSHA PEL
Cocnpoo^ ^SpecificChemicai
Section til — Physical/Chemical Characteristics
Spwafic Gr«vi(y (HaP - 1)
Vtpof PTOKUW (mm Hfl.)
Ev«por«iion Bale
SolubiKty in Water
-------
Section V — Reactivity Data
xxnpatibitity (Materials to Avoid)
All arids: strpn
Hazardous Decomposition of Byproducts
Conditions to Avoid
ection Vt — Hea Ith Hazard Data
Gastro- intestlonal
'FfSlaat
erse_ef£ects
wealth Hazards (Acute <§nd Ctvonic)
Skin dryness
Medical Conditions
jgngfiltv Aggravated by Exposure
None known
f W 1111 w *•"" f T '- r in a -
Precautions for Safe Handtlng and Use
with clean wa
Precautions to Be fliken in Handhng and Storing
Store cool, dry area
Other Precautions
Nrmo
Section VIU — Control Measures
Respiratory Protection (Sptcfy
Not required
-------
MATERIAL SAFETY DATA SHEET
c
o
r
245 FREIGHT ST • WATERBURY. CT 06702 • (203) S7S-S700 Health Flannab i 11 ty Reactivity Other
{PRODUCT
Met ex TS-40-A
Issue Date: 07/21/72
Revised Date: 11/19/90
Page 1 of 7
0 1
{PRODUCT
ODE
10501
oOE MUST ACCOMfAHY AU. INQUIRIES REGARDING. THtt PRODUCT
24 H«. EMERGEKCY KUMIER: CHEMTREC (8M) <24-»M9
SECTION 1
PRODUCT IDENTIFICATION
TRADE NAME: Metex TS-40-A
CHEMICAL FAMILY: ALKALINE SALTS
FORMULA: Proprietary Mixture
Cor OTHER
SECTION 2
HAZARDOUS, INGREDIENT?
MacDennid Incorporated ha« identified the following cheiaical
ingredient(s) as hazardous.
INGREDIENT(S)
CAS
BY WEIGHT .*
Sodium Metasilicata
PHYSICAL DATA
pRESSORE, n/a
SECTION 3
DENSITY: 50 LB/CU.FT FORM: Solid .
SPECIFIC GRAVITY: n/m pH: »/*
FREEZING POINT:n/« FLASH POINT: n/a
SOLUBILITY IN WATER: Appreciable
COLOR: "White to off-white
ODOR: Mild
NOTE: These physical properties are typical values for this product
SECTION 4 " FIRE AND EXPLOSION DATA^
============
FLASH POINT: n/a
EXTINGUISHING MEDIA: «.*.„«,,.
NEVER allow run-off to enter sewers or waterways.
«c.Y£^ aj.j.«i *^, At~~.*A~. AT-* i~\MMnie*ii\' foam; halon
or monitor
osuou fire conditions
SlarSlf -contained breathing apparatus /protective clothing
69
M o o n
TAMT MCALTH A SAFETY INFORMATION
-------
MacDe rmld Incorporated
14,-,M,«HT TWIT
. cr A,..
. .,.. - m«
- »*..,.»....,.
MATERIAL SAFETY DATA SHEET
Product: Meter TS-40-A I'SUe Date: 07721/72 i
Product Code: 10501 Raised Date: 11/19/90 |
TVTES:
fash affected eyes under slowly running water for 15 minutes ,
Contact physician immediately ;
JKIN:
If contacted wash the skin with water for "minutes. I
Remove and isolate all contaminated clothes and shoes. j
INGESTION:
If invested rinse the mouth and throat liberallj with water •
ConSct physician immediately; do not move victim ,
INHALATION: j
Remove the victim to cool uncontaminated area !
Monitor the patient for respiratory distress j
CAUTION- If unconscious-having trouble breathing-or in convulsions-do not
induce vomiting or give water. j
i
Always clean cdntaminated clothing and gear prior to reuse.
NEVER administer anything to an unconscious person.
Page 2 of 7
24 Hour Emergency Number: CHEMTREC (1-800-424-9300)
FIRST AID DATA
SECTION
First aiders should provide
Contact a physician in all «ses of exposure
f^their !£n safety priSr to rendering assistance
HEALTH EFFECTS DATA
Primary Route(s) of Exposure: Eye Skin Inhalation and Inge.stlon
__._ _~..~_. --..». /-.<_ __.f __ i i~*-t+*+inn fnilrnfit Initial mechanical irritation
EYE CONTACT:
SKIN CONTACT:
INGESTION:
INHALATION:
Chemical irritation follows initmi meunauj.w-.* *j-;r-
Maycause slight irritation to sensitive individuals
Intense watering of eyes will occur
Prolonged or repeated contact may cause irritation
Itching and tingling sensation may be produced
Painful sensation will occur
Irritation and -Burning sensation
The substance is moderately toxic if swallowed.
Headache and general weakness may occur
and throat
Temporary headache may occur
may occur
70
-------
MacDermid Incorporated
. CT 0,70,
MATERIAL SAFETY. DATA SHEET
Product: Mete* TS-40-A ' Issue Date: 07/21/72
Product Code: 10501 *"*"* Da'" 11/19/9°
Page 3 of 7
24 Hour Emergency Number: CHEMTREC ,( 1- 800 - 424 - 9300 )
PERSONAL PROTECTIVE: DATA
-PEL/ACGIH-TLV are exceeded, it is
*•"''.--
spac" "ith
apparatus is recommended
^ssasaa
be released.
PROTECTIVE EQUIPMENT:
Splash proof goggles: Face shields; Chemical aprons; Boots and gloves
The availability of an eye wash fountain and safety shower is recommended.
.t
in Section 2. The results are as follows:
ACUTE ORAL TOXICITY: Unknown
ACUTE DERMAL TOXICITY: Unknown
ACUTE RESPIRATORY TOXICITY: Unknown
TOXICITY HAZARD REVIEW (THR):
Unknown
Listed as suspected carcinogen by: IARC: no NTP: no OSHA: no
REACTIVITY DATA
INCOMPATIBILITY: Acidi
HAZARD DECOMPOSITION PRODUCTS: Phosphorus oxides
STABILITY: Stable
CONDITIONS TO AVOID: Unknown ?1
HAZARDOUS POLYMERIZATION: No
-------
MacDermid Incorporated
i
MATERIAL SAFETY DATA SHEEf Page 4 Or
Product: Met ex TS-40-A '""" Issue Date: 07/21/72
Product Code: 10501 Revised Date:
24 Hour Emergency Number: CHEMTREC (1,800-424-9300)
the followiag 24 hoar tclephone
facility.
drain with large quantities of water
by an approved method at an approved secure
TRANSPORTATION DATA
DOT PROPER SHIPPING NAME: Corrosive Solid HOS (contains sodium
metasilicate)
HAZARD CLASS: Corrosive Material
UN/NA #: UN17S9
IMO/IATA : Corr.iive Solids HOS (contains sodium
metasilicate
HAZARD CLASS: 8
GENERAL STORAGE DATA
Material should be stored in the properly sealed original container.
Materials (Poisons).
ACIDS/ALKALINES- Acid bearing material should be scored separate from
alkaline materials. *
72
-------
MacDermi d I ncorporated
PAX
MATERIAL SAFETY DATA SHEET
_ .. . Issue Date: 07/21/72
Product: Metex TS-40-A
Product Code: 10501
Z4 Hour Emergency Number: CHEMTREC (1-800-424-9300)
"SECTION 13 REGULATORY oW
Page 5 of 7
0 1
The Following Regulations applj to this product
FEDERAL REGULATIONS:
CHEMICAL NAME
CAS #
. the
BY WEIGHT % OSHA-PEL ACGIH-TLV
Sodium Met*silicate
6834-92-0
30-40 2 mg/m3 2 mg/m3
CERCLA/SUPERFUND. 40 CFR 117, 302/3*4: Notification of spills of this
product is NOT required.
SARA/SUPERFO^ INDENTS * REAOTHO^ZATION ACT .f 19S6 (TITLE III).8...I..
302, 311,312. a 313:
as
an extremely hazardous substance
73
-------
MacDermid Incorporated
S4S FRE.OHT STREET - WATEBBURY. CT 0«70S - TELEPHONE (203)S75-S700 - TELEX 44J.OH - PAX 203.37J.S.30
MATERIAL SAFETY DATA SHEET pagc 6 of i
Product: Met ex TS-40-A Issue Date: 07/21/72 . j
Product Code: 10501 Revised Date: 11/19/90
24 Hour Emergency Number: CHEMTREC (1-800-424-9300)
(Cont i nued)
REGULATORY DATA
SECTION 313 - LIST OF TOXIC CHEMICALS (40 CFR 372):
fhis product does not contain ingredients listed under 40 CFR 372.65.
'OX 1C SUBSTANCE CONTROL ACT,-tTSCA) : The chenm:al ingredient(s) in this
iroduct are listed on the 8(b) Inventory List (40 CFR 710).
RESOURCE CONSERVATION & RECOVERY ACT (RCRA) , 40 CFR 261 SUBPARTS C & D:
?lease refer to Section 10, disposal information for pertinent data. i
TOTAL TOXIC ORGANICS |
Chis product does not contain ingredients on the List of Total Toxic Organics.
STATE REGULATIONS:
:allfornia Proposition 65: '
This product complies with the MSDS and labeling requirements of the Safe,
Drinking Water and Toxic Enforcement Act of 1985. ,
Michigan Critical Materials: j
This product does not contain ingredients listed on the Michigan Critical
Materials Register. -
State Right -to-Know Laws;
Please consult your particular state's right-to-know law.
74
-------
MacDermid Incorporated
,„ FRE.OKT STREET - WATERBURY. CT 0,702 - TELEPHONE ,303,37,.,700 - TELEX «,aoi. - FAX 2o3.Sr3.3<,30
MATERIAL SAFETY DATA SHEET
Product: Metex TS-40-A <^ue Date: 07/21/72
Product Code: 10501 , *•*!«* Date:
Page 7 of 7
24 Hour Emergency Number: CHEMTREC (.1.800-424-9300)
REGULATORY DATA (Continued)
INTERNATIONAL REGULATIONS :
Canadian Domestic Substance List (CDSL):
The chemical ingredients in this product are listed with the C.D.S.L
_ _ "isS a§fimg?'!u.'5'«J3Ssa3H^rwr :wa«-3rK«$s
regulatory requirements.
Prepared by MacDermid Inc. Safety t Regulatory Compliance Department, based
upon publicly available reference information.
SECTION 14
USER NOTIFICATION
To th. b..t of ou, kn.wl.««. lh. •nform.t.on eont.ln.^ h.r.ln .. carr.e,. All eh.m.....
H«PECT TO THrtN^iA^ C^TA^O HERE.H Ol THE CHEM.CAU TO WH.CH THE .NFORMAT,ON REFERS.
75
-------
EB 1.8 '91 15:27 CHflUTflUQUft MET^L FINISHING SUPPU
™
Incorporated
NO;. -0501
i^
CLEANER TS-40A
WATER8URY. CT (203) 57S-S700 — FERNDALE. Ml (313) 399-3553 — LOS ANGElgS, CA (818) 240-9573
GENERAL PURPOSE SOAK CLEANER :
VERSATILE-,- EFFICIENT- SOAK CLEANER
Metex Cleaner TS-40A is a metal cleaning compound of low ;
alkalinity and high wetting agent content. Designed esueciailv
as a non-etch, soak cleaner .for aluminum, it is also very' effective
on copper,-brass/zinc, lead and ferrous metals. It is an excel-
lent remover of tar, pitch, marking inks, drawing compounds ~ '
including the heavy wax type, as well as normal'shop soils. Metax
TS-40A is not recommended for use in cleaning magnesium and
magnesium 'alloys* j
2IMC BASS DIE CASTING SOAK CLEANER "
.Metex TS-40A used as a soak cleaner for zinc base die castings
will effectively remove emu!:;ion films. i
TYPICAL'JJSSS' FOR MBTEX TS-4QA <
!«Cleaning aivBainiSTprior to painting, anodizing, or spot
welding. ' ; .
Removing stenciling Inks from aluminum. ;
Soak cleaning steel prior to electrocleaning or
phosphating. ' ;.
Soak.^cleahing zinc base die castings. 'i • '
Removing emulsion films. i
Cleaning multi-alloy assemblies such as automobile
engine'S7"'bearing assemblies, etc. !
Special applications in burnishing. . ;
Cleaning operations where more than one metal!must
be cleaned in the same solution. I
Removing of light ..mill oils from aluminum prior to
further processing or plating, etc. - !
In-process cleaning between fabricating operations.
FREE RINSING ' ?-
Metex Cleaner TS-40A rinses freely. This is a distinct
advantage of this compound because many cleaners designed for
similar work are very difficult to rinse adequately.
BENEFITS' FROM MSTE3C CLEANER" TS-40A j
Versatility, an all purpose non-etch soak cleaner -
C 3 f^± ^Nv4 ^*+^ •••••• ,«KUk i ^_ _» T — ;
2,
3.
4.
5.
6.
7,,
'8.
10
safe on, common metals .
2, Ccicplotely soluble,
3. Complete rinsing.
4, Unusual soil removal.
76
IMPORTANT: Please not* disclaimer on page 2. Also read carefully wa"..ng and ufery Information on the last page.
H1?.?*** sheet contains i«cnnieal information required for safe and economical ob«f ai.on of this product READ fTTHOROUGHLY PRIOR TO
-------
FEB 18 '91 15:28 CHAUTflUQUft METflL'FINISHING SUPPL '' P.3
WAST3 DISPOSAL ,
Solutions of Hetex TS-40A are alkaline and should be
neutralized with a weak acid to' a FH between 6 and 8 before
discharging to a sewer or lagoon.
MACDERM1D INCORPORATED ,
WATSKSURY, CONNECTICUT
Pg. 3 of 3 - C'
Metex. TS-4'OA
This bulletin is a revision of that dated 6/23/7-1, which is now
obsolete and should be destroyed.
I
All statements, technical information and recommendations
contained herein are based on testa we believe to be reliable,
but ths accuracy or comgleteness thereof is not guaranteed.
No statement or recommendation shall constitute a representation
,mT<=.«?« set forth in an agreement signed by ofricsrs or
SS!S Kd mInufac?uSr.gKO WA**ANTToF MERCHANTABILITY OH
waasMTCY OF FITNESS FOR A PARTICULAR PURPOSE is MADE. The
following warranty is made in lieu of such warranties and
all other warranties, express/ implied or statutory.
P-oducts- are warranted to be free from defects in material
and workmanship at the time sold. The sole obligation of
seller and manufacturer under Ithis warranty shall be to
r^o^ace anv product defective ;at the time sold. Under no
SiS^StSSeS shall manufacturer or seller be liable for any
loss, damage or expense, direct or consequential, arising
out of the usa of or inability to use, the product.
No suggestion for product use nor anything contained herein
shall be construed as a recommendation to use any product^in
irfringement of any patent rights, and seller and manufacturer
mm nb responsibility or liability for any such infringement.
(J
II
77 ' «
-------
'FEB 18 ''91 15-E3 CHflUTflUQUR flETflL FINISHING SUPPL "
P.4
03/07/89
MATERIAL SAFETY DATA SHEET
SECTION
CODE 10501
Man if
Mac lenaid
acture's Naae
Incorporated
EMERGENCY TELEPHONE
: 203-575-5700
ADD:
526
IESS (Number, Street, Cltry, State, Zip Code)
Huntingdon. Avenue Waterbury, CT. 06720
j CFR -49 - DOT Proper Shipping Name
i Coriosive Solid NOS (Sodium Metalsilicate) UN1759
EMERGENCY 24 nous.
HOTLINE:
(313) - 644 - 5626
CHEMICAL NAME AND SYNONYMS
N/A
TRADE NAME AND
Mate* TS-4QA
CLCAL FAMILY
All aline Salts
FORMULA
Mixture
SECTION II - HAZARDOUS INGREDIENTS
PAZ2
& SI
TS, PSES1SR7ATIVE
LVEHTS
TL7 (UNITS)
ALLOYS & METALLIC
COATINGS
TLV (UNITS)
PIG1EHTS
N/A
BASE METAL
N/A
CATALYST
ALLOTS
VEH3
CLE
HETAT.T.IC COATINGS
SOL\
ENTS
FILLER METAL PLUS
OR CORE FLUX
ADD1
TIVES
OTHERS
OTHiRS
_/ EA7AP?X)US MHJTORSS OE 'OTHER LIQUIDS* SOLIDS, 0& GASES
TLV (UNITS)
oodlua Mecasilicate (6834-92-0)
<40
2 mg?M"
SECTIOBf III - PHYSICAL DATA
son, ENG porsra:
N/A
SPECIFIC GRAVITY
1)
N/A'
VAPOL PRESSURE (MM. HG.)
PERCENT VOLATILE Bt VOLUME ( Z )
VAPO
J. DENSITY (AIR « 1)
N/A
EVAPORATION RATE (
- 1)
N/A
SOLUBILITY IN HATES.
Appreciable
N/A
APP.
ICE AND ODOR
White granular powder - mild odor*
SECTION IV = FIS2 AND EXPLOSION »A7Acn DATA
POINT (.METHOD USED)
Non Flammable
FLAMMABLE LIMITS
N/A
ETEIJ
Compj
SPECIAL FIRE FIGHTING PROCEDURES
self-contained breathing apparatus.
GUISHING MEDIA
cible with yatersoray. COo, dry chemical, foam,. Halon.
FIRE ASM EXPLOSION HAZARDS
Unknowia
78
-------
FEB 13 '31 15=23 CHftUTflUQUH METAL FINISHING SUPPL
P.5
( RESHOLD LTMTT VALUE
Hot established for product.
SECTION V - HEALTH
EFFtCTS OF OVEEE2POSI3RE-UNLESS OTHERWISE STATED, CHRONIC OR LONG-TERM HEALTH EFFECTS UNKNOWN1
Will irritace and burn eyes, skin and mucous membranes.
EMERGENCY AND FIRST AID PROCEDURES I •
: Flush with water for 15 minutes. Contact physician.
Skid:* Flush with water.
Ing u^E MATERIAL IS RELEASED OE SPILLED
up :ial and put in DOT approved container. Flush balance wich water to chemics.
VAST) DISPOSAL METHOD
Dispcse of as solid waste in secure, approved landfill.
SECTION VIII - SPECIAL PROTECTION INFORMATION
RESP] SATORS PROTECTION (SPECIFY TYPE)
NIOSH-approved dust mask
VENTILATION
LOCAL EXHAUST
N/A
MECHANICAL (GENERAL)
Z
SPECIAL
N/A
OTHER
N/A
BROTEJTIVE GLOVES
Kubber
EYE PROTECTION
• Face shield/Safety ec^arles
OTHER
PROTECTIVE EQDriPMEHT
Rubber aprou/'boots
SECTION IX - SPECIAL PRECADT10HS
P2ECAJTIONS TO BE TAKEN IH HANDLING AND STORING
Store in. dry area, in tightly closed containers.
PRECADTIONS
nknown
79
PREBA
ED BT; . MacDermld Incorporated
DATE; 03/07/89
-------
APPENDIX E
CONAX BUFFALO CORPORATION:
GENERAL CLEANING PROCEDURES
80
-------
c a r 53 a ro 11 a n
2300WALDENAVE. • BUFFALO.NY 14225
JAN 1- K
NO. TSD-12.003
REV.
A
B
DATE
3/28/91
10/15/91
•-_ --• -.? ^""^H w ?
GENERAL CLEANING PROCEDURES
PREPAREO BY
y
APPROVED BY
DATE
S.M. Dale, Chief Engineer - Industrial Products
•^^—^ 1— .
D0#^ki, Quality Control Manager
DATE
R! F. SchwaneklunpY Manufacturing Manager
//lj£^^^if«^> Date 5 j
A. L Haefn^rVchief Engineer - S.E.P.
I/
Date
G./P. Wittmann, Plant Manager
y /
2678A (200A)
81
-------
CQ&1CS2£ buffalo
corporation
NO. TSD-12.003
2:>00 WALDEN AVE. • BUFFALO. NY 14225
REVISION RECORD
REV.
Orig.
A
B
AFFECTED
PARAGRAPHS
Al 1
1.0
2.0
3.0
4.0
5.0
6.0
7.0
3.2,4.1.3,5.1,
5.2 (Caution),
5.2.2a, 5.2.2b,
5.2.3, 5.3.1,
5.3.2, 5.5.1,
5.5.2, 6.0, -J.o'
Add A, B, C^t>
BRIEF DESCRIPTION OF REVISION
Original Issue
Scope
Applicable Documents
Equipment
Materials
Alkaline Cleaning
Ultrasonic Cleaning
Quality Control
Added/Revised per EO.QP-0684
•
82
_t _
DATE
I
4/15/91
/
10/15/91
-
APPROVAL
SIGNATURE
^0. Jjt^tfi
tf.lS. SimonetfT
tJro j ect Eng i neer
E.G. QP-0611
/ft//. ^
lL&}di
-------
2300 WALDEN AVENUE. BUFFALO. NY 14225
an
IMI
company
PARAGRAPH
1.0
2.0
3.0
4.0
5.0
6.0
.-R OF CONTENTS
TSD-12.003
PAGE
SCOPE ........ • .......... -
APPLICABLE DOCUMENTS . .......... 1
EQUIPMENT ...... : .......... i
MATERIALS ................. ^
4.1 ALKALINE CLEANERS . 1
ALKALINE CLEANING . . I .......... 1
5.1 CLEANING RESTRICTIONS ........ 2
5.2 IMMERSE ...............
5.2.1 OAKITE BATH ......... 2
5.2.2 BOWDEN PARTS WASHER ..... 3
5.2.3 MICROCLEAN ULTRASONIC
CLEANING SYSTEM ....... 3
5.3 RINSE ................ 3
5.3.1 OAKITE BATH AND BOWDEN PARTS
WASHER . ........... 3
5.3.2 MIROCLEAN ULTRASONIC CLEANING
SYSTEM ............ 4
5.4 DRY ................. 4
5.5 BATH CONTROL . ............ 4
5.5.1 OAKITE BATH AND BOWDEN PARTS
WASHER ..... ..... • • 4
5.5.2 MIROCLEAN ULTRASONIC CLEANING
SYSTEM .:....' ..... • • 4
QUALITY CONTROL .............. 5
6 . 1 PROCESS CONTROL .......... • 5
APPENDIX A - MATERIAL SAFETY DATA SHEET
APPENDIX B - OPERATION PROCEDURE FOR
ULTRASONIC CLEANING SYSTEM
APPENDIX C - MACDERMID INSTRUCTIONS FOR
ALKALINE! CLEANER TEST KIT
APPENDIX D - ULTRASONIC BATH CONTROL RECORD
83
-------
2300 WAUDEN AVENUE BUFFALO, NY 14225 „ JJ^J ^pany
TSD-12.003
1.0 SCOPE
This specification describes the procedures to be |used for
the removal of oils, greases, waxes, dirt and other foreign
material from the internal and external surfaces of parts by
means of alkaline and ultrasonic cleaning.
2.0 APPLICABLE DOCUMENTS
The following documents form a part of this document to the
extent specified herein. Any conflicts between this document
and any referenced documents, this specification shall
govern. ;
2.1 Government ;
221 MIL-S-5002: Surface Treatment and Inorganic;
Coatings for Metal Surfaces of Weapons
Systems. \
3.0 EQUIPMENT i
3.1 Bowden PC-10. Workstation Parts Washer. j
3.2 Miroclean Ultrasonic Cleaning System. j
4.0 MATERIALS ;
4.1 Alkaline Cleaners i
4.1.1 Oakite 202. See Appendix A for material safety data
sheet. :
4.1.2 BB-100. Bowden Industries. See Appendix A for
material safety data sheet.
4.1.3 Metex TS-40A. See Appendix A for material safety data
sheet.
5.0 ALKALINE CLEANING j
Parts shall be subjected to alkaline cleaning as jnoted in
MIL-S-5002. \
- i -
84
-------
TSD-12.003
2300 WALDEN AVENUE. BUFFALO. NY 14225 an |^J company
_—
5.1 01 eaninq p^gt-r-j ctions
assemblies with this procedure.
5.2 Immerse in Oakite 202 or Bowden parts washer.
5.2.1 Oakite Bath
Mix Oakite 202 Alkaline Cleaner and tap water in
corrosive resistant container. Use mix chart:
MIX CHART
OAKITE 202
(b)
(c)
5 Oz.
1
10 OZ.
15 OZ.
20 OZ.
25 Oz.
Heat solution from 130°F to
Immerse parts for a minimum
of 30 minutes.
1 Gal.
2 Gal.
3 Gal.
4 Gal.
5 Gal.
160°F.
of 15 minutes and a
maximum
CAUTION
CONTAMINATED CLOTHES AND SHOES.
ALWAYS PUT ALKALINE INTO WATER WHEN MIXING BATH.
- 2 -
85
-------
2300 WALDEN AVENUE. BUFFALO. NY 14225
IMI
an mi company
5.3
TSD-12.003
5.2.2 Bowden Parts Washer
(a)
(b)
(c)
Mix Bowkleen BB-100 or engineering approved equiva-
lent with tap water in a Bowden PC-10 immersion parts
washer. Ph must remain below 12. j
I
Heat solution to 120°F minimum and 180°F maximum.
Immerse parts for a minimum of one minute and a maximum
of 10 minutes.
5.2.3 Miroclean Ultrasonic cleaning System.
(a)
Mix Metex TS-40A solution or engineering approved
equivalent in a corrosive resistant container or
the Miroclean Ultrasonic Cleaning System. Use mix
chart below.
(b) Heat solution to 120WF minimum and 160 F
maximum.
(c) Immerse parts for a minimum of one m:
maximum of 10 minutes. Use Appendix
for the operation of the Miroclean u:
Cleaning System.
MIX CHART
Metex TS-40A Tap Water
10 Oz. 1 Gal. = 10 Oz/<
1-1/4 Lbs. 2 Gals. =
1 Lb. 14 Oz. 3 Gals. =
2-1/2 Lbs. 4 Gals. -
3 Lbs. 2 Oz. 5 Gals. =
6-1/4 Lbs. 10 Gals. =
31-1/4 Lbs. 50 Gals. =
62-1/2 Lbs. 100 Gals. =
93-3/4 Lbs. 150 Gals. =
125 Lbs. 20° Gals. =
Rinse
5.3.1 Oakite Bath and Bowden Parts Washer
Immediately after removing parts from the
rinse parts in running tap water or agitat
water. Water temperature of 50°F to 130 F
Lnute and a
B as a guide
Ltrasonic
Sal (OPG)
M
/ \?'
c r
1-
*\S
mix, thoroughly
e in clean tap
- 3 -
86
-------
2300 WAUOEN AVENUE. BUFFALO. NY 14225
ro
TSD-12.003
5.4
5.5
5.3.2 Miroclean Ultrasonic Cleaning System.
rinse instructions .
Dry
See Appendix B for
Dry parts thoroughly immediately after rinse by toweling or
blowing with filtered air or dry nitrogen.
Bath Control
5.5.1 Oakite Bath and Bowden Parts Washer
A mix date for each bath must be displayed on or near
the bath.
The bath shall be changed monthly or when its cleaning
abilities are ineffective or if a material other than
described in Paragraph '5.1 is immersed or when the pH is
greater than 12 .
NOTE; SEE PLANT ENGINEER FOR PROPER DISPOSAL OF THE OLD BATH.
5.5.2 Miroclean Ultrasonic Cleaning System.
An Ultrasonic Bath Control Record (Appendix D) for the
bath must be displayed on or near the bath. The bath
must be removed, the tank cleaned and new bath mixed on
an annual basis as a minimum.
The bath must also be changed when its cleaning
abilities are ineffective or if a material other than
described in Paragraph 5.1 is immersed.
Add water to maintain the original mix volume. This
bath must be checked on a weekly basis using the
Alkaline Cleaning Test Kit with the J.2 solution and
recorded on the Ultrasonic Bath Control Record. The
instructions for using the test kit are in Appendix C.
It is the responsibility of the lead man of the
Precision Finishing Dept. to check and control the
bath. The bath should be maintained between 8-12
oz./gal. (OPG) . The following table indicates the
concentrationn of the solution from the alkaline
cleaning test kit results.
- 4 -
87
-------
TSD-12.003
!
2300 WALDEN AVENUE, BUFFALO. NY 14225
an 11*11 company
(1) Drop = 2 (OPG) ;
(2) Drops =5.34 (OPG)
(3) Drops = 8,01 (OPG) ',
(4) Drops = 10.68 (OPG) :
(5) Drops = 13.35 (OPG) ,
Where:drops x 2.67 = OPG |
Example: 6 X 2.67 = 16.02 (OPG)
Add Metex cleaner or room temperature tap water to
adjust OPG level. ',
i
Example: 2 Drops = 5.34 OPG i
For 200 gal. bath 5.34 x 200 = 1068 Oz./16|=
66-3/4 Lb. ;
From mix chart for Metex to get 10 OPG, need 125 Lbs.:
125 - 66-3/4 = 50-1/4 Lb. Add 50-1/4 Ib. of cleaner.
High OPG; i.e., 13.35 can be diluted by adding water it
may be necessary to dispose of some solution and add
water to dilute. '
6.O QUALITY CONTROL
6.1 Process Control
The Quality Control Representative shall maintain
surveillance over the processes specified herein to
assure compliance with all requirements of this
specification.
5 -
88
-------
2300 WALDEN AVENUE. BUFFALO. NY 14225
an 1£T|1 company
TSD-12.003
APPENDIX A
MATERIAL SAFETY DATA SHEET
89
-------
£
U.S. DEPARTMENT OF LABOR
"J Occupational Safety and Health Administration
or reproduction without I
Form Approved
OMB No. 44-R1387
Pi,
i\'
•5DUCTS, INC. i$ prchibT.y
ERIAL SAFETY DATA SHEET
Required under USDL Safety «nd Health Regulations for Ship Repairing.
Shipbuilding, and Shipbreaking (29 CFR 1915.1916. 1917)
SECTION I
MANUFACTURER'S NAME
OAKITE PRODUCTS, ISC.
EMERGENCY TELEP)
201-46J4-6900
ADDRESS (Numb*.Street.
Berkeley Heights, New Jersey 07922
CHEMICAL NAME AND'SYNOftYMS
CHEMICAL. FAMILY
Alkali
A
. TRADE NAME AND S
; Oakite 202
Proprietary
c
SECTION III - PHYSICAL DATA
BOILING POINT (°F.)
VAPOR PRESSURE (mm H«.)
VAPOR DENSITY (AIR-1)
SOLUBILITY IN WATER
Unknown
n '
Unknown
,^«^
Unknown
Complete
SPECIFIC GRAVITY (HjO-1)
PERCENT. VOLATILE
BY VOLUME (*)
EVAPORATION RATE .
( hutvi acetate •»!)
„ @ full strength
Pu (j U,"/. bv volume
APPEARANCE AND ODOR Pale yellow liquid; solvent odor.
,c:
SECTION IV _-. FIRE AND EXPLOSION HAZARD DATA
SECTION II - HAZARDOUS INGREDIENTS
PAINTS. PRESERVATIVES. & SOLVENTS
SMENTS
ITALYST
HICLE
LVENTS Butyl cellosolve
)DITIVES
•HERS
X
<5
TLV
(Units)
50 PPM
(skin)
ALLOYS AND METALLIC COATINGS
BASE METAL " j
ALLOYS i
METALLIC COATINGS :
FILLER METAL i
PLUS COATING OR CORE FLUX
OTHERS i
"
HA7ARPOUS *"i*TUR£S OF OTHER LIQUIDS. SOLIDS. OR GASES
odium metasilicate
•
• — '
- i
i
%
X
<5
(Units)
•
TLV
(Units)
establ
si
FLAMMABLE LIMITS
EXTINGUISHING MEDIA will not burn or support combustion.
"SPECIAL FIRE FIGHTING PROCEDURES
N/A
"UNUSUAL FIRE AND EXPLOSION HAZARDS
12/04/80 ; FormOSKA,-2Q
-------
;• i
Oakite 202
SECTION V - HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE H£xture: unknown. See Section .II.
"EFFECTS OF OVEREXPOSURE
Direct contact with eyes causes irritation. Prolonged skin
contact causes Irritation.
EMERGENCY AND FIRST AID PROCEDURES For eyes ^ fiush with plenty of water for at least
15 minutes: get medical attention. For skin, flush with plenty of water.
"SECTION vi •:REACTIVITY DATA
STABILITY
UNSTABLE
STABLE
x
CONDITIONS TO AVOID
\
iNcoMPATABiLiTY (Materials to noiaj Hjghly acidic materials affect performance.
HAZARDOUS DECOMPOSITION PRODUCTS
HAZARDOUS
POLYMERIZATION
MAY OCCUR
WILL NOT OCCUR
CONDITIONS TO AVOID
N/A
SECTION VII - SPILL OR LEAK PROCEDURES
STEPS TO BE TAKEN IN CASE MATERIAL. IS RELEASED OR
Flush area with plenty of water.
WASTE DISPOSAL. METHOD Neutralize yjth acidic material, dilute and discharge In
accordance with federal, state, and local regulations.
SECTION VIII - SPECIAL PROTECTION IN FORMATION
RESPIRATORY PROTECTION (Specify type) N^A
VENTILATION
LOCAL. EXHAUST
Provide adequate ventilation especially at elevated
MECHANICAL (General)
OTHER
tempei
PROTECTIVE GLOVES
Rubber for prolonged contact.
OTHER PROTECTIVE EQUIPMENT
Safety goggles if suMect to splash.
sfiafig^SP'feyggiSSSi! TnTo^go^^r^derat- >~.r-r.«-nr». . «««, fro, f^ezjn^
SECTION IX - SPECIAL PRECAUTIONS
Freezes at approx. 0°C (32°F.) (restores when thawed and agitated). Keep container..
X-u '
ATAotSin use. Do not get in eves. Avoid prolong akin cont
i:
thoroughly after handling.
91
_1
PAGE (2)
cro »».»*3
information herein is given
in good, faith, tut no warranty.
expresse$ or implied, is inaAe.
Form OSHA-20
R«r. May 7Z
-------
Material Safety Data Sheet
May be used to comply with
OSHA's Hazard Ckxnmunication Standard.
29 CFR 1910.120O. Standard must be
consulted for specific requirements.
- •
IDENTITY (As Used on Label
U.S. Department of Labor !
Occupational Safety and Health Administration-
(Non-Mandatory Form) .
Form Approved :
OMB No. 1218-0072
6ton*9>ac«* am notpemimd. * try,«jm fa noj
avafcote. the space must bt m»ri»d to
Emergency Tetephone Number
Manufacturer's Maine
BOWDEN INDUSTRIES
Tatephone Number fcx Worm«t«n
Address (Number. Stnet. City. Sate, and ZIP Code)
100A_QsterDrJvp N-w
Signature of Preparer (cpOona/J
Section 11 — Hazardous Ingredfents/ktentity Information
CaniDonarts (Specific Chemical MMfitv. Common Nama(s)) - OSHA PEL
Section III — Physical/Chemical Characteristlca
Appearance and Odor
flp
Section IV ~ Fire and Explosion Hazard Data
Flash Point (Method Usad)
Extinguishing M«dia
Special Fire Fighting ProcedurM
Unusual Fire aiid Explosion Hazard*
None
-------
Hazardous Dtcoropositioo or Byproducts
{action VI — Health Hazard Data
Routes) ot Entry
H«2Bfds (Acute and Ctvoruc)
- intestlonal
•HraJerseeffects
IARC Monographs?
Ctrctnogenicfty:
- vomltin
Ernergancy and FW AW Prc«edur«
mi .
Sectioni VII -- Precautions for Safe Handling and Use
Piectutrons to B« Taken in Handttng «nd Storing
Store cool, dry area
Section VIII — Control Measures
Rcspwaiwy Pro
-------
SAFETY DATA SHEET
Elee'micB
INCORPORATED
245 FREIGHT ST. • WATER8UBY. CT 06702 « (203) S75-S700
Co r
Health Flammbl 11 ty React Ivi ty Other
Metex TS-40-A
Issue Date: 07/21/72 !
Rerised Date: 11/19/90
Page 1 of 7
0 1
{PRODUCT
10501
PROOOClTcOOIEIMUST ACCOMPANY AU. IHQUIRIES BEGAWHMfi THIS PRODUCT
24 HH. EMEflG£NCY NUHIER: CHEMTREC (MO) 424-1300
PRODUCT IDENTIFICATION
TRADE NAME: Metex TS-40-A
CHEMICAL FAMILY: ALKALINE SALTS •
FORMUI-A: Proprietary Mixture j
HMIS RATING* 2 HEALTH 0 FLAMABILITY - 0 REACTIVITY ', Cor OTHER
0
-------
MacDermid Incorporated
J43 FREIGHT STREET • WATERBURY. CT ffiroa - TELEPHOM6 (303)979-5700 - TELEX 443*011 - PAX 303-979-5(130
MATERIAL SAFETY DATA SHEET Page 2 of 7
Product: Metex TS-40-A . Issue Date: 07721/72
« ' s
Product Code: 10501 Revised Date: 11/19/90
24 Hour Emergency Number: CHEMTREC (1-800-424-9300)
0 1
SECTION 5 FIRST AID DATA
Contact a physician in all cases of exposure. First aiders should provide
for their own safety prior to rendering assistance.
EYES:
Wash affected eyes under slowly running water for IS minutes
Contact physician immediately
SKIN:
If contacted wash the skin with water for IS minutes.
Remove and isolate all contaminated clothes and>shoes.
INGESTION:
If ingested rinse the mouth and throat liberally with water .
Contact physician immediately; do not move victim
INHALATION:
Remove the victim to cool uncontaminated area
Monitor the patient for respiratory distress
CAUTION: If unconscious-having trouble breathing-or in convulsions-do not
induce vomiting or give water.
Always clean c6ntaminated clothing and gear prior to reuse.
NEVER administer anything to an unconscious person.
SECTION 6 . HEALTH EFFECTS DATA :
Primary Route(s) of Exposure: Eye Skin Inhalation and Imgestion
EYE CONTACT: Chemical irritation follows initial mechanical irritation
May cause slight irritation to sensitive individuals
Intense watering of eyes will occur
SKIN CONTACT: Prolonged or repeated contact may cause irritation
Itching and tingling sensation may be produced
Painful sensation will occur
INGESTION: Irritation and 46urning sensation of lips/mouth and throat
The substance is moderately toxic if swallowed.
Headache and general weakness may occur
INHALATION: Mild irritation to respiratory system
Irritation of mucous' membrane of nose/mouth/throat may occur
Temporary headache may occur
95
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I MacDermid Incorporated
249 PR6IQHT STREET - WATERBURV. CT 01709 • TEUEPHOwe ( «S ) 37S - S700 - TELEX «43«OM - PAX 203.S7S.5«30
MATER.LAL SAFETX DATA SHEET pagc 3 of i
Product: Mete* TS-40-A * Issue Date: 07/21/72 j
Product Code: 10501 *"I"* Date: 11/19/90 ;
24 Hour Emergency Number: CHEMTREC (1-800-424-9300) | Q
SECTION 7 PERSONAL PROTECTIVE DATA ===
RESPIRATORY PROTECTION: If the OSHA-PEL/ACGIH-TLV are exceeded, it is
recommended that a NIOSH approved respirat9r be used. Consult with your
industrial hygienist for appropriate cartridge selection & use.
For large spills, entry into large tanks, vessels or enclosed smal£ spaces with
inadequate ventilation, a pressure-demand, self-contained breathing
apparatus is recommended. !
VFNTI1LA.TION* General ventilation is recommended . Additionally, local
exhaust ventilation Tie recommended where vapors, dusts, mists, or aerosols may
be released.
PROTECTIVE EQUIPMENT: I
Splash proof goggles; Face shields; Chemical aprons; Boots and gloves.
The availability of an eya wash fountain and safety shower is recommended.
If clothing is contaminated /- remove clothing aad thoroughly wash the affected
body area. Launder contaminated clothing before reuse. S
Consult with your Safety Prof essional /Industrial Hygienist » for specific
information regarding applications at your facility. ^
i
""flcfiON 8 TOXICOLOGY DATA I
TOXICITY STUDIES: Toxicity Studies have not been conducted on ^i product
However, toxicity literature surveys have been conducted on the ingredient(s)
in Section 2. The results are as follows: <
ACUTE ORAL TOXICITY: Unknown
ACUTE DERMAL TOXICITY: Unknown
ACUTE RESPIRATORY TOXICITY: Unknown
TOXICITY HAZARD REVIEW (THR) :
Unknown
Listed as suspected carcinogen by: IARC: no NTP: no OSHA: no
i
SECTION 9 ' REACTIVITY DATA
INCOMPATIBILITY: Acids i
HAZARD DECOMPOSITION PRODUCTS: Phosphorus oxides
STABILITY: Stable ,
CONDITIONS TO AVOID: Unknown
% i
HAZAFDOUS POLYMERIZATION: No S
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MacDermid Incorporated
3
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MacDermid Incorporated
a«S FRE.OHT STREET - WATEK8UKY. CT 0,70* - TELEPHONE , 203 , STS - ,,0. - TELEX .0,0,,
20, • 5,S
MATERIAL SAFETY DATA SHEET p.,. s: or 7
Product: Metex TS-40-A
Product Code: 10501
Issue Date: 07/21/72
Revised Date: 11/19/90
24 Hour Emergency Number: CHEMTREC (1-800-424.9300)
REGULATORY DATA
SECT JON 13
The Following Regulations apply to this product
FEDERAL REGULATIONS:
tha
CHEMICAL NAME
CAS
BY WEIGHT %;OSHA-PEL ACGIH-TLV
Sodium Hetasilicate
6334-92-0
30 - 40
2 mg/m3
2 mg/m3
CERCLA/SUPERFUND. 40 CFR 117, 302/304: Notification of spills of this
product is NOT required. - ;
SARA/SUPERFUND AMENDENTS & RE AUTHORIZATION ACT of 1986 ^TITLE I II) -Sect ion
302,3111, 312, & 313: j
as an extremely hazardous substance
«5rrTinNS 311 & 312 - M.S.D.S. REQUIREMENTS (40 CFR 370)
ou? haSId eilluItiJn ha. found this product to be Non-Hazardous. ;
98
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MacDermid Incorporated
,43 FKg.flHT STREET - WATEflSUBY. CT 0870S • TELSPHON6 ,203)S7S,S700 . TEL6X 44«011 • FAX
MATERIAL SAFETY DATA SHEET
Product: Metex TS-40-A I»« Date: 07/21/72
Product Code: 10501
- S930
Page 6 of 7
Revised Date: 11/19/90
24 Hoar Emergency Number: CHEMTREC (1.800-424-9300)
REGULATORY DATA (Continued)
SECTION 13
SECTION 313 - LIST OF TOXIC CHEMICALS (40 CFR 372):
This product does not contain ingredients listed under AO CFE 372.65.
TOXIC SUBSTANCE CONTROL ACTrfTSCA) : The chemicalingredient(s) in this
product are listed on the 8(b) Inventory List (40 CFR 710).
RESOURCE CONSERVATION & RECOVERY ACT (RCRA). 40 CFR 261 SUBPARTS C & D
Please refer to Section 10, disposal information for pertinent data.
TOTAL TOXIC ORGANICS
This product does not contain ingredients on the List of Total Toxic Organics.
STATE REGULATIONS:
Cslifornia Proposition 65:
This product complies with the MSDS and labelin| requirements of the Safe
Drinking Water and Toxic Enforcement Act of 1985.
Michigan Critical Materials:
This product does not contain ingredients listed on the Michigan Critical
Materials Register. -
State Right-to-Know Laws:
Please consult your particular state's right-to-kaow law.
99
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MacDermid Incorporated ;
S4S FREIGHT STREET • WATeRBURY. CT 08702 - TELEPHONE (203)379-5700 - TELEX 4438011 - FAX 203.379-3830
MATERIAL SAFETY DATA SHEET Page 7 of?
Product: iMetex TS-40-A Issue Date: 07/21/72 j
Product Code: 10501 . Revised Date: 11/19/90 j
24 Hour Emergency Number: CHEMTREC (1-800-424-9300) | . Q ^
SECTlfON 13 REGULATORY DATA (Continued)
INTERNATIONAL REGULATIONS: i
Canadian Domestic Substance List (CDSL): :
The chemical ingredients in this product are listed with, the C.D.S.L.
The information listed above" does not include all Federal, State, and
International regulations. The regulations listed **ow may change from
time to time; it is the user's responsibility to keep advised of current
regulatory requirements. :
i
Prepared by MacDermid Inc. Safety & Regulatory Compliance Department, based
upon publicly available reference information. |
""SECTTON 14 USER NOTIFICATION
To th. b..t of our knowl.dg. th. Inform.tlon cont.ln.d h.r.ln I* coff.et. All eh.mlc.li m«y pf...nl unknown
httlth h.r.rd. *nd ihould b. u.od with e.ullon. Although c.ftmln hazard* «f» d«*cflb«d h.r.ln. w. e»nnot
gu.r.nt.. th.t th... .r. th. only h.xmrdt which .«l«t. Fin.I d.t.rmln.tI on of .ultlblllty of th. eh.mie.l .»
th. .ol. r.pon.lblllty of th. u«.c. U..r. of .ny ch.mle.l .hould ..tl.fy th.m..l».. th.t th. ""«•''""» "*
m.thod. of «.. ...u,. th.t th. eh.mle.1 d ..f.ly. NO R6PR636NTATIONS OR WARRANTIES. EITHER EXPRESSED
OR IMPLIED OF MERCMANTA* 111TY. FITNESS FOR A PARTICULAR PORP086 OR ANY OTHER NATURE! ARE MADE MERE UNDER
WITH RESPECT TO THE INFORMATION CONTAINED HEREIN OR THE CHEMICAL TO WICH THE INFORMATION REFERS.
100
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2300 WALDEN AVENU& BUFFALO. NY 14225
IMI
an Ifrll company
TSD-12.003
APPENDIX B
OPERATION PROCEDURE FOR
ULTRASONIC CLEANING SYSTEM
101
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START-UP, OPERATION & SHUTDOWN PROCEDURE
FOR
ULTRASONIC CLEANING SYSTEM
START—UP
i
1) Check water levels in ultrasonic tank and hot rinse tank; fill if
necessary. j
K - '
2) Turn on heaters (2) hot and ultrasonic tank (morning).
. Note: Temperatures are preset; do not adjust. i
Ultrasonic Tank 120-160F Hot Rinse Tank JL40-180F ;
OPERATION
i
1) Turn on recirculating pumps (2) and ultrasonic switch; also water
• overflow for cold rinse. !
Remove only necessary covers for length of basket. i
2) Lower parts in basket in ultrasonic tank in front of Ultrasonic
generator. Use hoist to raise and lower basket or geritly swing
to cause slight motion to aid in removal of soils. !
Note: Time depends upon amount of soil to be removed; ^usually a
minimum of three (3) minutes.
3) Rinse in first cold rinse tank. Again create slight motion to .
aid in removal of solution. :
' _ . I
Repeat in second cold- rinse tank - 1 to 3 minutes both tanks.
i
4} Place basket in hot rinse tank to remove any remaining solution
and also to heat up the parts to aid in drying (1 to 3 minutes).
5) After removing parts from hot rinse, turn off the two i
recirculating pumps and ultrasonic switch and replace bovers.
SHUTDOWN :
\
1) Be sure all covers are in place. Turn off heaters, ultrasonic
tank:, hot rinse tank, and ultrasonic switch. !
Turn off overflow for cold rinse tank. 1
102
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! 2300 WALDEN AVENUE, BUFFALO. NY 14225
EMI
an ijv|l company
TSD-12.003
APPENDIX C
MACDERMID INSTRUCTIONS FOR
ALKALINE CLEANER TEST KIT
103
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MocO.rmld, lrtcarpor«e«d A Soecialcy Ctxymcnl Comonuy. WWartxjry. Cont XJCUCUL O67OS (3O3) S7S-S7OO TX
INSTRUCTIONS FOR ALKALINE CLEANS* TEST KIT PSINg J-2 SOLOTION
mark with
1. Clean test bottle with cleac. water.
2. Pill the marked or etched dropper up
cleaner to be checked and add to the -test bottle.*
3, Pill the test bottle to approximately half way with water.
4. Add with the unmarked dropper/ the J-2 solution, a drop at a
fcirae, until the pink color just disappears.
5. Note the number; of "drops used.
BTo., of drops x factor = 02./gal. of cleaner/ or
No,, of drops x factor x 7.5,. = grams/liter of cleaner.
NOTS: If brom phenol • blue (BP8) indicator is required for the test,
~th"eh"~E'dc2~'about S drops o'2"thi« indicator.•• .-—j-ust before tHe- ._
addition of the J-2 solution. |
•« i
The use of brom phenol blue is indicated by the use of
BPB with the factor. " ' ;
The color change from brcm phenol blue will be; from blue
to yellow. . .
*In some cases, more than 1 dropperful of cleaner may;be required.
In some cases, a note of this vill be made with the factor.
MACDERMID INCORPORATED ;
; WATERS URY, CONNECTICUT ;
6/17/72 . |
This sheet is a revision of that dated 8/11/69, which! is now
obsolete and should be destroyed. j
104
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r
2300 WALDEN AVENUE, BUFFALO. NY 1422S
IMI
an IJfrll company
TSD-12.003
APPENDIX D
ULTRASONIC BATH CONTROL RECORD
105
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2300 WAL.DEN AVENUE. BUFFALO, NY 14225
an p company
TSD-12.003
Appendix D
ULTRASONIC BATH CONTROL RECORD
Bath Composition Date: : Cleaner Type:
DATE
TEST
READING
WATER
ADDED
* INCLUDE STAMP & DATE
CLEANER
ADDED
FINAL
READING
Q. C.
VERIFY
106
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