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RI Workshop: Tools for TCE Substitution

RI Workshop: Tools for TCE Substitution. Hands-On Training from the TURI Lab Jason Marshall – Laboratory Director Heidi Wilcox – Research Associate. March 14, 2008 CCRI-Warwick Knight Campus Warwick, RI Funding from EPA Region 1. Workshop Agenda.

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RI Workshop: Tools for TCE Substitution

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  1. RI Workshop:Tools for TCE Substitution Hands-On Training from the TURI Lab Jason Marshall – Laboratory Director Heidi Wilcox – Research Associate March 14, 2008 CCRI-Warwick Knight Campus Warwick, RI Funding from EPA Region 1

  2. Workshop Agenda • 8:30 - 9:00 Registration and Refreshments • 9:00 - 9:05 Introduction & Overview • 9:05 - 9:15 Choosing an Alternative • 9:15 - 9:25 Past TCE Work • 9:25 - 9:35 Success Stories from RI • 9:35 - 10:15 Other Resources Available • 10:15 - 10:20 Break • 10:20 - 12:25 Hands-on Cleaning • 12:25 - 12:30 Next Steps

  3. Introduction & Overview • TURI • EPA Region 1 • NBC • RI DEM • RI DOH

  4. TURI-Lab • www.turi.org/laboratory • Information on cleaning basics • Past projects • Capabilities of lab • Future workshops - projects • Database link • www.cleanersolutions.org

  5. Choosing an Alternative • Don’t shift the risk • From worker to environment OR • From environment to worker • Ex. Replacing flammable solvent with a ozone depleting chemical • Want to select a product that is safer for one or the other • Would be best if safer for both

  6. What are Indicators at TURI’s Lab? • The lab uses five criteria for screening products • Volatile Organic Compounds (VOCs) • Global Warming Potential (GWPs) • Ozone Depletion Potential (ODPs) • Hazardous Material Information System/ National Fire Protection Association (HMIS/NFPA) • pH

  7. Why These Five Indicators? • Worker Health & Safety • VOC, HMIS, pH • Environmental Safety • VOC, GWP, ODP, pH

  8. Guidelines

  9. Guidelines

  10. Solvent Alkaline Aqueous Example Screening Values

  11. Find a Safer, Effective Alternative • CleanerSolutions Database • Used to identify safer and effective products • Safety Scores • VOC, ODP, GWP, HMIS/NFPA, pH • Matching Performance • Contaminant, substrate, equipment, current solvent

  12. CleanerSolutions • How it works - http://www.cleanersolutions.org

  13. Search

  14. Results

  15. Past TCE Work • TURA Work in MA • EPA Grant in MA • EPA Funding in RI

  16. TURA Work in MA • SSL Testing (1993-2003) • Worked with 21 companies trying to replace TCE in cleaning applications • A wide range of industries were represented • Aircraft • Electronics • General Mfr • Metal working • Optical • Plating

  17. Conducted over 100 experiments 11 Contaminant types Abrasives Buffing Compounds Coatings Fluxes Grease Inks Paints Cutting Fluids Lubricants Oils Waxes Contaminants Removed

  18. Previous Testing for TCE Replacement • Abrasive • 1 Company in semi-conductor industry • Ceramics parts for a company that manufactures parts for the • Buffingcompound • 2 Companies • Metal working shop • Light manufacturer • Brass and silver parts • Coatings • 1 Company - tool manufacturing • Steel surfaces • Immersion

  19. Previous Testing for TCE Replacement (cont.) • Flux • 1 company manufactured brass bellows • Flux removal • Grease • 2 Companies • Musical instrument manufacture • Tool maker • Brass, ceramics & steel parts • Immersion and/or ultrasonic energy

  20. Previous Testing for TCE Replacement (cont.) • Paint/Ink • 2 companies • Ceramic capacitor/electronics manufacturer • Tool maker • Plastic bottles and steel pieces • Immersion • Oil • 8 companies • Steel, carbon steel, stainless steel, aluminum, brass and ceramics • Immersion, ultrasonic and mechanical agitation • Wax • 4 companies • Electronics • Metal working • Aluminum, brass, ceramics, copper, glass and steel surfaces • Manual wiping, immersion and /or ultrasonic energy

  21. Summary of Alternatives Testing to TCE • 21 Vendors • 44 Products • 11 Product Types

  22. EPA Grant to Replace TCE & Chlorinated Solvents • Two year grant - 2003-2005 • Conducted with MA Office of Technical Assistance • Help small companies move away from TCE & chlorinated solvents in vapor degreasing • Work focused on drop-in substitutes • Due to capital investment of large closed looped systems • Gathered EH&S data for • TCE and other chlorinated solvents • The chemical classes of the substitutes for comparisons • Article in Process Cleaning Magazine on Drop In Alternatives • Sept/Oct issue • http://www.processcleaning.com/

  23. SSL Testing (2003-2005) • 8 companies trying to replace TCE/ Chlorinated Solvents in cleaning applications • Six joint site visits by OTA and TURI • Two site visits by TURI • A wide range of industries are represented by these companies • Aircraft • Electronics-Ceramic • Jewelry • Metal working job shops • Tool • Capacitors • Wire & Cable

  24. Contaminants Removed • Conducted over 70 experiments • 8 Contaminant types • Buffing • Coating • Grease • Ink/Paint • Mold Release/Silicone • Oil • Resin/Rosin • Waxes

  25. Testing for TCE/Chlorinated Solvent Replacement • Buffingcompound • Removal had been conducted for brass parts for ornament industry • Coating • Cleaning trials conducted for a metal job shop and a tool manufacturer • Grease • Testing performed for the electronic/ceramics manufacturer • Ink/Paint • Trials run for the electronic/ceramics manufacturer and the tool mfr

  26. Testing for TCE/Chlorinated Solvent Replacement • Mold Release/Silicone • Worked with a wire and cable manufacturer • Oil • Testing conducted for a jewelry manufacturer, a capacitor company, aircraft component manufacturer and the tool manufacturer • Resin/Rosin • Worked with a wire & cable manufacturer • Waxes • Testing performed for the electronic/ceramics manufacturer

  27. EPA Funding in RI 2006-8 • Workshop Fall 2006 • Worked with 13 companies • On-site testing for 6 • Second Grant 2007-8 • Worked with 4 so far • Plus all of you…

  28. Success Stories from RI • Types of Parts Cleaned • IRA Green • Three A’s

  29. RI Parts Cleaned

  30. RI Parts Cleaned

  31. RI Parts Cleaned

  32. RI Parts Cleaned

  33. RI Parts Cleaned

  34. RI Parts Cleaned

  35. Ira Green - Background • 270 employees - Products consist of metal pieces for the DoD • Military unaware of TCE use in metal finishing operations • Used 12,500 pounds of TCE in 2004 • When EPA contacted Ira Green, the company was very close to exceeding permit limitations • Already had enforcement action against them by the RI DEM 2003 and 2004

  36. Ira Green – Finding an Alternative • EPA collected parts for TURI to test • Set up a test tank in Ira Green’s facility • Determined that alternative solution works as well as TCE • TURI provided free gallon of alternative solution

  37. Ira Green Summary • One product line completely converted to aqueous cleaning • Installed additional soap cleaning tanks in plating area • Have done enough hands on shop floor testing to know they can effectively clean 95-100% of all products • Now working through the logistics, material handling, and queue/work in process issues to make a total conversion • Critical to process • Clean as soon as possible after polishing • Very concerned about drying, watermarks or staining

  38. Contact Ira Green • Gary Eich • 401-467-4770 x113 • geich@iragreen.com

  39. Three A’s - Background • Small, family-owned job shop – 4 employees • Owner wanted to stop using TCE because of associated health risks • Used approximately 55 gallons (~690 pounds)/ year at a cost of about $1000

  40. Three A’s – Finding an Alternative • EPA collected parts for TURI to test • Needed to find an alternative process that would maintain an antique finish on metal parts • An alternative was found that will allow Three A’s to retrofit current degreaser with an immersible transducer, saving money on equipment costs • Switched to a Steam Cleaner • Eliminating TCE from their plant

  41. Contact Three A’s • Alfred Mekuto III • 930 Plainfield St, Johnston, RI 02919 • 401-944-8600

  42. All Companies from 1993-2008 46 companies Used 297,300 lbs Reduced 195,200 lbs 66% RI 2006-7 Used 24,500 lbs Estimated reduction 12,500 lbs 51% reduction RI 2007-8 Used 16,500 lbs Estimated reduction 11,100 lbs 67% reduction Overall TCE Reduction

  43. Other Resources Available • RI DEM • NBC • RI DoH • EPA • How-to-Guide • nPB information • DoD

  44. Break • Grab some coffee while we get set up for the fun stuff…

  45. Hands-on Cleaning • Product Selection Based On • Contaminant removal • Substrate compatibility • Equipment compatibility • Use CleanerSolutions.org or Vendor Literature

  46. Buffing Compound Magnaflux Daraclean 283 US Polychemical Polyspray Jet 790 XS Oakite Inproclean 3800 Buckeye XL 100 Matchless Metal Polish Co. MC 132 Matchless Metal Polish Co. Buffclean 14L, 125L and 175 Alconox Detergent 8 Magnaflux Daraclean Kx 43 Oils Magnaflux Daraclean 283 US Polychemical Polyspray Jet 790 XS Oakite Inproclean 3800 Brulin Aquavantage 1400 International Products Surface Cleanse 930 Warren Chemical Sea Wash Blue Successful Products Previously Tested

  47. Testing Process • Establish Baseline • Measure how effective your current process is • Compare the alternatives • Test the Alternatives • Dilutions to use • Hot or cold • Equipment • Time • Rinsing • Drying

  48. Four Phases of Process • Phase 1 Testing Chemistry Only • No mechanical energy • Phase 2 Add Mechanical Energy • Use best cleaners

  49. Four Phases of Process • Phase 3 Piloting – Lab Setting • Clean supplied parts using best products • Phase 4 Piloting On-site • Set up cleaning process at your facility and compare directly with current process

  50. Next Steps • Sign up for lab testing • Arrange for soils and part pickup • Sign up for on-site testing • Schedule a visit with TURI

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