Vacuum Vapor Degreasing
At
Raytheon Missile Systems
Paul W. Fecsik, Presenter (1)
1
Project Manager
Raytheon Missile Systems
Pollution Prevention
Tucson, Arizona
520-794-4105
[email protected]
The Challenge
High Usage of IPA (Isopropyl Alcohol):
• 10 Year Old IPA Vapor Degreaser
• 1,560 lbs per year VOC emissions
High Usage of MEK (Methyl Ethyl Ketone):
• Manual cleaning operations.
• Varying cleaning requirements.
• 1,800 lbs per year HAP and VOC emissions
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Goals
• Implement an automated vacuum vapor degreasing
system using a non HAP and non VOC cleaning agent.
• Remove polar and non polar contaminants.
• Continue to meet “water break free surface”
cleanliness requirement prior to painting or bonding.
• Give Production Areas a competitive reason to
switch from IPA vapor degreasing and manual
MEK based cleaning processes to a central and
automated process.
• Reduce worker exposure to solvents.
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New Degreaser Requirements
New Vacuum Vapor Degreaser Requirements:
• Minimum basket load size of 26.4” x 19.0” x 12.0”
• 480 V, 3 Phase electrically powered.
• Factory buyoff of turnkey system using Raytheon
provided missile hardware and a solvent cleaning
chemistry identified by Raytheon.
• Achieve a water break surface after cleaning.
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Process Chemistry
Process Chemistry:
• A DOW Clene 1601 product from Europe was selected for
use in the degreaser.
• DOW agreed to supply the chemistry to Raytheon.
• Non HAP ! Low VOC.
• Price per gallon very comparable to similar chemistries on
market and already in use at Raytheon.
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IPA Versus DOW Clene 1601
ISOPROPYL ALCOHOL
Flash Point:
12° C (53.6° F)
Boiling Point: 82.4° C (180.3° F)
Density:
0.785
DESCRIPTION
Isopropanol = 2-propanol
2-propanol means [ OH ] is on the 2nd carbon
OH
C
C
C
1-BUTYL 2-PROPANOL ALCOHOL
OH
Flash Point:
67.7° C (153.7° F)
Boiling Point: 170.2° C (338.4° F)
Density:
0.880
C
C
C
O
C
C
2-propanol
C
C
DESCRIPTION
1-butoxy 2-propanol = DOWCLENE 1601
1-butoxy means [ O ] is on the 1st carbon
1 oxygen, 4 carbons
butoxy = alkoxy ∴
butoxy alcohol = alkoxy alcohol
1-butoxy
DOWCLENE 1601
OH
C
C
Polar Solvent
( Hydrophilic )
C
O
C
C
C
DESCRIPTION
Hydrophilic = dissolves water soluble
substances
Lipophilic = dissolves oilt substances
C
Non-Polar Solvent
( Lipophilic )
Courtesy of:
Mary Parke, Ph. D.
E.F.I., Inc.
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June 20, 2005
Manufacturer Selected
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Vacuum Degreasing Process
Vacuum pump
Condenser
Vacuum pump
Heat
recovery
CondenserP-21
Gasexchange
P-26
Tank 2
Washing
Chamber
Cooling
tank 2
Filter
2
Heating
tank 2
Cooling
Destillation
Heating
Destillation
Tank 1
Filter
1
Cooling
tank 1
Pump
Tank 2
Pump
Tank 1
Process diagram courtesy of Durr Ecoclean GmbH, Stuttgart, Germany
Heating
circuit pump
Water
separator
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Programmable Process Sequence
Programmable Process Sequence:
• Wash 1 (Remove all of or bulk of contaminants)
- High volume solution circulation (selectable)
- Ultrasonics (selectable)
- Parts load rotation or oscillation (selectable)
- Vapor degreasing (selectable)
• Wash 2 (Optional)
- Much cleaner version of Wash 1.
- Same selections as Wash 1.
• Vapor Degrease (Optional).
• Vacuum Drying at 1 mBar.
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Results (2005)
• Better, Cheaper, Faster, Greener and Safer Process.
• Elimination of IPA Vapor Degreaser except for one legacy
missile program component having a critical pyro-ceramic
to titanium bond.
• Closed working system - No solvent emissions!
• Reduced manual cleaning operations and thus reduced
use of MEK and other HAP/VOC containing solvents.
• Minimal worker exposure to solvents.
• Distillation unit to significantly reduce hazardous wastes
since cleaning solution is continuously recycled.
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2nd Vacuum Vapor Degreaser (Space)
Space Cleaning Requirements at AFP 44:
The system shall be capable of cleaning parts to Level 100 A/5
per IEST-STD-1246.
Which really means…
The solvent collected at the sample port after cleaning
the part will contain no more than 0.100 mg NVR (Non
Volatile Residue) per 100 ml solvent and 10 particles
max per 100 counted between 50 and 100 microns.
A whole new ball game ! ! !
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