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Vapour degreasing – A guide for production engineers
Vapour degreasing – A guide for production engineers
This guide for production engineers explains why vapour degreasing is the most effective and economical process for cleaning of manufactured components. The start of a new year is always a good time to review your existing cleaning process and ask yourself ‘am I using a safe modern solvent for vapour degreasing?’.
Vapour degreasing is the simplest but most effective degreasing and cleaning process which, until recently, has been subject to little change since it was first invented in the early part of the last century. This is a very mature chemical technology which legislation is now effecting changes so fundamental that the more accurate name for the process “Condensation Cleaning” should be used to reflect the improvements in equipment design, chemistry, reduced emissions, economies in usage of solvents and the subsequent environmental acceptability compared to the open topped tanks so ubiquitous in factories and workshops worldwide. The alternatives in equipment design offer differences in technology, which guarantee the continuing use of this process in the future, need to be considered and understood.
The cleaning tank in the corner of most engineering shops hides a very well researched process using sophisticated chemistry. Its popularity is in its simplicity. The tank sump is heated, fitted with cold coils around the internal surfaces at the top to retain the vapour. Fill to a few centimetres with a non-flammable solvent able to dissolve contaminants, boil to form a vapour 3 to 4 times heavier than air to fill the tank. Hot solvent vapour condenses on the cooler target parts at workplace temperature. The hot liquid solvent dissolves oil and grease and other contaminants. Used solvent returned to the sump revaporises continuing the cycle until parts have achieved the same temperature as the vapour when, with no further condensation, the process is complete. Simple but perfect. Highly productive and economical, parts removed from the cleaning process are clean, warm, and dry in 5 to 10 minutes.
Historically chlorinated hydrocarbons have been the solvents of choice for the “Condensation Cleaning” process. Compatible with most materials of manufacture, stable in constant use, producing a non-flammable saturated vapour heavier than air at a temperature greater than ambient. In Europe, the United States and in other advanced industrialised economies increasingly stringent legislation to control emissions of VOCs, especially solvents, has led to new formulations for paints and other coatings where water replaces most of the solvent. In the early days the quality of water-based paints was not as good as traditional solvent-based coatings, but innovation has driven the development of new polymers with results as good as, if not better than, the solvent-based originals.
As with coatings, cleaning systems have had to change. With increasingly demanding standards of cleaning required for precision engineering, electronics, optics etc solvents are often first choice, for reasons outlined above, but these have been targeted by regulators and alternatives are encouraged by the relevant authorities and law makers often without serious consideration of unintended consequences. For example, water-based cleaning is encouraged as the obvious alternative, but this has many disadvantages compared to condensation cleaning as although the machines are simple and relatively cheap the processes require multiple heated tanks for immersion or spray processing or long programmed cycles in batch machines for cleaning, rinsing, and drying. Water based processes are slow, energy intensive and occupy more floor space than solvent-based condensation cleaning equivalents where only one tank with a small footprint is needed, delivering shorter process times and, most importantly for the environment, using minimal energy.
The ideal cleaning process would be “Condensation Cleaning” using water but due to the physical characteristics of the water vapour/steam and the inability to carry onto the surface of the targeted parts surfactants to remove the oil, grease and soils and the difficulty and expense of rinsing and especially drying this can only ever be a dream.
Historically chlorinated hydrocarbons have been the solvents of choice for the “Condensation Cleaning” process. Compatible with most materials of manufacture, stable in constant use, producing a non-flammable saturated vapour three to four heavier than air at a temperature greater than ambient. The traditional solvents such as trichloroethylene exhibits all these characteristics however concerns about its carcinogenic properties and the danger to operators by exposure, led to a continuing search for a safer alternative. 1,1,1 trichloroethane based solvent formulations became popular in the mid part of the last century as a safer replacement. An excellent solvent, safer for users, it proved to be depleting the protective ozone layer around the Earth and was subsequently banned. With the development of the REACH legislation in Europe, trichloroethylene was again allowed with restrictions and stringent controls for use in authorised machines which control emissions to very low figures close to zero.
High performance vapour degreasing and cleaning
EnviroTech Europe have been supplying vapour degreasing solvent formulations for 40 years constantly responding to increasingly stringent regulatory requirements for environmental and safety laws and the need for improved cleaning standards. ProSolv® 5408e is a new sustainable solvent blend with near zero OPD (Ozone Depletion Potential) and GWP (Global Warming Potential) for high performance degreasing and cleaning which ticks all the boxes with the perfect profile for a vapour degreasing solvent. Soft on the environment and safer for users with high performance, improved cleaning, and lower costs. Lower boiling point, economical with energy with low solvent losses, faster production, reduced costs, easy handling. Exceptionally low surface tension to penetrate micron sized holes and close contact surfaces. Sustainable and secure for future use as your ‘forever solvent’.
Sealed Tanks
As with all legislation for chemical use regulation and restrictions drive development of associated processes and equipment. Sealed tanks are now standard with many different designs available. The most common are discussed below.
The single tank hermetically sealed machines favoured by some manufacturers uses a process tank to contain the solvent and a separate storage tank/vapour generator. Baskets loaded with parts to be cleaned are introduced from the top or through access points on the side of the tank. Lids or doors hermetically seal the tank. Solvent is pumped into the process tank where agitation, ultrasonics or pumped liquid is circulated through the parts. Used Solvent is removed to the vapour generator, condensing coils controlling the vapour are linked to coils located in the vapour zone which, when the cycle is complete, collapse the vapour. The process tank is emptied. Controlled air introduced to process tank is then recycled through carbon absorption units to remove traces of solvent until the concentration is within regulatory standards when the lid is released for the basket of parts, clean and dry, to be removed and replaced with a further basket. Variations of process within the hermetically sealed tank are possible using sprays of cold or hot condensed solvent, immersion with or without ultrasonics and revolving baskets to cover most of the problems experienced when processing machined and fabricated parts. Continuous external distillation of the contents of the vapour generator is also an option depending on contamination.
The alternative technology is much simpler and uses well tried techniques not requiring the long recovery times of the hermetically vacuum sealed processes. The multilevel system uses a standard vapour degreasing tank design with a sealed loading section above the process tank. Components to be cleaned loaded in work baskets or jigs are fed to the load section by hand or conveyor, an internal platform raises and lowers the baskets in controlled cycles.
Loading complete – the load enclosure is sealed to completely isolate the process. Then seal on the process tank is opened and the basket automatically lowered into the cleaning section which can be simple condensation cleaning or immersion cleaning with or without ultrasonics or power sprays. Revolving baskets can also be added to improve cleaning in blind or through holes or oil ways in castings and fabrications.
On completion the basket rises to the area where the condensation coils are located, and parts allowed to drain and dry, basket raises into the load section when the process tank is sealed. A fan circulates air within the load area which can be recycled through carbon absorption systems if no external exhaust is preferred.
As baskets entering the loading space contain parts drained and dried only very small amounts of solvent are carried in the exhausted air which is monitored to ensure compliance with appropriate legislation. When this is complete the seal opens fully for removal of cleaned components. The loading section can be fitted with top or side seals allowing baskets to flow through on conveyor systems or be removed by hand or hoist. No solvent enters the work area. Both processes will produce parts cleaned to the highest standards but the choice of which offers the best solution needs a little more consideration.
The hermetically sealed vacuum process is complicated with the need to move liquids in the machine. It is relatively slow as the carbon adsorption process has to remove high levels of solvent from the recirculated airstream from the process tank. This is inefficient as adsorption rates for carbon fall rapidly with increasing saturation. Final levels of solvent in the tank when the lid or loading door opens will be dragged into the workshop and the area where the operator is working. Long process cycles reduce throughput.
The simpler multilevel systems where movement of liquids is not required are more efficient and offer much faster process times. Cost of manufacture is also reduced as no liquid movement or vacuum is involved. The extracted loading section ensures no leakage of solvent into the work area giving complete safety for operators and factory staff. Envirotech Europe also offers workplace air monitoring to ensure VOC’s from the solvent are within exposure limits and your machine is operating to specification.
Conclusions
Both designs of process machines discussed above fully comply with the emission regulations of the EU and U.S authorities. Which to choose will depend on many factors which should be discussed with equipment and solvent suppliers who have the experience to advise on which offers the best process for the application. Equipment and solvent must work together, so it is advisable to ensure that the suppliers co-operate to offer a package with high levels of responsible care and product stewardship to ensure the best and safest installation. EnviroTech personnel and distributors are trained to work with equipment suppliers to advise on the use of ProSolv® 5408e vapour degreasing solvent for the most satisfactory outcome.
The “Condensation cleaning” process still gives the highest levels of economical cleaning with minimum energy usage, low footprint on the factory floor, safety for the operator, and high production rates with low solvent usage and environmental impact. With the new generation of sealed cleaning machines its future as the process of choice is assured.
Photograph of Solvac equipment courtesy of C&C Hydrosonics.
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/prosolv5408e for information about other uses and applications for ProSolv 5408e.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
For more advice, please telephone us on +44 (0) 20 8281 6370 or use our website contact form.
All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Related Posts
Avionic and electronic component corrosion inhibitor
SuperCORR A – Avionic and electronic component corrosion inhibitor
Super CORR A was originally developed for the U.S. Air Force to comply with Mil-DTL-87177B (formerly Mil-L-87177A) specifications. A water displacing lubricant and corrosion protection compound that prevents avionic as well as electrical and electronic components from systems failures caused by corrosion. It is now the industry standard for electrical corrosion protection, for in service maintenance by both military and commercial aircraft major repair and overhaul (MRO) facilities worldwide.
Super CORR A is a unique and proprietary formulation with long-lasting, anti-corrosion inhibitors and components providing a superior lubrication coefficient and protection against moisture, wear, general and fretting corrosion, static electricity, corona, and other electro migration problems. The non-flammable film is only 7 microns (0.007mm) in thick and is formulated without sulphates, chlorides, petroleum-based material, or halogens, to meet the EU RoHS directive.
Manufactured and supplied by EnviroTech Europe Ltd, it is unexcelled in preventing failures of electrical systems and electronic equipment caused by corrosion as well as preventing the corrosion of metal components surfaces, including those of components comprised of dissimilar metals such as those found in aerospace environments.
Super CORR A is packaged in aerosol cans make access to component parts easy for the engineering crew in difficult locations and conditions. Unpainted mild steel will not rust on exterior surfaces directly exposed to sea water environments for at least 6 months, protecting electrical connectors, switches, chains, drive shafts from corrosion while maintaining lubrication on moving surfaces.
Use Super CORR A for protection and lubrication of connectors, electrical systems and switches and mechanical controls during servicing. The ability to displace water from exposed contacts can ensure reliable operation in extreme conditions all in one small aerosol can.
EFFICIENT AND ECONOMICAL
- Extremely long-lasting, specially formulated and proprietary anti-corrosive inhibitor.
- Eliminates premature failure of components created by moisture, general or fretting corrosion.
- Prevents deterioration and contamination on all surfaces of electronic and electrical equipment and mechanical close tolerance moving components.
- Reliability increased, maintenance intervals increased and costs reduced, manufacturers save costly warranty service calls or product re-call.
APPROVED
- Industry approval from: NASA, Boeing Aircraft, Bombardier, Embraer, Lear, Gulfstream, Hawker-Beechcraft, Cessna, Raytheon, Polish Airforce, Northrop-Grumman, Royal Navy and Royal Norwegian Air Force.
- Exceeds Mil C 81309 Corrosion Prevention Compounds.
- Approved in US Tri-Service Corrosion Manuals.
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/supercorr-a for for information about other uses and applications for Super CORR A.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
For more advice, please telephone us on +44 (0) 20 8281 6370 or use our website contact form. All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Video: ProSolv 5408e – Vapour degreasing cycle using hermetically sealed equipment
Vapour degreasing cycle using hermetically sealed equipment.
ProSolv 5408e is a high- performance solvent cleaner used for sustainable and future proof vapour degreasing. Soft on the environment and safe for users, it offers improved cleaning at lower costs. Low boiling point, economical with energy with low solvent losses, faster production.
Innovation driven by legislation
Vapour degreasing, with or with-out ultrasonics, is the oldest, simplest and most effective solvent degreasing and metal cleaning process used today. It has, until recently, been subject to little change since it was first invented in the early part of the last century. In the UK, Europe, United States and other advanced industrialized economies increasingly stringent legislation to control emissions of VOCs, Solvents with a high Global Warming Potential (GWP), or a high Ozone Depletion Potential (ODP), and those compounds associated with human health concerns has led to Envirotech Europe manufacturing new formulations for precision cleaning solvents with low or near zero potential.
Halogenated hydrocarbons are the solvents of choice for vapour degreasing and cleaning. The process is essentially simple. A tank with a sump to contain the solvent, heaters at the base and condensation coils around the top section to control the height of the vapour is all that is needed. When heated in the sump halogenated solvents produce, in most cases, a saturated vapour between 3 and 4 times heavier than air at a temperature greater than the ambient temperature of the parts to be cleaned. This allows the solvent vapour to condense on the surface of the parts. The condensate dissolves the contaminants such as oil, greases, flux, and soils returning the used solvent into the sump of the machine for recycling into vapour which continuously condenses onto the parts until they have achieved vapour temperature when, with no further condensation, the process is complete. Parts removed from the cleaning machines are very clean, warm and dry.
The most common halogenated solvents, in use for commercial purposes, are non-flammable so present no risk in this process. Perchloroethylene, used mainly for dry cleaning, methylene chloride previously used widely in paint strippers, 1,1,1- trichloroethane and trichloroethylene used for vapour degreasing were the original materials used based on chlorine chemistry. However continuing concern about the environmental impact and danger to operators by exposure to chlorine-based solvents, especially trichloroethylene, has led to a continuing search for safer alternatives, such as ProSolv 5408e , a trans-1,2-Dichloroethylene based solvent mixture that is non-flammable.
The ProSolv 5408e vapour degreasing process gives the highest levels of economical cleaning with minimum energy usage, low footprint on the factory floor, safety for the operator, and high production rates with low solvent usage or environmental impact. With the new generation of sealed cleaning machines its future as the process of choice is assured.
A more detailed version of this article can be viewed here:
https://www.vapour-degreasing.com/solvent-degreasing-and-metal-cleaning/
Animation of Solvac hermetically sealed equipment by kind permission of CC Hydrosonics Ltd. https://www.cchydrosonics.com/
FURTHER INFORMATION
For more advice, please telephone us on +44 (0) 20 8281 6370 or use our website contact form. All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Latest News
Solvent Cleaner For Electronics
High performance solvent cleaner for electronics and electrical components
Evolving legislation by governments worldwide has resulted in the need for new and original formulations to be offered for use in solvent cleaning and vapour degreasing processes. Companies must continue to comply with legislation for protection of the environment and safety of operators who may be exposed to harmful substances. In applications where formulated blends of halogenated solvents have been used very effectively in the past, these are now required by changes in legislation to be phased out of use.
With a wealth of experience in this field, EnviroTech Europe have developed a new solvent cleaning formulation based on recent research, a replacement for the “old” technology, which has been found to perform just as effectively without the negative environmental, health and safety issues.
Near Zero OPD and GWP solvent blend for high performance vapour degreasing solvent cleaner
ProSolv 5408e is the perfect replacement for trichloroethylene, nPB (n-propyl bromide), perchloroethylene or other flammable solvents used in general engineering cleaning processes.
ProSolv 5408e is a high-performance solvent cleaner used for sustainable and future proof vapour degreasing. Soft on the environment and safe for users, it offers improved cleaning at lower costs. Non-carcinogenic, low boiling point, economical with energy with low solvent losses, faster production, reduced costs, easy handling.
ProSolv 5408e has been developed to provide superior critical cleaning performance for manufacturers of electronic and electrical components. High Solvency (KB Value 98) for removal of organic residues, compatible with organic and synthetic oils and most plastics and metals,
non-flammable, with low ozone depletion (ODP) and global warming potential (GWP).
Listed above are some of the benefits from using ProSolv 5408e, a sustainable vapour degreasing solvent for cleaning and defluxing in the electronics and electrical components industry and an economical and efficient replacement solution for vapour / vapour liquid cleaning systems using older legacy solvents, which are now either banned or being phased out. EnviroTech Europe have many years of experience and our experts are available to guide you through your solvent cleaner changeover procedures or to advise on equipment.
FURTHER INFORMATION
Please visit our website www.envirotech-europe.com for information about other uses and applications for our vapour degreasing and cleaning products.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
For more advice, please telephone us on +44 (0) 20 8281 6370 or use our contact form. All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Solvent Degreasing and Metal Cleaning
Solvent Degreasing and Metal Cleaning –
Future proof Vapour Degreasing from EnviroTech Europe
Innovation driven by legislation
Vapour degreasing, with or with-out ultrasonics, is the oldest, simplest and most effective solvent degreasing and metal cleaning process used today. It has, until recently, been subject to little change since it was first invented in the early part of the last century. In the UK, Europe, United States and other advanced industrialized economies increasingly stringent legislation to control emissions of VOCs, Global Warming Compounds, Ozone Depleting Compounds, and those compounds associated with human health concerns has led to new formulations for precision cleaning solvents.
Cleaning systems have had to change too. With increased legislation concerning the regulation of health and environmental safety, uses of solvents have been targeted and alternatives are encouraged by the relevant authorities and law makers, often without serious consideration of unintended consequences. For example, water-based cleaning is the obvious alternative but this has many disadvantages compared to vapour degreasing as although the machines are simple and relatively cheap the processes require multiple tanks for immersion or spray processing or long programmed cycles in batch machines for cleaning, rinsing and drying. Water based processes are slow, energy intensive and occupy more floor space than vapour degreasing equivalent where only one tank with small footprint is needed delivering shorter process times and most importantly using minimal energy. Then there is the disposal concern as the used water cannot just be disposed of by pouring it down a drain.
The ideal cleaning process would be vapour degreasing and cleaning with water, but due to the physical characteristics of the vapour/steam and the inability to carry surfactants to remove the oil, grease and soils and the difficulty of rinsing and especially drying this will only ever be a dream.
Halogenated hydrocarbons are the solvents of choice for vapour degreasing and cleaning. The process is essentially simple. A tank with a sump to contain the solvent, heaters at the base and condensation coils around the top section to control the height of the vapour is all that is needed. When heated in the sump halogenated solvents produce, in most cases, a saturated vapour between 3 and 4 times heavier than air at a temperature greater than the ambient temperature of the parts to be cleaned. This allows the solvent vapour to condense on the surface of the parts. The condensate dissolves the contaminants such as oil, greases, flux, and soils returning the used solvent into the sump of the machine for recycling into vapour which continuously condenses onto the parts until they have achieved vapour temperature when, with no further condensation, the process is complete. Parts removed from the cleaning machines are very clean, warm and dry.
The most common halogenated solvents, in use for commercial purposes, are non-flammable so present no risk in this process. Perchloroethylene, used mainly for dry cleaning, methylene chloride previously used widely in paint strippers, 1,1,1- trichloroethane and trichloroethylene used for vapour degreasing were the original materials used based on chlorine chemistry. However continuing concern about the environmental impact and danger to operators by exposure to chlorine-based solvents, especially trichloroethylene, has led to a continuing search for safer alternatives, such as ProSolv 5408e, a trans-1,2-Dichloroethylene based solvent mixture that is non-flammable.
As with all legislation for chemical use regulation and restrictions drive development of associated processes and equipment. The most important developments in vapour degreasing cleaning machines to use solvents for vapour degreasing use two different approaches and raise difficult questions as to which is the best most economical and simplest in use.
The single tank hermetically sealed machines favoured by mainly German manufacturers uses a process tank to contain the solvent and a separate storage tank/vapour generator. Baskets with parts to be cleaned are loaded from the top and lowered into the process tank. A lid then closes over the tank and is hermetically sealed. Solvent is pumped into the process tank. Baskets are immersed in the solvent where agitation, ultrasonics or pumped liquid is circulated through the parts. When the immersion process is complete solvent is pumped to the storage tank and vapour fed to the process tank from a vapour generator for rinsing and drying. Condensing coils/panels controlling the vapour height are linked to coils located within the vapour zone which, when the cycle is complete, collapse the vapour. The process tank is emptied. The saturated air/solvent from the process tank is then recycled through carbon absorption units to remove traces of solvent from the air until the concentration is below 2 grams per cubic meter when the lid opens automatically for the basket of parts, clean and dry, to be removed and replaced with a further basket.
Variations within the hermetically sealed tank are possible using sprays of cold or hot condensed solvent, immersion with or without ultrasonics and revolving baskets to cover most of the problems experienced when processing machined and fabricated parts. Continuous external distillation of the contents of the vapour generator is also an option depending on contamination.
The alternative technology is much simpler and cheaper and less time consuming using well trained techniques. This is favoured by UK based manufacturers. The multilevel system shown in the diagram uses a standard vapour degreasing tank design with a sealed loading section above the process tank.
Work baskets are fed to the load section from a hoist or conveyor. The loading door is then pneumatically sealed to hermetically isolate the process. The sealing lid on the process tank is opened and the basket lowered into the cleaning tank which can be simple vapour degreasing with vapour generator below or an offset generator can be used with the lower section being filled with clean solvent for immersion cleaning with or without ultrasonics or power sprays. Revolving baskets can also be added to improve cleaning in blind or through holes or oil ways in castings and fabrications.
When the process is complete the basket rises to the freeboard area where the condensation coils are located, and parts are allowed to drain and dry. The tank seal opens to allow the basket into the load section while the lid closes again across the process tank. A fan is then activated which produces a negative vacuum in the load area. The loading door is then partially opened to allow a flow of air through the loading section which is exhausted to atmosphere or can be recycled through carbon absorption systems if no external exhaust is preferred. As baskets entering the loading space contain parts drained and dried only very small amounts of solvent are carried in the exhausted air which is monitored to ensure compliance with local legislation. When this is achieved the door opens fully for removal of basket. The loading section can be fitted with top or side sealed doors allowing baskets to flow through on conveyor systems or be loaded from hoists. No solvent enters the work area. Both processes will produce parts cleaned to the highest standards but the choice of which offers the best solution needs a little more consideration.
The single tank process is complicated with the need to move liquids in the machine. It is relatively slow as the carbon adsorption process needs to remove high levels of solvent from the recirculated airstream from the process tank. This is inefficient as adsorption rates for carbon fall rapidly with increasing saturation. Final levels of solvent in the tank when the lid opens will be dragged into the workshop and the area in which the operator is working. Long process cycles reduce throughput.
The simpler multilevel systems where movement of liquids is not required are more efficient and offer much faster process times. Cost of manufacture is also cheaper as no liquid movement is involved. The extracted loading section ensures no leakage of solvent into the work area which offers complete safety for operators and factory staff. The disadvantage of the multilevel machine is the height of the equipment compared to the single tank machine. This will often require the equipment be installed in a pit for easy access.
Both designs of process machines fully comply with the emission regulations of the UK, EU and U.S authorities. Which to choose will depend on many factors which should be discussed with both the equipment and solvent suppliers who have the experience to advise on which offers the best process for the application. Equipment and solvent must work together and it is advisable to ensure that the suppliers work closely together to offer a package with high levels of responsible care and product stewardship to ensure the best and safest installation.
The vapour cleaning process still gives the highest levels of economical cleaning with minimum energy usage, low footprint on the factory floor, safety for the operator, and high production rates with low solvent usage or environmental impact. With the new generation of sealed cleaning machines its future as the process of choice is assured.
Envirotech Europe supplies three distinct products that use this process and we are happy to advise you on the best solution to suit your needs. Please visit our website to find out more about ProSolv 5408e, ProSolv and EnSolv® CC-A.
Image of Solvac hermetically sealed equipment by kind permission of CC Hydrosonics Ltd.
FURTHER INFORMATION
Please visit our website www.envirotech-europe.com for information about other uses and applications for our vapour degreasing and cleaning products.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
For more advice, please telephone us on +44 (0) 20 8281 6370 or use our contact form. All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Electrical corrosion protection
Electrical corrosion protection – Prevent hydrogen sulphide corrosion in electrical and electronic equipment
Super CORR A is a proven and cost-effective way to prevent or inhibit corrosion from destroying electronics and electrical components. Adverse work environments where corrosive gases such as hydrogen sulphide are found, can cause severe corrosion and rapid deterioration of electronic components and equipment, including connectors and switches.
Lost productivity and revenue caused by plant and equipment downtime
Corrosion, in its many forms, costs both private and public sectors hundreds of billions of Euros a year to repair or replace electrical, electronics, or avionic components because of failures caused by corrosion. While all metals corrode, due to a number of different factors, there is no simple or single solution to the overall corrosion problem. However there are some very cost effective and proven ways to prevent corrosion and failures caused by corrosion and thereby reducing or eliminating associated costs and increasing safety which should be foremost in the mind set of any preventative maintenance programme manager.
Super CORR Awas specifically designed to lubricate and prevent corrosion in electrical fittings and connectors; electrical and avionic harness assemblies and connectors; electrical and electronic switches; close tolerance and dissimilar metal components; lighting connectors and sockets. A unique non-flammable “self-healing” ultra-thin film lubricant with a proprietary corrosion preventive compound that will not harden or crack, is not a wax or oil-based product and is formulated without sulphates, chlorides or halogens.
Super CORR A inhibits corrosion caused by exposure to both fresh and salt water moisture as well as the corrosive vapours from Sulphur dioxide (SO2), Nitrogen dioxide (NO2), Hydrogen Sulphide (H2S), Ammonia (NH3), and Chlorine (CL12) based gases found in waste water and sewer treatment plants, pulp and paper mills and plants, chemical and petroleum plants, maritime industry, aircraft/airline industry, military equipment including ships, aircraft, and rolling stock, auto industry, farming and agriculture industry, and the list goes on.
Super CORR A extends the working life of electrical components and systems and other critical items by preventing the deterioration and/or failure caused by corrosion and can significantly reduce downtime, operating and maintenance costs as well as enhance safety. An ultra-thin film, water displacing lubricant and corrosion inhibiting compound Super CORR A has undergone extensive testing by Battelle Labs as well as the U.S. Air Force and meets MIL-DTL-87177B (revised MIL-L-87177A) specification. SuperCORR-A is used by NATO (NATO NSN 8030-99-226-6966) to protect avionic, electrical, electronics, electrical switches and connectors and components from corrosion in both the military and civilian aircraft. Savings for the U.S. government alone is estimated to be in excess of $50 million per year.
Super CORR Aprovides a superior lubrication coefficient and protects components against moisture, wear, general and fretting corrosion, surface static electricity, corona, and other electromigration problems. The super thin non-flammable lubricant film is only 7 microns (0.00028 inch) thick and is formulated to meet the RoHS directive. It is unexcelled in preventing deterioration and contamination on all surfaces of electronic equipment.
The question for you is: What is the cost of NOT using Super CORR A in your preventative maintenance programme?
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/supercorr-a for for information about other uses and applications for Super CORR A.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
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ProSolv®5408e vapour degreasing solvent cleaner for flushing refrigeration pipeline systems
Vapour degreasing solvent cleaner for flushing refrigeration pipeline systems
Concerns connected with the challenging environmental profile of traditional refrigerant gases have led to changes in legislation which are a driving factor in phase-outs and bans on the use of some gases to remove the older materials typically with high ozone depletion (ODP) and global warming potential (GWP). Systems can be replaced or refurbished with new models using compressors able to use more sustainable and acceptable gases. The evolving trend to newer refrigerants continues as the chemistries develop. The refrigerant R-22, which itself was an improvement over earlier refrigerants, is phased out and replaced with R-410a and other alternatives based on HFOs are being marketed.
Retrofitting of current refrigeration systems to accommodate the new developments is not straightforward as most refrigerant gases are not cross-compatible, so the necessity to completely remove all traces of the older versions from the system, including refrigerant lines is essential.
Of course, where possible it’s best simply to replace existing lines with new ones. However, it’s not always possible to do this cost-effectively, especially when the old piping runs under floors or through walls. In such cases thoroughly flushing existing pipework is especially important because even tiny traces of impurities left in the lines can damage new equipment and lead to compressor failure.
THE PERFECT SOLVENT FOR FLUSH CLEANING REFRIGERATION PIPEWORK
Your first step to proper pipework flushing is to select the right solvent. The solvent you choose must be highly effective at dissolving oil grease and other contaminants, to ensure that all residue is removed from the pipes and must be sustainable, environmentally friendly and comply with current legislation.
ProSolv 5408e is the ideal solution to this problem with a profile of properties and advantages making it perfect as your solvent of choice for refrigerant pipeline flushing.
• No flash point Non flammable liquid.
• High specific gravity gives a high soil suspension loading.
• High solvency strength with a KB value of 98.
• Powerful cleaning agent that can flush lines fast, dissolving oil and grease releasing soils from the inner surfaces of pipelines and fittings
• Volatile for fast evaporation. Removing ALL solvent from the pipework after flushing is vital, very volatile so evaporates fast.
• Environmentally responsible. ProSolv 5408e is sustainable and kind to the environment with very low global warming potential, zero ozone depleting potential (ODP).
• Safe for operators when user conditions are followed.
• Economical as it is easily distilled for reuse. No testing or stabilisation required.
PROCEDURE FOR FLUSH CLEANING REFRIGERANT PIPELINES WITH ProSolv®5408e
Of course, simply replacing old piping is the only way to be 100 percent sure that your lines are clean. But in retrofit situations where complete replacement is not possible, flushing the lines with ProSolv 5408e solvent is the best alternative solution for the protection and long working life of your refrigeration system upgrade.
1 – Remove any obstacles. Any equipment and components such as valve, filters and expansion valves that might obstruct the line should be removed prior to the purge.
2 – Pre-flush. This will dislodge any loose debris from the sides of the lines enabling more effective use of the solvent, oil free air or nitrogen at 120 psi is recommended. It’s also good practice to oscillate the pressure to encourage dislodging of debris.
3 – Preparing the pipework. Reducing the length of piping can be more effective due to the pressure loss in long lengths. Section the operation into 15 metre lengths by cutting pipes where necessary. One end of the pipe must be fitted with a connector for the pipe to the nitrogen supply while the exit needs a restrictor valve to allow variable pressures to shock loose particles from internal walls.
IMPORTANT – Flushing with solvent. Refer to ProSolv 5408e Safety Data Sheets for advice on operator protection using solvents.
4 – Safe working. Full PPE with suitable eye protection goggles and gloves must be worn. Solvent fumes are heavier than air and exposure levels can easily be reached working in pits or enclosed spaces. Always institute a ‘buddy system’ and use air fed face masks with attached line.
5 – Delivering solvent. Use a drum pump electric or hand operated with a flexible tube connection for delivering the solvent to the open end of the pipe or tubing to flush the internal surfaces. Using a fresh drum of ProSolv®5408e connect drum pump and the delivery tube to the end of pipe/tube to be cleaned using a pre-fitted screwed or compression fitting.
6 – Drainage and Testing. The drainage end of the pipe or tube should be fitted with a flexible tube into a tank or drain sump allowing samples to be taken in a glass bottle or tube at regular intervals to be sure when no particles or soils are being expelled. The colour of the solvent will change as oil and soluble contaminants are removed and flushing must continue until the flow is totally clear and water white.
7 – Post-flush. ProSolv 5408e solvent is volatile so will dry completely using an oil free airline or nitrogen supply connected to the end of the cleaned pipe/tubing.
8 – A wipe of the pipe/tubing surface at the inlet and outlet using solvent saturated lint free cloth completes the cleaning. If not connected immediately to other parts of the system enclose both ends of cleaned item to prevent recontamination.
Used ProSolv 5408e should not be reused for flushing but can be recovered for reuse by a simple distillation process. Removal from site should use licensed disposal companies.
Further information:
For more information and advice please contact us by telephone on +44 (0) 20 8281 6370 or use our contact form. All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
ProSolv 5408e is not just flushing refrigeration pipeline systems,
https://www.vapour-degreasing.com/prosolv5408e/ for information about other applications.
We can provide you with a Material Safety Data Sheets, independent laboratory reports, product samples and technical assistance..
For more information or advice please telephone us on +44 (0) 20 8281 6370 or use our contact form.
All of our products are manufactured, supplied and supported by EnviroTech Europe Ltd and are available on short delivery times through our dedicated team of distributors worldwide.
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VOC Exposure Monitoring
Exposure monitoring – Reassurance that your equipment is functioning within agreed safety margins.
Envirotech Europe has always considered it has a duty of care to its loyal and new customers and VOC monitoring is an issue we take seriously. As an employer, it’s your job to ensure that you correctly control the personal exposure levels of staff to a wide range of chemicals, substances and even radiation.
The Control of Substances Hazardous to Health (COSHH) Regulations 2002 places a duty on the employers to undertake assessments to evaluate the risks to health when using hazardous substances in the workplace.
We have portable test equipment that logs the Volatile Organic Compound (VOC’s) content in the air from various strategic positions around your degreasing equipment, including the operator position.
This kit is based on very accurate photoionization detectors (PID) designed to constantly log the quality of the atmosphere and keep your workers safe.
We would generally test for a full shift, analyse the data and report back within a few weeks with any suggestions for improvement.
Reassurance that your equipment is functioning within agreed safety margins and that any emissions into the working environment surrounding the machine are within prescribed limits.
A check that the ProSolv 5408e, EnSolv® CC-A or ProSolv system is operating economically and with the minimum of wastage. We can still carry out the testing for you even if you are using an alternative solvent.
FURTHER INFORMATION
For more information please contact: sales@envirotech-europe.com
Please visit www.envirotech-europe.com for information about uses and applications for all EnviroTech Europe products.
For more advice, please telephone us on +44 (0) 20 8281 6370 or use our website contact form.
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Vapour degreasing solvent for precision parts cleaning
EnSolv® CC-A vapour degreasing solvent for precision parts cleaning
The EnSolv® CC-A formulation for precision parts cleaning responds to the need for high performance vapour degreasing solvents for critical cleaning in general engineering, aerospace, medical optical and electrical industries.
EnSolv® CC-A removes cutting oils, lubricants, lapping compounds grinding pastes and water based cutting oils or fluids. This complex synergistic blend utilises environmentally compliant solvents combined with selected surfactants to remove oils and lubricants to the highest standards for critical cleaning applications and releases and suspends inorganic solids and soils such as fingerprints, polishing compounds and grinding paste from finely finished and highly polished surfaces such as stainless steel and plated parts, optical lenses and components for medical appliances.
IMPROVES PRODUCTIVITY AND OPERATING ENVIRONMENT
Suitable for processing temperature sensitive components as well as the conventional engineering substrates. The very low surface tension cleans through holes on castings and penetrates between overlapping metal spot welds eliminating oil leaching in paint and powder coatings during oven curing.
Easy handling – Cleaned components are dry and comfortable to handle immediately at the ideal temperature for painting or powder coating. No time lost waiting for parts to cool which allows immediate quality control testing or assembly of machined parts due to minimal dimensional changes.
Cleaning cycles reduced, productivity improved with output doubled compared to conventional solvents.
Minimises flash rusting on mild steel cleaned components due to the advanced stabiliser/inhibitor package compared to alternative formulations.
Compatible with mixed metal components. No staining of yellow metals, bronze, copper, aluminium.
Reduced maintenance – unique additive suspends contaminants in boiling solvent sump preventing tar formation and continuously cleans heating surfaces. Longer periods between cleanouts reduces labour costs and solvent losses.
Talk to us about whether EnSolv® CC-A is the best choice for your application. Advice, literature, changeover instructions are all available to make the change quickly, easily and at no extra cost of usage.
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/ensolvcc-a for information about other uses and applications.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
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Corrosion protection – Reduce fretting corrosion
Corrosion protection – SuperCORR A helps to reduce fretting corrosion on gas turbine connectors.
LP Gas Turbines are used throughout the world by extraction industries and manufacturing plants in remote and hostile locations for essential power production. Dusty and wet environments in deserts, mines, grinding mills, pulp and paper mills and on land or sea drilling rigs for gas and oil production. Turbines powering aircraft services while stationary connect and disconnect many times a day in extreme conditions. These applications and locations test connector sealing continuously allowing dust or water to penetrate. This with the flexing of the connecting cables allows sufficient movement between the metal surfaces of the connecting pins to produce fretting corrosion which reduces, interrupts or produces failures in supply. Regular maintenance of electrical connectors is essential to be certain of uninterrupted supply.
RUB TEST RESULTS
Super CORR A is an aerosol lubricant containing corrosion preventive compounds.
A manufacturer of connectors tested Super CORR A to see what the “life” of the lubricant was in a “rub test”. The typical test is 20,000 cycles, i.e. unplug, plug in is one cycle. The test results demonstrated that after 20,000 cycles there were no failures. It was decided to take it one more step and run the same tests for 200,000 cycles. The results again showed no indications of galling or scoring on the connectors at all. The connector looked and tested as good as new. This test was run under clean conditions in a laboratory but demonstrates the effectiveness Super CORR A.
As it meets Mil MIL-DTL-87177B (revised MIL-L-87177A) specifications it is used by the U.S. Air Force to protect the intricate workings of the F-16 and F-15 fighter jets and by the U.S. Navy on the P 3 Orion electronic surveillance aircraft. Savings for the U.S. government is estimated at $50 million per year. Commercial Aviation aircraft manufacturers recommend it for avionics and electrical switches and connectors and close mechanical application, especially where flights are in salt fog or high humidity.
Containing extremely long-lasting, proprietary anti-corrosive inhibitors Super CORR A provides a superior lubrication coefficient and protects components against moisture, wear, general and fretting corrosion, surface static electricity, corona, and other electromigration problems. The super thin non-flammable lubricant film is only 7 microns (0.007mm) thick and is formulated without sulphates, chlorides or halogens to meet the RoHS directive. It is unexcelled in preventing deterioration and contamination on all surfaces of electronic equipment.
Very fast drying, environmentally acceptable solvents are used as carriers and propellants which will not affect most plastics, substrates, metals or other materials used in connector manufacture. The aerosols are supplied with probes which allow access to pins and connector tubes where the low surface tension repels water, dirt dust and metal particles from blind holes and surfaces to produce thoroughly clean holes and surfaces before a second application applies the lubricant film. Reconnection to the supply with cleaned sections of the connector ensures reliable operation even in the most testing of environments. One can of Super CORR A allows this essential task to be carried out in any conditions quickly, easily and securely.
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/supercorr-a for for information about other uses and applications for Super CORR A.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
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Methylene chloride based vapour degreasing solvent with a unique blend of surfactants giving it superior cleaning quality
EnSolv® CC-A is a methylene chloride based vapour degreasing solvent with a unique blend of surfactants giving it superior cleaning quality
EnSolv® CC-A responds to the need for high performance vapour degreasing solvents for critical cleaning in general engineering, aerospace, medical optical and electrical industries. It builds on 30 years of experience supplying the EnSolv® range of powerful and reliable vapour degreasing solvents to industries worldwide
EnSolv® CC-A removes cutting oils, lubricants, lapping compounds grinding pastes and water based cutting oils or fluids. This complex synergistic blend utilises environmentally compliant solvents combined with selected surfactants to remove oils and lubricants to the highest standards for critical cleaning applications and releases and suspends inorganic solids and soils such as fingerprints, polishing compounds and grinding paste from finely finished and highly polished surfaces such as stainless steel and plated parts, optical lenses and components for medical appliances.
SAFE FOR USERS AND THE ENVIRONMENT
Environmentally friendly cleaning all the constituents of EnSolv® CC-A are environment friendly and compliant with REACH. This proprietary blend has no global warming potential (GWP) no ozone depletion potential (ODP) does not produce ozone at ground level and is biodegradable. EnSolv® CC-A addresses many of the problems faced by the engineering industries in meeting environmental legislation.
Easily biodegradable all the components of the EnSolv® CC-A formulation are widely used in industry but only trace elements have been detected in atmosphere and they are not detectable in rivers, oceans or ground water. This is attributed to its high volatility and biodegradability by naturally occurring organisms. Released into the atmosphere it is photochemically degraded reacting with naturally occurring hydroxyl radicals producing only carbon dioxide and hydrogen chloride simple chemicals already present in the environment.
No depletion of the ozone layer and no global warming. EnSolv® CC-A has an atmospheric lifetime of only 6 months and does not accumulate in the atmosphere so is not transported into the ozone layer. The most urgent challenge for the future is reduction of gases which produce global warming. The solvents and any breakdown products of this formulation do not produce greenhouse gases and the reduced energy needs of vapour degreasing with EnSolv® CC-A lower the power station production of CO2 for equivalent work throughput.
No ground level ozone production – authorities are becoming increasingly concerned at ground level pollution causing increased asthma and bronchial diseases much of it due to photochemical production of Ozone affecting children and adults. EnSolv® CC-A has a minimal impact on ozone formation with an extremely low photochemical ozone creation potential (POCP).
Reduced solvent emissions (VOCs). Improving air quality is a high priority for the European Union and governments worldwide with the elimination of VOCs as a high priority. The use of EnSolv® CC-A with its excellent environmental profile assists the engineering industry to meet increasingly severe environmental legislation on solvent emissions allowing continued use of vapour degreasing with all the production benefits it offers.
PRODUCT BENEFITS
Designed for vapour degreasing
Removes oil, grease and soils fast
Simple drop-in replacement for n-propyl bromide and trichloroethylene
Low surface tension
Reduced costs
Compatible with all metals
User friendly
Increased production
Faster cleaning cycles
Components easily handled after cleaning
Safe for the environment
FURTHER INFORMATION
Please visit our website https://www.envirotech-europe.com/ensolvcc-a for information about other uses and applications.
Visit www.envirotech-europe.com/applications-and-case-studies for information about uses and applications for all EnviroTech Europe products.
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