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: :05 Introduction & Overview
9: :15 Choosing an Alternative
9: :25 Past TCE Work
9: :35 Success Stories from RI
9: :15 Other Resources Available
10: :20 Break
10: :25 Hands-on Cleaning
12: :30 Next Steps

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

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

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 VOC content (g/l) GWP Values ODP Values 0-24 Good 25-49
50-74
Okay
75-99
Fair
300
Poor
>350
GWP Values
GWP = 0
Good
GWP = 1 (CO2)
Okay
All others =
Poor
ODP Values
ODP = 0
Good
All others =
Poor

9. HMIS/NFPA Point Assessment
Guidelines pH
0-1.0
Poor
Fair
Okay
Good
13-14
HMIS/NFPA Point Assessment
H-0 F-0 R-0
Good
H-0 F-0 R-1, H-0 F-1 R-0
H-1 F-1 R-0, H-2 F-0 R-0
H-1 F-1 R-1, H-2 F-1 R-0
Okay
H-3 F-0 R-0
Poor
H-2 F-2 R-0, H-1 F-2 R-1 
H-1 F-3 R-0
H-2 F-2 R-1
Fair
H-1 F-3 R-1, H-2 F-3 R-0
H-2 F-2 R-2 
H-3 F-3 R-0 
H-3 F-3 R-1, H-3 F-3 R-2

10. Example Screening Values
Product Name
Indicator
Value
Comments
Perchloroethylene
VOC
1620g/l
Poor
GWP
Good
ODP
HMIS H 2
HMIS F
Okay
HMIS R pH NA
Solvent
Alkaline Aqueous
Product Name
Indicator
Value
Comments
Brulin Formula 815 GD
VOC
1.1 g/l
Good
GWP
ODP
HMIS H 1
HMIS F
HMIS R pH
11.6
Okay

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 -

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

18. Previous Testing for TCE Replacement
Abrasive
1 Company in semi-conductor industry
Ceramics parts for a company that manufactures parts for the
Buffing compound
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
Class
# of Products
Alkaline Aqueous 23
Caustic 1
Ester 3
HCFC
Neutral Aqueous 2
Organic
Petroleum Distillate
Semi-Aqueous
Terpene 5
Terpene-Organic
Terpene-Semi-Aqueous

22. EPA Grant to Replace TCE & Chlorinated Solvents
Two year grant
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

23. SSL Testing ( )
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
Buffing compound
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 Second Grant 2007-8
Worked with 13 companies
On-site testing for 6
Second Grant
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 Alternative Tested Parts Cleaned Part description
Contaminant removed
Process
US Polychem Corporation Polyspray Jet 790 XS
Brass bracket
Buffing compound
Ultrasonic
Brass rifle pin
Thin brass buckle

30. RI Parts Cleaned US Polychem Corporation Polyspray Jet 790 XS
Brass dog tags
Buffing compound
Ultrasonic
Carbon Steel dog tags

31. RI Parts Cleaned US Polychem Corporation Polyspray Jet 790 XS
Brass belt buckle
Buffing compound
Ultrasonic
Alconox Inc Detergent 8
Hubbard Hall Inc Ultrasoak 127
Brass Army pins
Low Pressure Spray; Ultrasonic

32. RI Parts Cleaned Hubbard Hall Inc Ultrasoak 127 Brass Army pins
Buffing compound
Low Pressure Spray; Ultrasonic
Alconox Inc Detergent 8
US Polychem Corporation Polyspray Jet 790 XS
Brass U.S. Army pins

33. RI Parts Cleaned Micro Care Heavy Duty Degreser C Brass Parts
Buffing compound
Vapor Degreasing
Kyzen Corporation Metalnox M6960
DuPont Vertrel XP 10
Petroferm Inc Lenium CP
Warren Chemical Company Sea Wash Blue
Steel Parts
Oil
Ultrasonics
US Polychem Corporation Polyspray Jet 790 XS
Nickel, Chrome

34. RI Parts Cleaned Bio Chem Systems Bio T Max Stainless steel parts
Buffing
Compound
Ultrasonics
Solsafe 245
Dynamold Solvents Inc
DS 104
Kyzen Corporation
Optisolv OP 7168
Solvent Kleene Inc
D Greeze 500 LO

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 % 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
x113

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

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

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

44. Grab some coffee while we get set up for the fun stuff…
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. Successful Products Previously Tested
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

47. Testing Process Establish Baseline Test the Alternatives
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 Sign up for on-site testing
Arrange for soils and part pickup
Sign up for on-site testing
Schedule a visit with TURI