Reducing solvent wastes through on-site recycling is currently one of the most important elements of pollution prevention (P2) programs nationwide. All generators of solvent wastes can profit by reducing the costs associated with waste disposal. Recycling solvents will also reduce the cost or need to purchase virgin solvents as well as reducing storage and management costs.
Distillation Process Overview This is a process which is used to separate solvents from contaminating materials. Example: a mixture of alcohol, paint thinner and paint resins. The process consists of heating the mixture to boil off the alcohol and paint thinner, leaving just the paint resins behind in the boiling tank. The alcohol and paint thinner vapors are then condensed back to a liquid mixture of alcohol and paint thinner.
Simple Distillation does not use a reflux column. All solvent vapors travel directly from the boiling tank to the condenser, and the non-volatile contaminants are left behind in the boiling tank. Simple Distillation
"Fractional Distillation" utilizes a specially packed column (reflux column) placed between the boiling tank and the condenser. As solvent vapors travel upward from the boiling tank through the reflux column to the condenser, they are purified and separated. Solvent recoveries approach 99.5% as CBG systems are "closed systems". Solvent purities often approach 100%, depending upon what the other solvents were in the original mixture. Fractional Distillation
CBG Technologies recycling systems are versatile. In addition to recycling traditional chemical solvents, our recyclers have built in Water Concentration systems. This can be effectively used to recycle large portions of water. This means the water can now be disposed down a drain or reused. The remaining concentrated waste will contain a much lower volume of contaminant since the water is no longer present. Therefore, this will result in significantly lower monthly disposal costs.
Simple Distillation cannot separate varied volatile components from a waste stream. All solvent components will be recovered together. Often the recycled material will have a purity of only 90% - 95%. During the boiling process in Simple Distillation, many micro-droplets of the contaminants are carried upward along with the solvent vapors into the condenser. The result is that the recycled solvent is still contaminated with as much as 4-5% of the contaminant. This is the difference of not having a reflux column present in Fractional Distillation, which yields a purity of near 100% for the recycled solvent. In some applications, these disadvantages are a non issue. In these cases Fractional Distillation is not needed. Example: Simple Distillation can be used to recycle solvents used to clean paint lines, flush guns or remove fiberglass resins from equipment as long as purity is a non issue. However, whenever recycled solvents need to be either very clean and/or separated from one another, then Fractional Distillation must be used.
Simple Distillation UL 2208 listed 6-gallon heavy-duty 304 stainless steel boiling tank Vacuum-assist option available for higher boiling solvents Air cooled; no water connections required Chillers available for low boiling solvents Multiple redundant safety features with automatic shutoffs; meets OSHA standards No hard-wiring or special ventilation needed Bag-lined tank allows easy removal of solid contaminants Mobile – mounted on locking wheels for easy relocation Electric fill-pump (optional) Quiet operation Designed and manufactured in the USA by CBG Technologies SPECIFICATIONS: Easily self installed to a standard connection: 220-240V (120V available upon request) Small Operating Footprint – 40.25 w x 39 l x 36 h
UL 2208 listed Class1 Div 1 Explosion-Proof available 15 Gallon 304 stainless steel tank Simple Distillation High purity recovered solvents Waste removal versatility – tank drain for liquids and bag function for solids Batch style or optional continuous feed processing Manual or optional automatic filling Air cooled; no water connections required (chillers available for low boiling solvents) Multiple redundant safety features with automatic shutoffs; meets OSHA standards Microprocessor controlled with user friendly LCD display and prompts Easily modified programming for special solvent requirements or additional solvents Designed to be operated on multiple shifts Mounted on wheels for enhanced flexibility or legs for fixed locations Designed and Manufactured in the USA by CBG Technologies Specifications Electrical hookup: 220/240 Volt, 3-phase (20 amp); 440/480 Volt configuration available Small footprint – 30 wide x 48 deep x 50 high Operating volume – 15 gallons up to 2 runs per day
UL 2208 listed Class1 Div 1 Explosion-Proof available 30 Gallon 304 stainless steel tank Simple Distillation High purity recovered solvents Waste removal versatility – tank drain for liquids and bag function for solids Batch style or optional continuous feed processing Manual or optional automatic filling Air cooled; no water connections required (chillers available for low boiling solvents) Multiple redundant safety features with automatic shutoffs; meets OSHA standards Microprocessor controlled with easy read LCD display Easily modified programming for special solvent requirements or additional solvents Designed to be operated on multiple shifts Unlimited usage from one batch of solvent Designed and Manufactured in the USA by CBG Technologies Specifications Electrical hookup: 220/240 Volt, 3-Phase; 440/480 Volt configuration available Small footprint – 30 wide x 48 deep x 69 high Operating volume – 30 gallons up to 2 runs per day
UL 2208 listed Class1 Div 1 Explosion-Proof available Simple Distillation (Fractional Distillation in development) 60-gallon heavy-duty 304 stainless steel boiling tank and condenser Semi-continuous operation – with a precision float system Fast and easy filling– foot-operated high-speed (20 GPM) fill pump High-speed removal pump included for liquid wastes TechnoClean Tilt System® – for quick and easy removal of disposable bags TechnoClean Vapor Purifying System® – provides cleaner effluents Microprocessor controlled – with user-friendly LCD display and prompts Multiple redundant safety features with automatic shutoffs; meets OSHA standards Air cooled; no water connections required (chillers available for low boiling solvents) Closed loop system operation Oil-jacketed tank – for indirect evenly dispersed thermal heating Solvent-resistant, powder-coated, heavy-duty steel cabinetry Oil/water separator available upon request SPECIFICATIONS: 440/480 V, 3 phase 60 wide x 76 long x 75 tall (152 cm x 193 cm x 190 cm) Operating volume – 60 gallons (230 liters), up to 2 runs per day Average output: 6+ gal (24 L)/hr
UL 2208 listed Class1 Div 1 Explosion-Proof available Fractional Distillation 8-gallon heavy-duty 304 stainless steel boiling tank Purity of solvents up to 99.5% Built for hazardous and non-hazardous placement Waste removal versatility – tank drain for liquids and bag function for solids Batch style or continuous feed processing Manual or automatic filling Air cooled; no water connections required (chillers available for low boiling solvents) Multiple redundant safety features with automatic shutoffs; meets OSHA standards Microprocessor controlled, with user friendly LCD display and prompts Easily modified programming for special solvent requirements or additional solvents Can be operated on multiple shifts Mounted on wheels for enhanced flexibility and mobility (*stationary model available) Designed and manufactured in the USA by CBG Technologies SPECIFICATIONS: Electrical hookup: 220V, 3 phase (208V, 1 phase or 480V, 3 phase available upon request) Small Operating Footprint – 34 1/8 wide x 54 1/8 deep x 68 1/4 high Operating volume – 8 gallons up to 2 runs per day Average output: 2+ gal (8 L)/hr
UL 2208 listed Class1 Div 1 Explosion-Proof available 25-gallon heavy-duty 304 stainless steel boiling tank Simple or Fractional Distillation Built for hazardous and non-hazardous environments Purity of solvents up to 99.5% Waste removal versatility – tank drain for liquids and bag function for solids Batch style or continuous feed processing Manual or automatic filling Air cooled; no water connections required (chillers available for low boiling solvents) Multiple redundant safety features with automatic shutoffs; meets OSHA standards Microprocessor controlled, with user friendly LCD display and prompts Easily modified programming for special solvent requirements or additional solvents Can be operated on multiple shifts Designed and manufactured in the USA by CBG Technologies SPECIFICATIONS: Electrical hookup: 220/240 V, 3 Phase (440/480 V, 3 Phase available upon request) Footprint – 37 wide x 60 deep x 111.5 high (120 high with extended legs option) Operating volume – 25 gallons up to 2 runs per day Average output: 4+ gal (16 L)/hr
Project Date: 8/3/08 Industry: Contract Production Coatings Region: Midwest (WI) Waste Streams: 1- MEK/Paint 2- Xylene/Paint 3- Lacquer Thinner/Paint Project Focus: Recover Line-flush/gun cleaning solvent for reuse Project Objectives: A) Drastically reduce costs associated with purchase and disposal of solvents B) Lower waste generator status
Current Solvent Usage & Disposal Costs 8/3/2008 MEKXyleneLacquer Thinner Annual Usage:3,900 Gallons1,820 Gallons Cost Per Gallon:$7.18$6.38$5.18 Cost Per Drum:$394.90$350.90$284.90 Total Solvent Cost: $28,002$11,612$9,428 Total Disposal Cost $9,945$4,641 Total Combined Cost:$37,947$16,253$14,069 Projected Savings with a TechnoClean Recycler Total Annual Costs: $37,947$16,253$14,069 Projected Recovery x 95% x 90% Annual Savings:$36,050$15,440$14,069 Combined Annual Costs: $68,269 ($5,689/monthly) Return on Investment : 5 Months Combined Annual Savings: $64,856 ($5,405/monthly)
Project Date: 4/16/08 Industry: Optical Lens Manufacturing ( ISO) Government Contractor Region: West (OR) Waste Streams: 1- Acetone/Paint 2- Alcohol/Paraffin 3- Lacquer Thinner/Paint 4- Xylene/Paraffin 5- Mineral Spirits/Paint Project Focus: Recover all cleaning solvent for reuse Safety: Operate the system in a Explosion Proof Room ( C1D1 Requirement) Project Objectives: A) Drastically reduce costs associated with purchase and disposal of solvents B) Stabilize waste generator status
Current Solvent Usage & Disposal Costs 4/16/08 AcetoneAlcoholLacquer Thinner Mineral Spirits Xylene Annual Usage:27,132 Liters 45,510 Liters 13,893 Liters14,760410 Liters Cost Per Liter:$2.75$1.40$1.21$1.38$1.52 Total Solvent Cost:$74,613$63,714$16,811$20,369$623 Total Disposal Cost:$11,677$19,883$3,280$4,715$60 Total Combined Cost: $86,290$83,597 $20,091$25,084$683 Projected Savings with a TechnoClean Recycler Total Annual Costs: $86,290$83,597 $20,091$25,084 $683 *Projected Recoveryx 88% x 90% x 95% Annual Savings:$75,935$73,565 $18,082$22,576$649 Combined Annual Costs: $215,745 ($17,979/monthly) Multiple Unit Purchase : $76,530 Combined Annual Savings: $190,807 ($15,901/monthly) Annual Savings: $190,807 Return On Investment: 3.3 Months *Recovery percentage accounts for evaporation and misuse
Recycling of Isopropyl Alcohol A manufacturer of hearing aids in Minnesota uses isopropyl alcohol to clean laser-formed plastic parts. The solvent waste stream was comprised of isopropyl alcohol contaminated with plastic resin particulate. While alcohol waste volumes were a modest 120 gallons per month, stringent regulatory oversight compelled the manufacturer to devise a solvent management program. The manufacturer needed a solvent recycler that was compact and mobile, yet capable of processing sticky plastic resin residue. In addition to those requirements, the unit also had to yield a high-purity recovered product. After successfully testing several waste samples, CBG's engineers designed and built the TechnoClean solvent recycler to their specifications. This model combined the smaller footprint and mobility of a laboratory unit with the heavy-duty processing capabilities of a stationary industrial unit. The polyethylene bag tank liner captured the problematic, sticky resin, allowing for safe and easy handling of the residue. The units fractional distillation column resulted in a much higher purity and concentration of the recovered product than could have been achieved by a simple distillation approach. Implementation of the CBG TechnoClean solvent recycler resulted in a 90% reduction in solvent purchasing and disposal, as well as lowering their waste generator status. The customers payback was achieved within 10 months.
Recycling Multiple Solvent Waste Streams An electronic circuit board manufacturer in New Jersey uses three different solvents for various cleaning applications, and they needed to reduce both their costs and their EPA reporting levels. The three different waste streams were: (i) A suspension of silicon primer and dust in alcohol; (ii) a solution of oil in a mineral spirits solvent; and (iii) a solution of ink in acetone. The costs for new solvent and the disposal of the different wastes was almost $125,000 per year. The manufacturer needed to recover these three solvents at high purity, at high recovery levels, and free of the other solvents. There also were several safety concerns including the need for a Class I Division II recycler, and the need for a virtually automatic operation. After successfully recycling samples of their solvent wastes, CBG Technologies installed an 25 gallon solvent recycler having a conical Teflon-lined boiling tank. The recycler was capable of recycling all three of these waste streams (one at a time), and its computer had separate programs for each waste stream. The recycler uses Fractional Distillation in order to obtain the higher purities and good separations that are needed by the customer. The Teflon lining in the boiling tank permits viscous wastes to be easily drained at the end of a run. The built-in safety features provided the necessary comfort for the customer, and an auto-fill attachment minimized the need to continually add solvent wastes. The payback on investment was achieved in less than 6 months, and their EPA issues were greatly reduced.
Is the system safe? Yes! all CBG Recycling systems are UL2208 listed with additional multiple safety features built in. Automatic shutdown sensors and pressure relief valves are a standard on the TechnoClean systems. For those customers who want to recycle, but need to operate a recycler in a Hazardous setting, CBG offers Class1 Div 1 for these specific needs. Will the recycled solvent meet or exceed virgin purchased specifications? Yes, with every cycle, as long as the system is operated correctly and according to the provided users manual. The quality of the recycled solvent will not contain any contaminant-based color. What, if any permitting is required to operate a TechnoClean recycling system? No special or additional permitting is required under Federal EPA Laws The recycling process itself is exempt from RCRA regulations found under 40#CFR 261.4 (a)(8) Storage of hazardous waste is still regulated in the same manner. Can I recycle solvents in the State of California without permitting? Yes, the only district that has restrictions on the amount of solvent that can be recycled is the SCAQMD South Coast Air Quality Management District. The rule stated below is applicable to all cities within the district. Page 219-21 rule 6: Closed loop solvent recovery systems used for recovery of waste solvent generated on-site using refrigerated or liquid-cooled condenser, or air-cooled (where the solvent reservoir capacity is less than 10 gallons) condenser. Furthermore a company may choose to recycle more than the mandated 10 gallon maximum capacity by obtaining the proper permitting that will allow them to do so. Outside of this district all other districts can recycle without permitting with almost unlimited volumes.
Will the leftover material after the recycling process be considered Hazardous Waste? Yes. The only two products that result from recycling process are the recovered solvent and the recovered waste. You are simply separating the two existing components. Disposal of the recovered waste will be handled In the same manner used prior to recycling. Is there any special expertise required to operate the recycling system? No. A relatively untrained person can easily operate the recycler. CBG offers the option for onsite installation and training for all who wish to receive it. How much operator time is needed to run the recycling system? You can expect to spend roughly 15 minutes per day, This accounts for loading the solvent/waste into the recycler, closing the lid and hitting the start button. At this point the operator can walk away the system operation is automatic and will monitor itself including the final phase of shut down. Is there any special equipment, or containers that are needed to operate the recycler? NO. Most facilities choose to use whatever collection drum or vessel they are currently using. But if you do not currently use such containers, CBG can provide them. Typically 55 gallon drums or polypropylene vessels are used for the collection and transport of the final waste material and the same for collection of the recycled solvent. Why do I need to use a collection bag? These bags are recommended for all recycling projects that will contain a solid contaminant such as paints, inks, resins etc. These bags make it much easier for disposal of this type of final waste. What is the lifespan of the collection bag? The bags are provided in case quantities of 25. These specially designed heat resistant bags can be used several times or until a bag is filled with 20-30% with leftover solid waste after processing. The bags can be used over and over until physical signs of wearing occurs.
What is the clearance required for operation and routine maintenance on the system? This depends on the size of the transfer and recovery drums, vessels or totes used for recovery. Typically a 3 foot clearance is more than ample. What are the electrical requirements needed to operate the system? TechnoClean® S-600 220 V, 1 Ø or 120 V TechnoClean® F800 208 V, 1 Ø, 220/240 V, 3 Ø, or 440/480 V, 3 Ø TechnoClean® F/S 2500 220/240 V, 3 Ø or 440/480 V, 3 Ø TechnoClean® S6000T 440/480 V, 3 Ø What other type of utilities such as Water, Compressed air or ventilation is required for operation? None. All CBG recycling systems are air cooled and self contained. This means our units do not emit any fumes during processing. As a general rule all solvents that have a Boiling Point of 180˚C/356˚F or higher will require a vacuum assist. This is required to lower the boiling points of these solvents to maintain the integrity of the recovery bag. When working with these high boiling solvents, on site compressed air is utilized for the vacuum assist. If a customer does not have on-site compressed air, CBG can provide an electrical operated vacuum assist. *CBG can offer water cooling if requested Are there any equipment or electrical drawings/schematics available? Yes. Simply contact us and we will provide them for you. How much time is required to clean or maintain the recycler? Time spent maintaining or cleaning the recycler varies on frequency of use and consistency of waste stream. A technical review by CBG Technologies will provide you with more precise data, specifically suited to your application.
How is the Residue ( still bottoms ) removed from the systems tank? Depending on the consistency of the residue, the residue will either be collected in a specially designed heat resistant disposable bag or removed through the drain located on the bottom of the tank. If your waste contains a solid contaminant such as paint, glass, resin etc.. then CBG recommends a disposable bag for those recovery applications. If your waste is more viscous such as oil then the drain would be recommended for removal. What is the cost for repair service? All CBG TechnoClean Recyclers come with a 1 year warranty. If there ever is a need for a repair, in most cases in house maintenance personnel can perform the adjustments. If needed a CBG Technician will come on-site for a service call. CBG also offers Preventative Maintenance packages on all TechnoClean systems. Please inquire for PM pricing.
What is the expected Life span of the TechnoClean recycling system? The expected life span of the recycling system is well beyond 10 years! All CBG TechnoClean Recycling systems are built and constructed durable. The processing tanks are custom manufactured and constructed of heavy gauge stainless steel. The frame and shell casing are made from the same durable stainless steel with a superior powder coated finish to resist corrosion and rusting. CBG also uses very heavy duty heaters that provide shorter cycle times for processing, but equally important they are designed for better reliability and life span. What type of Financing options does CBG Technologies offer? We have many options available to meet just about everyones needs. The traditional method of a capital purchase with terms is by far the most popular format. However CBG can offer leasing options, such as a Fair Market Value (FMV) or a buyout option that will meet your needs. Is it more Cost effective to utilize a recycling/hauling service or purchase a TechnoClean Recycling system? Are you spending more than $300 per month in disposal costs? Are you spending more than $300 per month in virgin solvent purchasing? Are you a LQG or SQG waste generator looking to lower your status or stabilize it? Do you have 15 minutes in your day to control and lower your expenses? Then the obvious answer should be - it is more cost effective to purchase a TechnoClean Recycling System!