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Toxics Use Reduction Institute RI Workshop: Tools for TCE Substitution Hands-On Training from the TURI Lab Jason Marshall – Laboratory Director Heidi Wilcox.

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Presentation on theme: "Toxics Use Reduction Institute RI Workshop: Tools for TCE Substitution Hands-On Training from the TURI Lab Jason Marshall – Laboratory Director Heidi Wilcox."— Presentation transcript:

1 Toxics Use Reduction Institute 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 - 9:00Registration and Refreshments 9:00 - 9:05Introduction & Overview 9:05 - 9:15Choosing an Alternative 9:15 - 9:25Past TCE Work 9:25 - 9:35Success Stories from RI 9: :15Other Resources Available 10: :20Break 10: :25Hands-on Cleaning 12: :30Next Steps

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

4 TURI-Lab –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) 0-24Good 25-49Good 50-74Okay 75-99Okay Okay Fair Fair 300Poor >350Poor GWP Values GWP = 0Good GWP = 1 (CO2)Okay All others =Poor ODP Values ODP = 0Good All others =Poor

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

10 Example Screening Values Solvent Alkaline Aqueous Product NameIndicatorValueComments Perchloroethylene VOC1620g/lPoor GWP0Good ODP0Good HMIS H2 HMIS F0 Okay HMIS R0 pHNAGood Product NameIndicatorValueComments Brulin Formula 815 GD VOC1.1 g/lGood GWP0Good ODP0Good HMIS H1 HMIS F0Good HMIS R0 pH11.6Okay

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 ( ) –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 Aqueous23 Caustic1 Ester3 HCFC1 Neutral Aqueous2 Organic1 Petroleum Distillate3 Semi-Aqueous2 Terpene5 Terpene-Organic1 Terpene-Semi-Aqueous2

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 Workshop Fall 2006 –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 Alternative Tested Parts Cleaned Part description Contaminant removed Process US Polychem Corporation Polyspray Jet 790 XS Brass bracket Buffing compound Ultrasonic US Polychem Corporation Polyspray Jet 790 XS Brass rifle pin Buffing compound Ultrasonic US Polychem Corporation Polyspray Jet 790 XS Thin brass buckle Buffing compound Ultrasonic RI Parts Cleaned

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

31 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 Buffing compound Low Pressure Spray; Ultrasonic Alconox Inc Detergent 8 US Polychem Corporation Polyspray Jet 790 XS 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 RI Parts Cleaned

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

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 OilUltrasonics US Polychem Corporation Polyspray Jet 790 XS Nickel, Chrome Buffing compound Ultrasonics

34 RI Parts Cleaned Bio Chem Systems Bio T Max Stainless steel parts Buffing Compound Ultrasonics Bio Chem Systems 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 –

42 Overall TCE Reduction All Companies from –46 companies –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 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 –Measure how effective your current process is –Compare the alternatives Test the Alternatives –Dilutions to use –Hot or cold –Equipment –Time –Rinsing –Drying

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

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

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


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