Investment Costs and ValueAdded Related to EnclosedSolvent Cleaning MachinesDr Donald GrayChemical Engineering DeptUniversity of Rhode IslandOTVC Costs And Emissions ReductionsAirtight Degreasers• End of pipe emissioncontrols• Slightly pressurizedcleaning chamber• Usually spray orimmersion systems• Vapor degrease at thenormal boiling point of thesolvent onlyAirless Degreasers• Pollution prevention atthe source• Vacuum to highpressure degreasing• Spray, immersion andvapor degreasingsystems• Vapor degrease attemperatures below orabove NBP of solventAdvantage In Using An OTVCDegreaser• Low capitalinvestment• Simple to operate• Long timeinvestmentrecovery for smallunitCAPITAL COSTS OF SOLVENT DEGREASING MACHINES$0$50,000$100,000$150,000$200,000$250,000$300,000$350,0000.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0SQUARE FEET OF OTVC

TOTAL COSTOTVC CAP$ENCLOSEDCAP$AIRLESSCAP$Lower Labor Requirements• Automated soak• Automated spray• Automated degreaseOPERATING COST COMPARISON$0$5,000$10,000$15,000$20,000$25,000$30,000$35,000$40,000OTVC $ AIRTIGHT DEGR $ AIRLESS DEGR $

$ / YEA R* MISCELL $REPORTING $UTILITY $LABOR $SOLV WASTE $WASTE $SOLVENT $•Automated dry•All of the above canbe multiple stepsLow Solvent Usage• Reduced cost• Exemption fromreporting• Less shipping andhandling• Less storageOPERATING COST COMPARISON$0$10,000$20,000$30,000$40,000$50,000$60,000$70,000$80,000OTVC $ AIRTIGHT DEGR $ AIRLESS DEGR $

$ / YEAR* MISCELL $REPORTING $UTILITY $LABOR $SOLV WASTE $WASTE $SOLVENT $RETURNINFO RMATIONEPA MODELS DEGREASER SIZE 4.6SQ FEETOVERALL COST COMPARISONSALL $ IS COST / YEAROTVC $ AIRTIGHT DEGR $ AIRLESS DEGR $SOLVENT $$24,870 $7,485 $330WASTE $$420 $420 $341SOLV WASTE $$8,262 $8,262 $206LABOR $$23,526 $11,700 $11,700UTILITY $$332 $332 $990REPORTING $$583 $525 $500* MISCELL $$12,974 $8,790 $2,695TOTAL OPER $$70,968 $37,515 $16,762SAVING $$24,404 $57,856 $78,609$ / LB METAL0.197 0.104 0.024OPERA TING COST COMPA RISONSSafety To The Work Area• Meet OSHA requirements• Comfort of operators• Easier introduction of new solvents• Reduced liability risk• Customer perception of the companyLow Emissions To TheEnvironment• NESHAPcompliance• BACT / LAERstandards• Set MACTstandards• CLEANROOMapplications• AQMD approvalNESHAP COMPARISON ENCLOSED VS OTVC DEGREASERS0501001502002503000 500 1000 1500 2000 2500 3000LBS ALLOWED PER MONTH

CUBIC FEET (ENCLOSE D0102030405060708090100 INTERFACE SQUARE FEET (OT VENCLOSEDOTVCBetter Quality Control• System process times and steps areoperator independent• Cycle operation parameters can becollected• System is load size independent• Menus can be used for specific partFlexible Operating Temperatures• Wider application of solvents• Optimization of cleaning of various parts• Longer solvent life• Greater uses for a given solventBetter Cleaning Efficiency• Solvent can operate above normal boilingpoint temperature and pressure• Elimination of air pockets• Elimination of air-solvent surface tensionproblems• Rapid flushing with condensing heattransferExcellent Drying• Solvent boils off part rather than evaporates• Vacuum not site sensitive• Parts dried in an oxygen free environment• Parts can be dried at a lower temperatureIncreased Capacity• Cleaning starts immediately in a vacuum• Solvent vapor tank can be custom sized tomatch load• Multiple chambers very economical• Different size chambers saves time andmoneyCan Use Many Solvents• Elimination of oxygen allows forflammable solvents• Unlimited solvent mixtures availablefor use• Higher boiling solvents can clean withvaporsReduced Reporting & Permit Costs• Generally under 2000 lbs no reportingrequired• NESHAP charges by the ton• Often no permitting required under 2000 lbsEnergy Savings• System is downwhen not cleaning• System can operateat temperaturesway below NBP• Refrigeration notnecessarilyrequired• No energy loss dueto fugitiveemissionsReduced Waste Disposal• Solvent concentrationin waste reduced from50% to 2%• Possible to reducebottoms to nonhazardous wastecategory• Half the shipping,storage and handlingSOLVENT CONCENTRATION IN WASTE AFTER DISTILLATIONTCE IN CUTTING OIL0501001502002503000% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50%% SOLVENT IN WASTE

TEMPERTURE REQUIRED DEG F76075102VACUUMPRESSURETORREnclosed Machines Cost LessDepending on Solvent Cost• Depends on solvent price• TCE - $0.65COST OF SOLVENT DEGREASING MACHINES1 SHIFT, 6 HR WORKING, TCE, 3 YR PAYBACK$0$20,000$40,000$60,000$80,000$100,000$120,000$140,000$160,0000.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0SQUARE FEET OF OTVC

$ / YEAROTVC OPER$OTVC TOT$AIRTIGHT OPER$AIRTIGHT TOT$AIRLESS OPER$AIRLESS TOT$Enclosed Machines Cost LessDepending on Solvent Cost• Depends on solvent price• NPB – $4.50COST OF SOLVENT DEGREASING MACHINES1 SHIFT, 6 HR WORKING, 3 YR PAYBACK, NPB$0$50,000$100,000$150,000$200,000$250,0000.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0SQUARE FEET OF OTVC

$ / YEAROPER$ OTVCTOT$ OTVCOPER$ AIRTIGHTTOT$ AIRTIGHTOPER$ AIRLESSTOT$ AIRLESSEnclosed Machines Cost LessDepending on Solvent Cost• Depends on solvent price• HFE - $15COST OF SOLVENT DEGREASING MACHINES1 SHIFT, 6 HR WORKING, 3 YR PAYBACK, HFE'S$0$50,000$100,000$150,000$200,000$250,000$300,000$350,000$400,000$450,0000.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0SQUARE FEET OF OTVC

$ / YEAROPER$ OTVCTOT$ OTVCOPER$ AIRTIGHTTOT$ AIRTIGHTOPER$ AIRLESSTOT$ AIRLESSEnclosed Machines Cost Less• Labor cost $13 / hr Waste disposal $350 / drumCOST OF SOLVENT DEGREASING MACHINES3 SHIFTS , 18 HR WORKING, TCE, 3 YR PAYBACK$0$50,000$100,000$150,000$200,000$250,0000.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0SQUARE FEET OF OTVC

$ / YEAROTVC OPER$OTVC TOT$AIRTIGHT OPER$AIRTIGHT TOT$AIRLESS OPER$AIRLESS TOT$Who Should Consider Buying AnEnclosed System• Companies that:• Have degreasers larger than 13 ft2interface area• Use designer solvents• Are located in a non-attainment areas• Have degreasers working more than 4 hours / day• Have heavy waste from process• Need to clean intricate parts or complex shapes• Need flexibility in temperature• Have high labor costs and quality controlrequirements