United States Air and Energy Engineering

Environmental Protection Research Laboratory

Agency Research Triangle Park, NC 27711

Kenneth R. Monroe

E AP Project Summary

Replacing Solvent Cleaning with

Aqueous Cleaning

Research and Development EPA/600/SR-94/131 November 1994

The report documents actions taken

by Robert Bosch Corporation, Charleston, SC, in replacing the cleaning solvents 1,1-2trichloro-1,2,2-trifluoroethane

(CFC-113) and trichloroethylene (TCE)

with aqueous solutions. Bosch has succeeded in eliminating all their CFC-113

use and, so far, has eliminated twothirds of their TCE use. Their goal is to

completely free of chlorinated cleaning

solvents by the end of 1995.

This Project Summary was developed

by EPA’s Air and Energy Engineering

Research Laboratory, Research Triangle Park, NC, to announce key findings of the research project that is fully

documented in a separate report of the

same title (see Project Report ordering

information at back).

Overview

Experience of the Bosch Company at

Charleston, SC, indicates that, with innovative engineering, it is possible to reduce, even eliminate, the use of solvents

for a range of cleaning applications.

These changes in cleaning have not

only responded to the environmental goals

of the Montreal Protocol and EPA’s 33/50

program, but have also resulted in improved cleaning at dramatically reduced

costs. An early key decision was to replace their aging, large, central degreasing

stations with several small cleaning units,

each designed and dedicated for cleaning

just one part, at one step, in the product

assembly process. This strategy demanded reassessment of each cleaning

step and the identification of apparatus

and chemistry for optimizing each aqueous replacement. The report summarizes

the actions taken to achieve aqueous

cleaning of four typical components, previously cleaned with chlorinated solvents.

The report provides quantitative comparisons of cleaning performance and costs

of the old chlorinated (1988) and the new

aqueous (1992) cleaning methods. For

each of these components, the new aqueous cleaning step matched or exceeded

the cleanliness levels of the old chlorinated cleaning methods, and did so at

similar or lower costs.

The solvent replacement program, which

was carried out, resulted in a major reduction in the use of chlorinated solvents.

The facility totally eliminated the use of

CFC-113 by 1993, from 544,000 lb

(250,000 kg) in 1988. It reduced the use

of TCE from 133,00 lb (60,00 kg) in 1988

to 43,000 lb (20,000 kg) in 1992. This

conversion to aqueous cleaning also resulted in major solvent and utility cost

reductions. The total non-labor annual cost

reduction for these categories was greater

than 90% of the 1988 solvent and utilities

costs.
2

K. Monroe is with Research Triangle Institute, P.O. Box 12194, Research

Triangle Park, NC 27709.

Charles H. Darvin is the EPA Project Officer (see below).

The complete report, entitled “Replacing Solvent Cleaning with Aqueous

Cleaning,” (Order No. PB95-129128/AS; Cost: $17.50; subject to change) will

be available only from:

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22161

Telephone: 703-487-4650

The EPA Project Officer can be contacted at:

Air and Energy Engineering Research Laboratory

U.S. Environmental Protection Agency

Research Triangle Park, NC 27711

• •

United States

Environmental Protection Agency

Center for Environmental Research Information

Cincinnati, OH 45268

EPA/600/SR-94/131

Official Business

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