METHOD AND COMPOSITION FOR CLEANING ARTICLES

Abstract: The invention relates to a method and composition for cleaning articles made of, for example, metal, ceramic or glass. The composition of the invention comprises: one or more C9-C12 aromatic hydrocarbons of formula (I), wherein R is CH3, R2 is hydrogen or a straight-chained or branched lower alkyl, and R3 is hydrogen or a C1-C5 straight-chained alkyl; and a C7-C10 organic polar component, wherein the solvent composition comprises from about 99 to about 1 weight percent of the aromatic hydrocarbon and from about 1 to about 99 weight percent of the organic polar component. The invention also relates to a method of cleaning a dirty article, comprising the steps of: contacting the dirty article with a composition of the invention, the contact resulting in a solvent residue being deposited on a surface of the article; and removing the solvent residue by contacting the article with an aqueous medium.

Description: METHOD AND COMPOSITION FOR CLEANING ARTICLES BACKGROUND OF THE INVENTION This invention relates to a method and -composition for the cleaning of dirty articles. Such articles may be, for instance, relatively small metal, ceramic or glass articles, for instance, circuit boards or machined parts. It is routine practice to clean dirty surfaces by contacting them with an aqueous or non-aqueous liquid, and to promote the cleaning by forcing the liquid against the surfaces. Surfaces can be cleaned by water, often brushed on or applied as a jet, and then left to dry. However, water is not very effective for removing organic residues, and steaming is sometimes used. Aqueous detergent compositions will remove organic residues, but typically leave residues of detergents, necessitating thorough rinsing to remove these residues. The most effective way of removing organic dirt from articles is generally recognized as involving contacting the articles with organic solvents that will dissolve the residues. This method typically requires large capital investment in equipment to clean the articles by contacting the articles with an organic solvent while the articles are held within a vessel. The contact can be by immersing the articles in a liquid phase solvent or by exposing the articles to a vapor phase solvent, generally at a relatively cool temperature so that the solvent will condense on the articles. The selected solvent must have adequate solvency power for the residues that are to be removed, it must have a flash point sufficiently above the temperature of use that it is safe to use, and preferably have a volatility such that it does not leave a residual film of solvent on the article. Preferably, therefore, the solvent evaporates relatively quickly when exposed to the ambient atmospheric temperature of, for instance, 30 ° C or below. Most low boiling hydrocarbons often have adequate solvency power and have adequate volatility, but they suffer from the disadvantage that they have low flash point. Higher boiling hydrocarbons may have adequate solvency power and a reasonably safe flash point, but their volatility is sufficiently low that residues remain on the articles unless the articles are deliberately heated, and this is undesirable because of the risk of the temperature approaching or exceeding the flash point. Because of these difficulties, halogenated solvents were widely accepted as cleaners having suitable solvency power, adequately high flash point, and suitable volatility at safe temperatures. Examples are chlorocarbons, fluorocarbons and chlorofluorocarbons, the compounds generally containing below 4 carbon atoms, often 1 or 2 carbon atoms. The industry has made vast investment in apparatus for cleaning hard surfaces such as circuit boards and soft surfaces such as fabrics with such solvents. Possible environmental disadvantages of the use of such solventsare widely recognized. A very large number of alternative solvents have therefore been investigated, especially in recent years, but none of them have yet proved to be commercially as convenient to use as the halogenated hydrocarbons which they are intended to replace. There is therefore an acute need for achieving satisfactory cleaning of articles using a solvent having good solvency power which is preferably not a volatile halogenated hydrocarbon in such a way that there are substantially no solvent residues left on the article and workers are not exposed to a flash hazard. Preferably this objective would be achieved with a minimum of modification of the existing apparatus designed for use with, for instance, chlorofluorocarbons. Among the solvents that have been investigated heretofore are terpene solvents. Such solvents have been known for a very long time. For instance, terpene-based solvents were commercially available in the early 1940's. However, they have never proved to be of widespread commercial value. Part of the problem was that they tended to contaminate the article with residues of the terpene solvent, and this contamination rendered the article unacceptable. Also, the terpenes tend to readily contaminate or to form resinous products which are difficult to remove. Para-menthadienes and mixtures of para-menthadienes and terpene alcohols are known as solvents ("Monocylic Terpene Hydrocarbons" and "Blended Terpene Solvents," Hercules Review. 1942) . However, para-menthadienes are susceptible to atmospheric oxidation (even in the presence of anti-oxidants) , resulting in both formation of residue and conversion of para-menthadienes to other products (primarily para-cymene and epoxides) . Oxidation and residue formation in an immersion cleaning tank will adversely affect the efficiency of the cleaning process, and cause the build-up of co-boiling impurities which reduce solvent recyclability. Hydrolytic instability resulting in residue formation in the water rinse tank also leads to contamination of the cleaned work piece. If the hydrolytic instability is oxygen promoted, residue formation in both the rinse and immersion tanks can be significantly reduced by operating both process steps under inert gas blankets (e.g., nitrogen). However, ■ provision of full blanketing and prevention of ingress of oxygen into the two tanks increases equipment cost and complicates the operation of the cleaning process. Furthermore, differences in boiling point of the components of the above solvent mixture leads to different distillation rates during solvent recycle. The object of this invention is to meet the acute need to provide a method of cleaning dirty articles, which method is environmentally acceptable and that provides articles having a cleanliness that can meet the highest standards, for instance, the standard of the electronics industry. Additionally, the invention here is aimed at developing a solvent composition for use in the immersion- clean/steam-rinse process as described hereinunder, which does not suffer from the previously described problems. SUMMARY OF THE INVENTION In accordance with the present invention, dirty articles are cleaned by contact with a solvent composition comprising a portion of a Cr,-Cι Z aromatic hydrocarbon of from about 99 to about 1 weight percent, a portion of a C 7 -C 10 organic polar component of from about 1 to about 99 weight percent, and, optionally, a portion of water sufficient to form a water-in-oil emulsion. The solvent composition may further contain a surfactant for the purpose of assisting in forming the water-in-oil emulsion. The aromatic hydrocarbons can be made synthetically starting from, for instance, petrochemicals, or they can also be made by dehydrogenation of certain terpenes. The polar component may be either an alcohol, an amine, a ketone, or an ester which is selected such that it will either form an azeotrope with the aromatic hydrocarbon or has a boiling point sufficiently similar to the boiling point of the aromatic hydrocarbon such that a distillate of the solvent composition is substantially uniform in constituency throughout distillation. The solvent composition is capable of cleaning a wide range of soil types from articles and exhibits improved solvent life and cleaning performance, quantitatively expressed as the soil loading capacity of the solvent, which allows the solvent to be used in cleaning a large quantity of soil. The solvent composition is used in a cleaning process wherein a dirty article is contacted with the solvent under conditions that result in cleaning of dirt from the articles. Any residue deposited on the surface of the article is removed by contacting the contaminated article at an elevated temperature with an aqueous medium which removes the residual solvent from the article surface. The residual solvent may form an azeotrope with condensed steam in the rinse stage of the cleaning process, which azeotrope can then be removed from the article surface by evaporation. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a graphic representation of cleaning performance comparisons in the removal of a low poiarity soil, such as a light oil. Figure 2 is a graphic representation of cleaning performance comparisons in the removal of an intermediate polarity soil, such as abietic acid. Figure 3 is a graphic representation of soil loading capacity with respect to an intermediate soil, such as abietic acid, as a function of weight percent of a preferred polar organic component (2-ethylhexanol) . Figure 4 is a partially cut away 3-dimensional side view of an apparatus for performing cleaning and rinsing of dirty articles. Figure 5 is a cross-sectional view of the condenser and azeotrope collection trough taken along the line 5-5 in Figure 4. Figure 6 is a partially cut away 3-dimensional side view of a preferred apparatus for cleaning and rinsing dirty articles. DESCRIPTION OF THE PREFERRED EMBODIMENTS In accordance with the present invention, it is possible to obtain articles having exceptional cleanliness, in a manner that is highly desirable from the environmental point of view. Both solvent and water used in the cleaning process can be recycled, and vapor emissions can be reduced to satisfactorily low values. The use of solvents for cleaning articles, particularly for the removal of organic soils, is of major importance to industry. In many cleaning applications a solvent is required to remove more than one type of soil contaminant from individual articles. Different types of soil contaminants which must be removed include low polarity soils, such as oils and grease; intermediate polarity soils, such as rosin acid flux used in printed circuit board manufacture; and high polarity soils, such as inorganic ionic residues. For a solvent to be effective in removing a wide, range of soils of different polarity, it should preferably contain a mixture of non-polar and polar components. The advantage of the solvent composition of this invention is that such a wide range of soil types can be cleaned from articles. Most important is the removal of oils and grease from metal parts, and the removal of rosin fluxes and residual grease, for example, finger prints, from printed circuit boards. Accordingly, the invention provides for methods and solvent compositions for cleaning of a wide range of soils from individual articles. Disclosed is a constant boiling, high soil loading capacity, oxidation stable, and environmentally safe solvent composition comprising a portion of a C-C 12 aromatic hydrocarbon selected from the group consisting of or the mixtures thereof, wherein R t is CH 3 , R 2 is hydrogen or a straight-chained or branched lower alkyl, and R_ is selected from the group consisting of hydrogen and a C-,-C 5 straight-chained alkyl; and a portion of a c 7 ~ c ιo organic polar component, wherein the solvent composition comprises from about 99 to about 1 weight percent of the aromatic hydrocarbon and from about l to about 99 weight percent of the organic polar component. Optionally, the solvent composition may contain a portion of water sufficient to form a water-in-oil emulsionf which emulsion is capable of removing high polarity soils. Where water is present in the solvent composition, a cationic, anionic, or nonionic surfactant may be used to facilitate the formation of the emulsion. The water/surfactant portion of the solvent composition, when utilized, is present at levels up to about 40 weight percent. Preferably, the solvent composition comprises from about 95 to about 5 weight percent of the aromatic hydrocarbon and from about 5 to about 95 weight percent of the organic polar component. More preferably, the solvent composition comprises from about 75 to about 25 weight percent of the aromatic hydrocarbon and from about 25 to about 75 weight percent of the polar organic component. Most preferably, the solvent composition comprises about 75 weight percent of the aromatic hydrocarbon and about 25 weight percent of the organic polar component. The new solvent composition is superior to solvents previously used for cleaning articles in that it exhibits superior cleaning performance, is oxidative and hydrolytic stable under conditions of use, and during distillation a distillate of the solvent composition which is substantially uniform in constituency throughout distillation is recovered. The distillation procedure employed for solvent recycle can be either atmospheric or sub-atmospheric pressure distillation, or preferably steam distillation. An important factor for commercial cleaning operations is solvent life (before recovery or disposal, as required) , which is the ability of the same solvent to be reused for cleaning a large number of dirty articles. The operational performance of the solvent will depend in part upon the number of cleaning operations which can be completed with a given solvent before fresh solvent is required. This property can be expressed quantitatively as the solvent soil loading capacity, which is expressed by the formula: S = W X c V x P x 100 where W equals the average weight of soil removed from the article per cleaning cycle; C equals the last successful cleaning cycle; V equals the solvent volume; and P equals the solvent density. Laboratory trials simulating cleaning processes have demonstrated a surprising benefit for the solvent composition disclosed which is not predictable from a knowledge of the cleaning performance of the individual aromatic hydrocarbon and polar organic components. In combining the aromatic hydrocarbon and polar organic component, a synergistic effect has been noted whereby the solvent mixture has an actual soil loading capacity which is higher than the weighted average of the soil loading capacity for the individual aromatic hydrocarbon and polar organic components. This synergistic effect provides for improved solvent life, which makes the inventive solvent composition desirable from both an economic and environmental aspect, in that less solvent will be required over a longer period of time in the cleaning process. Another important characteristic which the solvent composition must exhibit is similar steam distillability of both components for more effective solvent removal in the steam rinse step of the disclosed process. The solvent must also possess the desired atmospheric pressure boiling points and vapor pressures for cleaning applications. Solvents with low vapor pressures do not significantly contribute to volatile organic chemical emissions, and are easily contained within cleaning equipment without the need for specialized vapor collection or scrubbing devices. Therefore, the lower molecular weight limit for the solvent components is C for the aromatic hydrocarbons and C 7 for the organic poldr components. On the other hand, solvents with too high a boiling point are difficult to distill with simple equipment during solvent recovery and recycle processes. Therefore, the upper molecular weight limit for the aromatic hydrocarbon is C 12 , while the upper limit for the polar organic component is C 10 . Preferably, boiling points should not exceed 220 * C, and ambient temperature vapor pressure should not exceed 2 millimeters mercury per 20"C. To be used economically in a cleaning process, the solvent must be easily recycled. It is therefore essential that the solvent composition distill over a very narrow range, or form an azeotrope boiling at a single temperature. The preferred technique for solvent recycle is steam distillation in the immersion- clean/steam-rinse process. For these reasons, the aromatic hydrocarbon and polar organic component must either be capable of forming an azeotrope, or have boiling points sufficiently similar such that a distillate of the solvent composition is substantially uniform in constituency throughout recovery. In a preferred embodiment wherein the solvent composition comprises a portion of an aromatic hydrocarbon and a portion of a polar organic component, it is demonstrated that the solvent composition efficiently cleans intermediate and low polarity soils from the articles. While the solvent composition will clean intermediate and low polarity soils, certain high polarity soils will require the concurrent use of water. Preferably, a water-in-oil emulsion would be employed through the use of a suitable surfactant. The portion of water employed will be sufficient to form a water-in-oil emulsion, which emulsion will be capable of removing the high polarity soils. The surfactant is anionic, cationic, or nonionic, and is either azeotropically volatile, or sufficiently volatile to ensure that the surfactant is removed from the article's surface along with the water-in- oil emulsion. The solvent composition must also be stable to oxidation under the hydrolysis conditions encountered in the hot water/steam distillation during the immersion- clean/steam-rinse process. If the solvent composition does not exhibit the required stability, polymerization or degradation reactions take place, thereby forming undesired resinous or residual impurities. The aromatic hydrocarbons utilized in the solvent composition contain from 9 to 12 carbon atoms, and are selected from the group consisting of or mixtures thereof, wherein R T is CH 3 , R 2 is hydrogen or a straight-chained or branched lower alkyl, and Rg is selected from the group consisting of hydrogen and a C-^-Cg straight-chained alkyl. The hydrocarbons can be made synthetically starting from petrochemicals, or can be derived by dehydrogenating certain terpene compounds found in, for instance, wood and other vegetable products. More preferably, the aromatic hydrocarbon is selected from the group consisting of para-cymene, meta-cymene, trimethylbenzenes, and ethyltoluenes. Most preferably, the aromatic hydrocarbon is para-cymene. The C 7 -C 10 organic polar component may be an amine, alcohol, ester, or a ketone. It is selected such that it is capable of forming an azeotrope with the aromatic hydrocarbon, or has a boiling point sufficiently similar to the boiling point of the aromatic hydrocarbon such that a distillate of the solvent composition is substantially uniform in constituency throughout distillation. The organic polar component is preferably a C 7 -C 10 alcohol; more preferably a C 8 saturated alcohol, such as 1-octanol, 2-octanol, or 2-ethylhexanol; and most preferably the organic polar component is 2-ethylhexanol. In a most preferred embodiment, the solvent composition comprises about 75 weight percent para-cymene and about 25 weight percent 2-ethylhexanol. The para- cymene can be manufactured from a number of turpentine- derived feedstocks, as well as from petrochemical sources. Atmospheric oxidation studies have shown that para-cymene stabilized with an anti-oxidant does not oxidize under normal conditions (immersion tank temperature 35°C) , and even unstabilized para-cymene shows a very low susceptibility to oxidative attack. Table 1 compares the oxidative stability of para-cymene versus para-menthadienes in terms of peroxide and residue formation. The higher the peroxide and residue values are, the more susceptible to oxidative attack is the solvent. These tests were conducted under conditions of limited exchange of oxygen into the head space. In the immersion-clean/steam-rinse process described hereinunder, it is important that the solvent exhibits a high degree of stability in hot water, i.e., hydrolytic stability. Our studies have confirmed that, unlike para-menthadienes, para-cymene is stable on prolonged exposure to boiling water (Table 2) . These tests similarly were conducted under conditions of limited exchange of oxygen into the head space. Steam distillation studies have shown that while 2-ethylhexanol does not appear to form an azeotrope with para-cymene, its boiling point is sufficiently similar to that of the para-cymene such that the distillate of the mixture is substantially uniform in constituency throughout the steam distillation recycle process (Table 4) . In addition, solvent recovery was 99% for the para-cymene based solvent, and again reflects the greater stability of the para-cymene/2-ethylhexanol to hot water/steam distillation conditions. The weight ratio of solvent to water in steam distillation of the 2-ethylhexanol/para- cymene mixture is 40% solvent and 60% water. This high ratio of solvent will provide an efficient solvent recovery process by steam distillation. Cleaning performance studies comparing para- cymene/2-ethylhexanol mixtures of varying concentrations, neat para-cymene, neat 2-ethylhexanol, para- menthadiene/terpene alcohol mixtures, and para- menthadienes, were conducted to determine the soil loading capacity of the relative solvents. Soils employed in the tests were a low-polarity light oil and an intermediate polarity abietic acid (component of rosin flux) . The soils were selected to demonstrate broad cleaning performance over a range of low polarity and intermediate polarity soils. Figures 1 and 2 show how cleaning performance is affected by soil buildup in the solvent waen removing abietic acid and light oil. It can be seen that in successive cleaning cycles, soil deposition is linear on reuse of the solvent. The results surprisingly show that para-cymene/ 2-ethylhexanol mixtures give superior performance " " to both the para-menthadiene/terpene alcohol solvent mixture and para-menthadiene alone (Table 3). More surprising is that the performance of the mixture is significantly greater than would be predicted from the weighted average of the individual components. For example, a solvent composition having 90% para-cymene and 10% 2-ethylhexanol has relative soil loading capacities of 2.6 for abietic acid and 3.3 for light oil, compared to weighted average soil loading capacities of 0.17% for abietic acid and 2.6% for light oils. The process is preferably conducted in multi-stage apparatus comprising one or more solvent-cleaning tanks and one or more rinsing tanks, including at least one azeotroping tank that has an outlet for volatile gases across which there is a condenser, including means for recovering condensate from the surfaces of the condenser. A solvent cleaning tank is, preferably, an immersion tank, i.e., it is designed for immersion of the dirty article into liquid solvent in the tank. If there is more than one solvent cleaning tank, the second tank can be another immersion tank or it can be designed for vapor contact and for recovery of condensed solvent off the article. The azeotroping tank preferably has a reservoir at its base for containing aqueous medium and a heater for heating the aqueous medium. The condenser across the outlet (often an open top) of the azeotroping tank may be a cool heat exchanger, for instance cooled by cold water, equipped with means for collecting condensate that condenses onto its outer surfaces. The condenser should be constructed so as essentially to prevent the escape of any solvent from the tank. The condensate, comprising the solvent and water, preferably is subjected to phase separation, with the solvent being recycled to one"of the solvent cleaning tanks, and the water either being run to waste or recycled to the azeotroping tank. Although it is adequate for the apparatus to consist solely of a liquid solvent cleaning tank and an azeotroping rinse tank, particularly good results can be achieved when the apparatus consists of a liquid solvent cleaning tank, a second solvent cleaning tank wherein the articles are contacted with vaporized solvent in the presence of steam, and the azeotroping tank. The inclusion of steam with the solvent vapor reduces flam ability, making the vapor cleaning of the articles safer. The mixed condensate of solvent and water can be recycled to the reservoir of this intermediate solvent cleaning tank without phase separation, or phase separation can be performed to facilitate control of the proportions of solvent and water in the reservoir. Generally, contact of the articles with the solvent composition is by immersion in liquid solvent at a temperature that preferably is well below the flash point, for instance at least 10'C and often at least 20*C below the flash point of the solvent. The cleaning effectiveness of contact can be promoted by mechanical or, preferably, ultrasonic agitation of the solvent. Contact of the article with the solvent composition generally results in a solvent residue being deposited on the surface of the article. Upon contact of the article with the aqueous medium, the solvent residue forms an azeotrope with the medium. Azeotroping is generally conducted at a temperature of below 100 * C. The surface from which azeotropic evaporation is to occur should preferably have an elevated temperature The article may be pre-heated (either in the solvent treatment stages or previously) , but often the article is heated to the desired azeotroping temperature by contact with the aqueous medium at an elevated temperature. Preferably the temperature of the surface is at least 60"C, usually at least 80°C, and preferably at least 95°C. Best results are achieved if the temperature is 98 * C or, preferably, 100 ° C. The use of such temperatures facilitates removal of residue from the article surface. Indeed, it can be desirable to continue contact with hot aqueous medium after substantially all the azeotroping has been completed, primarily to raise the surface to a sufficiently high temperature as to promote final evaporation of the solvent residue. A preferred method of performing the contact with the aqueous medium is to contact the contaminated surface with the aqueous medium at a temperature of at least about 98 * C. Preferably, therefore, the aqueous medium is applied as steam, and this steam can either consist substantially only of water vapor or it can comprise water vapor and a spray of water very near to its boiling point. Thus, a boiling water spray (i.e., wet steam) is particularly preferred. The steam that condenses onto the article will remove from the article water-soluble residues that may not have been removed by the contact with solvent, examples being inorganic salts. Best results are generally obtained when the azeotropic evaporation of the solvent residue is conducted while the article is exposed to a gaseous atmosphere. Often, therefore, the article is held in a stream of steam, and in particular by holding the article above a reservoir containing boiling water or other aqueous medium. However, another method that can be conducted is to immerse the article in hot aqueous medium and then to lift the article out of the medium and allow azeόtropic evaporation to occur off the surface of the article, due to the elevated temperature of the surface. For instance, the aqueous medium can have a temperature of from 60 to 99°C and the temperature must be such, having regard to the components in the aqueous medium and the solvent, that evaporation will occur off the surface when the article is lifted out of the aqueous medium. In another method, the solvent-cleaned article (preferably pre-heated) is immersed in liquid aqueous medium and azeotropic evaporation of the solvent and water is conducted while the article remains immersed in the liquid. An advantage of the presence of the aqueous medium, and in particular of processes in which the atmosphere above the aqueous medium is saturated by steam, is that this raises the flash point of the solvent in the ambient a- * -nosphere. In the absence of the steam the solvent would frequently be above its flash point and so simple heating at the temperature of the steaming would be dangerous. The safety of the process, and the performance, can be improved further by including additior~l materials in the steam atmosphere either to promote volatilization of the solvent or to raise the flash point of the combined vapors, or both. For instance, the flash point of the vapors will be raised if the steaming is conducted in the presence of an inert gas, such as nitrogen. The process of the present invention can be applied to the treatment of soft surfaces such as fabrics and other fibrous materials, but preferably is applied to the treatment of hard surfaces such as glass, ceramics, and metal. The articles having these surfaces can be, for instance, machined metal -~rts or, preferably, printed circuit boards. The articles are held in the " solvent cleaning tank and the subsequent tank in or on suitable containers, for instance by being suspended from a holder or by being supported in or on a holder, for instance a tray. Apparatus suitable for use in the process of cleaning and rinsing articles as described above are illustrated in Figures 4-6. The apparatus .of Figure 4 includes a solvent cleaning tank 2 filled with solvent 4 to the level shown, and provided with ultrasonic generators 12, an open top 6 for the introduction -of articles 8 to be cleaned, and a heater 10. A second tank 14 equipped with a heater 16 is filled with an aqueous medium 24 to the level shown and is connected by a weir 18 to a third tank 20 having a heater 22. The third tank 20 is filled to the level shown with aqueous medium 24 that is boiled by a heater 22 to generate steam. The combined tanks 14,20 are open to permit articles 8 to be immersed in the aqueous medium in the second tank 14 and then exposed to the steam in the third tank 20. A condenser 26 extends around the open tanks 14,20 to collect azeotrope condensate in the collection trough 28. The condensate is carried to a vessel 32 in which the condensate separates into an aqueous phase 34 that is recycled by a line 36 to the second tank 14, and a solvent phase 38 that is recycled to the solvent cleaning tank 2 by a line 40. Means (not shown) are provided for moving the articles 8 in sequence through the tanks. Figure 5 is a cross-sectional view of the condenser 26 and collection trough 28 which extend around the open tanks 14,20 to collect the azeotrope condensate 30 as -it is evaporated from the article surface. Other embodiments utilizing the basic concept of Figure 4 are possible, wherein the solvent cleaning tank 2 is used in conjunction with only the aqueous medium immersion tank 14 being used for removal of the solvent residue from the surface of the article. Likewise, the solvent cleaning tank 2 could be used in conjunction with only the steaming tank 20 for removal of the solvent residue from the article surface. In Figure 6 is shown a preferred embodiment of the solvent-cleaning/steam-rinse process wherein the liquid solvent cleaning tank 2 is used in conjunction with a steam/hot water spray tank 42. The article 8 is removed from the solvent tank 2 and suspended in the steam/spray tank 42 which is filled with water 41 to the level shown, which water is heated to boiling by a heater 46. The article 8 is then subjected to steam, which is generated from the heated water 41, and a spray of near-boiling water which is sprayed from nozzles 44 located along the side and perimeter of the tank 42. The tank is equipped with a condenser 26 and collection trough 28 for collecting the azeotrope condensate and transferring the condensate to a vessel 32, wherein the condensate separates into an aqueous phase 34 that is recycled by a line 36 to the spray tank 42, and a solvent phase 38 that is recycled to the solvent cleaning tank 2 by a line 40. Example 1; Oxidation Tests The solvent to be tested (200 ml) was charged to. a 500 ml single neck (B19) flask f_ zted with a single surface condenser and placed in a water bath maintained at 35"C. A sample (40 ml) of the solvent was withdrawn from the flask on day one, then subsequently every 5 days over the 21-day period. Samples were analyzed for peroxide content (iodo etric titration) and residue (Kugelrohr distillation) . TABLE 1 Comparison of Oxidative Stability of Para-cymene and Para-menthadienes Peroxide Value fuM/L) Residue (wt%) para-cymene (stabilized) 2 0 para-cymene (unstabilized) 8 0. 1 para-menthadienes (stabilized) >20 13 Example 2: Hydrolvtic Stability Tests The solvent to be tested (200g) was charged with distilled water (300g) to a IL flask fitted with a mechanical stirrer, thermocouple and soxhlet/condenser. The stirred mixture was heated to reflux with return of the condensate via the soxhlet. Gentle reflux was maintained over a 70-hour test period. At the end of the test period the oil was analyzed for residue (Kugelrohr distillation) and peroxide formation (iodometric titration) , and also analyzed by gas/liquid chromatography. TABLE 2 Comparison of Hydrolytic Stability of para-cymene and para-menthadienes Residue (wt%l para-cymene 0.1 para-menthadiene 2.0 Example 3: Hiσh Soil Loading Capacity Laboratory testing of overall cleaning performance was completed in the following manner: A. A weighed, flat 60 x 55mm stainless steel te'st piece was coated with between 0.2 and 0.5g of soil (either rosin acid or light oil) . B. The soiled test piece was then immersed in 600 ml of solvent at 35°C and the mixture mechanically agitated for 12 minutes. C. The test piece was withdrawn and most of the solvent was allowed to drain back into the cleaning solvent bath. D. Remaining solvent residue was removed by holding the horizontal test piece above a steam bath for 3 minutes. E. Test pieces were then dried in an oven, for 5 minutes at 120 * C, cooled, and weighed. F. Steps A to E were repeated, with the same solvent volume being employed for the cleaning step, until greater than 1 mg of soil was retained on the test piece. The solvent performance is then expressed in terms of the solvent soil loading capacity (S) as follows: s _ x c χ Q where W = average weight of soil V x P removed from the test piece per cleaning cycle; C = last successful cleaning cycle; V = solvent volume; P = solvent density. Results for cleaning abietic acid and light oil are described in Table 3, and expressed graphically in Figures 1 and 2. The small case reference letters found in Figures 1 and 2 correspond to the respective solvent compositions contained in Table 3. The 1 mg residual soil criteria corresponds to 99.7% abietic acid removal arid 99.5% light oil removal. TABLE 3 Comparison of Solvent Performance in the Removal of Low and Intermediate Polarit Soils - 10% terpene alcohols . . Example 4: Steam Co-distillabilitv Solvent (500g; 90% para-cymene/10% 2-ethylhexanol) and water (2000g) was charged to a 5L, 3-necked flask fitted with stirrer, thermometer and distillation head. The mixture was heated to reflux and oil/water fractions were separated into oil and aqueous layers and the layers weighed to determine the oil:water ratio throughout the distillation. The oil composition was determined by gas/liquid chromatography analysis. Results in Table 4 show that the percent composition relative to the para- cymene and 2-ethylhexanol is substantially unchanged with nearly 95% of solvent recovered. TABLE 4 Steam Distillation of Para-c mene 2-eth lhe a o Oi o Example 5: Chemical Stability and Co-distillabilitv of Solvent Components for Solvent Recycle The following processing conditions were employed in an immersion-clean/steam-rinse cleaning process: A. The dirty article was immersed in an agitated solvent tank for 10 minutes at 35°C. B. The article was then transferred to a hot water rinse tank, held at 98-100 * C to remove residual solvent as a steam azeotrope. C. The article was then dried in hot air. D. Solvent collected from both the immersion tank and hot water tank was recovered for recycle by steam distillation. The process was operated over three consecutive days in which time many articles were cleaned. Both the immersion tank and rinse tank were covered with loose- fitting lids, such that the exchange of air in the tank headspace mostly occurred during transfer of articles between tanks when the lids were temporarily removed. The following differences were observed during cleaning with two solvent mixtures: (1) Para-menthadiene and Terpene Alcohol Mixture: The solvent mixture in the immersion tank underwent chemical changes in that 2% terpene epoxides and 5% polymeric residues were formed. Residual solvent on the surface of the water in the rinse tank became resinous and inhibited the evaporation of both water and solvent. An additional 5% residue was formed when the solvent was recovered by steam distillation, and the para-menthadiene components were recovered preferentially over the terpene alcohol components because of lower boiling points. All these chemical changes indicate a high susceptibility of the terpenes present in the formulation to air oxidation and/or hot water instability, which reduces their effectiveness in 5 cleaning processes. In particular, deposition of polymeric residues onto the "cleaned" article will nullify the cleaning process. (2) Para-cymene and 2-Ethylhexanol Solvent 10 Mixture: No polymeric residue or epoxides were formed in any of the immersion tank, rinse tank, or steam distillation recycle process stages. In addition, the para-cymene and 2-ethylhexanol components were 15 recovered at the same rates during the steam distillation solvent recovery step.

Claims: CLAIMS : 1. A solvent composition, comprising: a Cm.-C-. y aromatic hydrocarbon of formula wherein R, is CH-,, R~ is hydrogen or a straight- chained or branched lower alkyl, and R 3 is hydrogen or a C,-C,- straight-chained alkyl; and a C 7 -C-, 0 organic polar component, wherein the solvent composition comprises from about 99 to about 1 weight percent of the aromatic hydrocarbon and from about 1 to about 99 weight percent of the organic polar component. 2. The composition according to claim 1 wherein the aromatic hydrocarbon is para-cymene, meta- cymene, a trimethylbenzene or an ethyltoluene. 3. The composition according to claim 2 wherein the aromatic hydrocarbon is para-cymene. 4. The composition according to any one of claims 1 to 3 wherein the organic polar component is an alcohol, an ester, an amine or a ketone. 5. The composition according to claim 4 wherein the organic polar component comprises 1-octanσl, 2-octanol, or 2-ethylhexanol. 6. The composition according to claim 5 wherein the organic polar component comprises 2-ethylhexanol. 7. The cαtposition according to any precedingclaimwherein the organic polar component is capable of forming an azeotrope with the aromatic hydrocarbon. 8. The cαraposition according to any precedingcaimvtecein the organic polar component has a boiling point sufficiently similar to the boiling point of the aromatic hydrocarbon such that a distillate of the solvent composition is substantially uniform in constituency throughout distillation. 9. The cαnposition ax-ording to any preceding claim comprising from about 95 to about 5 weight percent of the aromatic hydrocarbon, and from about 5 to about 95 weight percent of the organic polar component. 10. The composition according to claim 9 comprising about 75 weight percent of the aromatic hydrocarbon and about 25 weight percent of the organic polar component. 11- The composition according to any precedingclatofurther comprising a portion of water sufficient to form a water- in-oil emulsion, which emulsion is capable of removing high polarity soils. 12. The composition according to claim 11 further comprising a surfactant. 13. The composition according to claim 12 wherein the surfactant comprises anionic, cationic, and nonionic surfactants. 14. A solvent composition as claimed in any preceding claim which has an actual soil loading capacity which is higher than a weighted average of the soil loading capacity for the individual aromatic hydrocarbon and organic polar components. 15. A process for cleaning a dirty article, the process comprising the steps of: contacting the dirty article with a solvent composition as claimed in any preceding claim, whereby the contact of the dirty article with the solvent composition results in a solvent residue being deposited on a surface of the article; and contacting the article having the solvent residue on the surface with an aqueous medium such that the solvent residue is removed from the surface of the article. 16. A process according to claim 15 wherein the solvent residue forms an azeotrope with the aqueous medium, and the azeotrope is removed from the surface of the article by azeotropic evaporation. 17. A process according to claim 16 wherein substantially all the solvent residue is immiscible with water, the azeotrope is condensed, an organic, solvent phase is separated, and the separated phase is recycled for subsequent cleaning of a dirty article. 18. A process according to claim 16 or claim 17 wherein the azeotrope is evaporated in a vessel, which vessel contains the aqueous medium in its base, and has a heater for heating the aqueous medium, and an outlet for evaporated azeotrope, and a condenser across the outlet on which the azeotrope is condensed. 19 . A process according to any one of claims 16 to 18 conducted in a multi-stage apparatus, the apparatus cαtprising a tank for inmersion of the dirty article in the solvent composition and a tank in which the azeotrope is evaporated, and including means for condensing the azeotrope, separating the solvent from the aqueous medium, and recycling the solvent to the immersion tank. 20 . A process according to any one of claims 16 to 19 wherein azeotrope formation is conducted at frcm about 60-100°C. 21. A process according to any one of claims 16 to 20 wherein the aqueous medium has a teπperature of at least 98 °C. 22 . A process according to any one of claims 16 to 21 wherein the aqueous medium is steam. 23. process according to claim 22 wherein the steam comprises water vapor and a spray of water at a temperature of at least about 98*C. 24. Aprocess accordingto anyone cf claims 16 to23wherein azeotropic evaporation of the solvent residue is conducted while the article is exposed to a gaseous atmosphere. 25. Use of a composition as claimed in any one of claims 1 to 14 for cleaning a dirty article.

Inventors: FERBER GERALD J, SMITH GRAHAM J, FERBER, GERALD, J., SMITH, GRAHAM, J.
Applicants: BUSH BOAKE ALLEN LTD, BUSH BOAKE ALLEN LIMITED
Application year: 1991
Main classification: C23G5
IPC codes: B08B3, C11D7, C23G5, H05K3