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New Realities in Aqueous Cleaning Boosts Reuse of Resources While Creating Vital Energy Savings
Date: 07/13/2007
Today's industrial sector has realized reducing water usage saves cost. Therefore manufactures are using a new highly efficient -- dynamic oil-water separation -- to remove process oils and even contaminants from an aqueous cleaning solution. This technology is an essential ingredient of improved productivity and higher profitability.
Traditional mechanical separation methods are based on one of two principles: (1) gravity separation, in combination with weir skimmers and tank overflow, or (2) adhesion, with hoses, wheel/disks or belt skimmers used to adhere oil to lift it from the surface of bath water. Both methods are problematic, particularly in high-volume production settings where delays to change or maintain aqueous baths involve downtime.
For instance, adhesion separation often allows dirt to settle through surface oil and cycle back into the bath water, leading to dirty parts and requiring frequent solution change. The adhesion method also draws up and removes cleaning agents along with water and oils, creating "wet" oil and adding to oil disposal costs.
Oil-water separation operates on a different principle -- Bernoulli's Effect. Developed by Aqueous Recovery Resources (ARR) and incorporated in its Suparator® systems, this system uses The Bernoulli Effect (best known as the principle that creates the "lift" of aircraft wings).
This unique oil-water separation removes oil so effectively, that lots of dirt and other foreign matter are separated with the oil. Elimination of these contaminants warrants a much cleaner process and cleaner parts, translating to better quality products and less rejects.
The Suparator also extends bath life, providing significant savings in detergents. Bath changes are greatly reduced, vast quantities of water are conserved, oils are more efficiently recycled and far smaller volumes of cleaners and coolants have to be disposed of.
At the Hydraulic Pump/Motor Division of Parker Hannifin Corporation, a Lindberg washer incorporated intentional overflow of the cleaning bath to remove quench oil from heat-treated parts. This method resulted in the loss of cleaner and "excessive volumes" of water being added to the plant's effluent, according to Larry McCracken, plant engineer.
To reduce the costs resulting from those cleaning and disposal problems, the washer was modified to eliminate the need to continuously overflow the bath. However, some oil-water separation system was needed to control the oil concentrations in the bath.
"Initially, a belt-type skimmer was tried, but was unsuccessful," plant engineer McCracken says. "So, a Suparator unit was tried on ARR's 30-day Trial Program. "Approximately 10 gallons of quench oil is removed from the bath daily. This result has greatly reduced operating costs as well as our getting cleaner parts from the washer."
Cost savings included a reduction in water consumption from 19,080 gallons per month to only 3,480 per month. Chemical losses, previously recorded at 298 gallons per month, were reduced by 244 gallons -- a savings of almost 82%. The monthly cost of water disposal was reduced by approximately 80 percent, and the monthly cost of chemicals reduced by over 80%. The total annual savings has been at least $101,184.
For more information, contact Aqueous Recovery Resources, Inc.'s (ARR) oil-water separation systems.
Kimberly Kaplan
Aqueous Recovery Resources
kbb@suparator.com
www.suparator.com
914-241-2827
Technorati Tags: oil water separation, aqueous cleaning
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