IV Dry Cleaning. Contents (Dry Cleaning)

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1 IV Contents () Checking Causes of VOC Emissions 86 List of VOC Emissions Control Measures 87 Details of Each Control Measure 1 Choosing Control Measures Evaluating the Current VOC Emission Status [New] 89 2 Improving Operation Processes/Facilities Reviewing the Necessity of the Pretreatment and Removal of Stains Preventing Leakage during the Changing and Charging of Solvent Cooling Solvent Preventing Residual Solvent on Laundry Reducing Volatilization of Solvent during Storage Reducing Volatilization during Water Repellent Treatment 95 3 Switching Raw Materials Switching to Water Washing 96 4 Introducing VOC Exhaust Treatment System Switching to a Hot Machine Switching to a Dryer with a Reclaimer Introducing a Hanger Dryer with a Reclaimer 99 Index

2 When petroleum solvents are used Ⅳ Checkiing Causes off VOC Emiissiions Prroocceesssseess aanndd Chheecckkppooi iinnt tss Petroleum solvents Process Checkpoint Causes of VOC emissions Estimated VOC generation rate Corresponding No. in Choosing control measures Preparation Review the necessity of pretreatment (bamboo whisk cleaning, brushing, pre-spotting, etc.) and removal of stains. Check if the proper amount of solvent is used. Check if dry cleaning solvent is not leaking while changing or charging it. Volatilization of dry cleaning solvent during charging Approx. 5% or less 2-1 to 2-2 Check the laundry is sorted depending on the thickness of the cloths. 2-4 Check if switching to water washing is possible. 3-1 Check if the washer is cooled. Washing Drainage Drying Check if laundry is put into the dryer immediately after washing. (When the dryer has a reclaimer.) Volatilization of dry cleaning solvent Approx. 90% 2-3 and 2-4 Check if the washer can be replaced to a hot machine. Check if a dryer with a reclaimer can be introduced. 4-1 to 4-3 Check if a hanger dryer can be introduced. Storage Check if the temperature in the storeroom is controlled. Check if the dry cleaning solvent cans are kept out of direct sunlight. Check if the dry cleaning solvent cans are closed airtight when not in use. Volatilization of dry cleaning solvent during storage Approx. 5% or less 2-5 Check if water repellent treatment can be conducted in a washer. Water repellent treatment Check if an aqueous water repellent can be used. Check if water repellent treatment is conducted at a place with local ventilation. (When a VOC exhaust treatment system is installed) Volatilization of water repellent solvents Approx. 5% or less 2-6 [Examples of VOCs used in dry cleaning] Applications: dry cleaning solvent, water repellent solvents VOCs: petroleum solvents, tetrachloroethylene (perchloroethylene), 1,1,1-trichloroethane, etc. 86

3 Work environment improvement effect Running (material purchase cost reduction effect)) Running (operating cost) Initial VOC reduction effect Perchloroethylene Petroleum Running (material purchase cost reduction effect)) Running Initial VOC reduction effect Perchloroethylene Petroleum Processes Running (material purchase cost reduction effect)) Running Initial VOC reduction effect Perchloroethylene Petroleum Ⅳ Liist of VOC Emiissiions Controll Measures Choosing control measures Types of VOCs Effects and costs of implementing measures Costs No. Measures 1-1 Evaluating the current VOC emission status [New] - 1 to Improving operation processes/facilities Types of VOCs Effects and costs of implementing measures Costs No. Measures 2-1 Reviewing the necessity of the pretreatment and removal of stains Preparation 2-2 Preventing leakage during the changing and charging of dry cleaning solvent Washing Drainage Drying 2-3 Cooling dry cleaning solvent Preventing residual dry cleaning solvent on laundry Storage 2-5 Reducing volatilization of dry cleaning solvent during storage Water repellent treatment 2-6 Reducing volatilization during water repellent treatment 1 1 to Switching raw materials Types of VOCs Effects and costs of implementing measures Costs No. Measures 3-1 Switching to water washing

4 improvement effect Running (material purchase cost reduction effect)) Running (operating cost) Initial VOC reduction effect Perchloroethylene Petroleum Introducing VOC exhaust treatment system Types of VOCs Effects and costs of implementing measures Costs No. Measures 4-1 Switching to a hot machine Switching to a dryer with a reclaimer Introducing a hanger dryer with a reclaimer Notes: VOC emission reduction effect: 1 (lowest) to 5 (highest) : 1 (lowest) to 5 (highest) : 1 (lowest) to 3 (highest) : 1 (lowest in effect) to 3 (highest in effect) (material purchase cost reduction effect) : 1 (lowest) to 3 (highest) See Legend on page iv for the detailed description of the scale. 88

5 Chhoooossi iinngg Coonnt trrool ll Meeaassuurreess Evalluatiing the Current VOC Emiissiion Status New Up to 200,000 yen (3) (1) (2) You can take more effective measures to reduce VOC emissions by clarifying the current status of VOC emissions at your company. The way VOCs are used differs among factories and sites. By understanding where in the factory and during which operations VOCs are emitted, you can optimize your VOC emission reduction measures. Understanding the current status of VOC emissions at your company will also enable you to verify the effect of each measure taken. The numbers (1) to (3) above correspond to the numbers of the measures explained on the right. Up to 100,000 yen/month [Measure (1): Measuring VOC concentration by a simplified method] When measuring VOC concentration as part of your voluntary efforts or self-management, simplified VOC measurement equipment may be useful. Purchase costs vary depending on the measurement principle and performance of the equipment (e.g. what level of components can be measured), but they are available at from around 100,000 yen. To keep the cost as low as possible, a gas detector tube system can be used to measure VOC concentration. The system comprises a gas sampling pump and a gas detector tube, with the former costing around 20,000 yen and the latter being available at from around 2,000 yen per box of 10 tubes. [Measure (2): Using VOC alarms] Gas alarms that provide light and sound warnings when VOC concentration in the factory exceeds a certain level are available on the market. Their unit prices range from around 100,000 to 200,000 yen. [Measure (3): Using the Dispatch System of Tokyo Metropolitan VOC Control Advisors] The Tokyo Metropolitan Government offers the VOC control advisor dispatch service free of charge for those who wish to request professionals to measure VOC concentration in their workplaces. Under this system, advisors visit business sites and provide advice on effective measures best suited to each business after conducting simplified measurement using a hand-held VOC sensor. Please contact the Planning Team, Chemicals Management Section, Environmental Improvement Division, Bureau of Environment (see Associated Organizations in the Appendix) for details on how to apply for this service. 89

6 Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess Reviiewiing tthe Necessiitty off tthe Prettreattmentt and Removall off Sttaiins Up to 5% You can reduce the use of solvents by optimizing pretreatment and removal of stains. Up to 10,000 yen Review the necessity of pretreatment (bamboo whisk cleaning, brushing, pre-spotting, etc.) and removal of stains with the use of processing liquid containing solvents to eliminate the work as much as possible. If the work is not eliminated, complete the work as quick as possible. If possible, conduct the work at the place with a local ventilation system (equipped with an exhaust treatment unit). Put the treated laundry into a dryer immediately after the treatment and implement other proper measures. No change Is pretreatment 前処理や染み抜 or stain removal necessary? きは必要か? Unnecessary 不要やらない Eliminate the work Necessary 必要 Less effective 速やかに作業 Quickly conduct the work. 処理した被洗物は直ちにドライ機に入れる Immediately put treated laundry into a dryer. 局所排気装置のある場所で作業 Conduct the work at a place with a local ventilation system. <Examples of main components of pretreatment agents; * Bold: Possible VOCs> Application Sweat remover Yellow stain remover Pretreatment agent Stain remover, pretreatment agent Oil stain remover Protein stain remover Tannic stain remover Ink stain remover (Oil-based ink) Ink stain remover (Water-based ink) Component Non-ionic surfactant, alcohol, organic acid, water Oxygen-based bleach, alcohols, silicone, stabilizer, water Non-ionic surfactant, alcohol, water, silicone Anionic surfactant, special alcohols, glycol ether Organic solvent, anionic/non-ionic surfactant Anionic surfactant, ph control chemical, ionic water Anionic/non-ionic surfactant, ph control chemical, ionic water Alcohols, etc. Anionic/non-ionic surfactant, water (Source: Created based on materials provided by the manufacturer) 90

7 Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess Prreventti ing Leakage durri ing tthe Changing and Charrgi ing off Drry Cleaning Solventt Up to 5% You can prevent the leakage of dry cleaning solvent during its changing and charging. Up to 10,000 yen To reduce VOC emissions, it is essential not only to improve the cleaning process but also to manage dry cleaning solvent during its changing and charging. Transfer Can Dryer No change [Measure: Using a pump for transferring dry cleaning solvent] When transferring dry cleaning solvent from a can to a dryer and vice versa, do not manually transfer it but use a manual or automatic pump. Dryers with a charging pump for dry cleaning solvent are available. Less effective Notes When tetrachloroethylene (perchloroethylene-based dry cleaning solvent) is used, use a pump exclusively for chlorine-based solvents. Wear personal protection equipment, such as protective goggles, protective gloves, and mask, as necessary. Do not charge dry cleaning solvent while the dryer is working. Leakage of tetrachloroethylene or 1,1,1-trichloroethane leads to soil and underground contamination. 91

8 Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess Coolliing Dry Clleaniing Sollvent 5 10% You can reduce VOC emissions by cooling dry cleaning solvent (when a cold-type open washer is used). 100,000 1 M yen When a cold-type open washer is used, the amount of solvents evaporated from the washer increases due to hot temperatures especially in summer. When you use a washer one or two times a day, the washer may have no cooling unit because the temperature of the solvents is less likely to rise; however, you should newly install a solvent cooling system to cool a washer. Two types of solvent cooling systems are available: built-in type and 1 2 times higher separate type. A type of washer that gives an alarm when the temperature of solvents rises is also available. <A separate type solvent cooling system> Solvent cooling unit Dryer base tank ドライ機ベースタンク溶剤冷却装置 Less effective Strainer ストレーナー Pump ポンプ (Source: Materials provided by the manufacturer) Benefits Preventing wasted dry cleaning solvent from evaporating into the air leads to less use of dry cleaning solvent, resulting in cost reduction. Related matters This measure is important in view of safety. Petroleum solvents are flammable when they are 36 C or more and the risk of fire or explosion increases. To improve cooling performance, costs of equipment and maintenance are incurred. 92

9 Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess Preventiing Resiiduall Dry Clleaniing Sollvent on Laundry 5 10% Up to 10,000 yen Residual dry cleaning solvent on laundry is a source of VOC. You can reduce residual dry cleaning solvent by appropriately sorting laundry and using a dryer with a reclaimer. Since residual dry cleaning solvent on laundry is a source of VOC, worsens work environment, and causes chemical burns when the clothes are put on, laundry must be completely dried. To reduce residual solvents, you must implement measures in each work process such as sorting laundry. However, a dryer with a reclaimer must be introduced before implementing these measures. 1 2 times higher [Measure (1): Sorting laundry] Since drying time varies depending on the thickness of the cloths of laundry, laundry must be sorted into clothes with a short drying time (thin cloths) and long drying time (thick cloths) before drying. If clothes are not sorted, thick clothes are not fully dried, resulting in residual dry cleaning solvent. [Measure (2): Optimizing the amount of laundry to be loaded] Each dryer has its standard capacity and the amount of laundry must not exceed it at a time. You may load a larger amount of laundry than the standard capacity especially in peak periods, and in such cases laundry will not be fully dried. Less effective [Measure (3): Putting laundry into a dryer immediately after washing] Residual dry cleaning solvent on undried laundry will gradually evaporate. Therefore, when using a cold machine, do not leave unloaded laundry after washing and put it into a dryer as soon as possible. [Measure (4): Optimizing drying time and temperature] To reduce residual dry cleaning solvent on laundry, set an optimum drying temperature and time according to the amount of laundry and types and thickness of cloths. It is important to fully dry laundry until the odor of solvents is eliminated. Benefits These measures improve finishing quality and prevent accidents such as chemical burns. Notes You can use a dry checker to detect residual dry cleaning solvent. You must introduce a dryer with a reclaimer before implementing these measures. Related section Also see 4-1 Switching to a Hot Machine. Also see 4-2 Switching to a Dryer with a Reclaimer. Also see 4-3 Introducing a Hanger Dryer with a Reclaimer. 93

10 Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess Reduciing Vollatiilliizatiion of Dry Clleaniing Sollvent duriing Storage Up to 5% You can eliminate volatilization losses by appropriately storing and managing dry cleaning solvent. Up to 10,000 yen To reduce VOC emissions, it is essential to manage the storage of dry cleaning solvent. [Measure (1): Tight closing of the lids of cans and containers for dry cleaning solvent] Make sure to keep the lids of cans and containers for dry cleaning solvent closed tightly when they are stored so that VOCs will not be volatilized. No change [Measure (2): Checking of the robustness of containers and their lids] Make sure that containers for dry cleaning solvent are made of robust materials so that they will not be damaged or their lids will not come off suddenly, causing the leakage of dry cleaning solvent. Please note that some solvents will expand and break plastic containers. Less effective [Measure (3): Placement of containers in proper locations] When dry cleaning solvent is stored outdoors, roof the storage area. If roofing is difficult, protect the containers from direct sunlight and rain by covering them or otherwise. When dry cleaning solvent is stored indoors, keep it in a cool, dark place where ventilation is available. 94

Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess 22--66 Reduciing Vollatiilliizatiion duriing Water Repellllent Treatment Up to 5% Some water repellents

10,000 1 M yen (2)(3) (1) When you apply water repellent treatment using a manual spray gun, VOCs in a water repellent will evaporate into the workplace. Implement measures against diffusion of VOCs.

11 Impprroovvi I iinngg Oppeerraat ti iioonn Prroocceesssseess/ /Faacci iil lli iit ti iieess Reduciing Vollatiilliizatiion duriing Water Repellllent Treatment Up to 5% Some water repellents contain VOCs. You can reduce VOC emissions by using an aqueous water repellent and reviewing how to apply water repellent treatment. 10,000 1 M yen (2)(3) (1) When you apply water repellent treatment using a manual spray gun, VOCs in a water repellent will evaporate into the workplace. Implement measures against diffusion of VOCs. The numbers (1) to (3) above correspond to the numbers of the measures explained on the right. [Measure (1): Applying water repellent treatment in a washer] Apply water repellent treatment in a washer as much as possible. Implementing this measure requires the retrofitting and addition of equipment shown as below. <Retrofitting required for water repellent treatment in a washer> No change Less effective Retrofit a drum to install a nozzle and attach a water repellent spray to it. Install a compressor and a pump to supply a water repellent into the drum. [Measure (2): Switching to an aqueous water repellent] Aqueous water repellents are available on the market. Examine the possible use of an aqueous water repellent. Water repellent treatment with an aqueous water repellent can be applied through immersion or using a washer or spray. [Measure (3): Changing a workplace] If you have a local ventilation system with an exhaust treatment unit, apply water repellent treatment near the system. 95

12 Detergent Equipment Ⅳ Swi iit tcchhi iinngg Raaw Maat teerri iiaal llss Swiitchiing to Water Washiing 90% or more You can eliminate the use of VOC-emitting dry cleaning solvent by switching washing method from dry cleaning to water washing. 2 M 3 M yen Even if the laundry label on a garment says dry clean only, stains may be removed using water. Examine whether the laundry that has been dry cleaned can be washed using water. Especially water washing is more suitable to remove sweat stains on summer clothes. Some synthetic fabrics are water-washable. 2 times or more <Tips for water washing> Water washing in a gentle way. For example: Handwash laundry. Use a household washing machine. Highly effective Use a lower spin speed for laundry. Use a detergent for water washing. <Features> Color-bleed resistant Shrink resistant Crease resistant etc. Notes Techniques for water washing and finishing, which are different from dry cleaning, are required. Finishing using a hand iron takes a time, leading to low productivity. 96

Innt I trroodduucci iinngg VOC Exxhhaauusst t Trreeaat tmeennt t Syysst teem 44--11 Swiitchiing to a Hot Machiine Approx.

13 Innt I trroodduucci iinngg VOC Exxhhaauusst t Trreeaat tmeennt t Syysst teem Swiitchiing to a Hot Machiine Approx. 80% You can reduce VOC emissions by collecting dry cleaning solvent evaporated while laundry is transferred and dried. 6 M 8 M yen A hot machine is a cleaning machine that serves multiple duties from washing to drainage to drying. The machine is enclosed, dries laundry after washing and drainage without transferring laundry, and collects dry cleaning solvent evaporated during the drying process. No change A cold machine using petroleum usually uses dry cleaning solvent with a flash point of about 42 C, while a hot machine uses dry cleaning solvent with a higher flash point, leading to a lower risk of explosion. In addition, a safety measure among (1) decompression method, (2) nitrogen replacement method, and (3) concentration control method is introduced to the drying process to control its flammability below the flammability limit. (Material purchase cost reduction effect) Reduction in dry cleaning solvent purchase cost by approx. 90% <Description of a hot machine> (1) Laundry is washed and rinsed, and waste fluid is drained. (2) Hot air evaporates solvents (dry cleaning solvent) on laundry. (3) A cooling unit cools and liquefies solvent gas. (4) The water separator isolates liquefied solvents from water. (Solvents will be collected.) (5) Collected solvents are reused as dry cleaning solvent. Less effective Benefits Collecting and reusing evaporated dry cleaning solvent lead to less use of dry cleaning solvent, resulting in cost reduction. Newly required space 1 10 m 2 Smallest Largest Notes The amount of solvents can be reduced; however, since laundry cannot be washed and dried in parallel, the productivity will decrease. 97

Innt I trroodduucci iinngg VOC Exxhhaauusst t Trreeaat tmeennt t Syysst teem 44--22 Swiitchiing to a Dryer wiith a Recllaiimer Approx.

14 Innt I trroodduucci iinngg VOC Exxhhaauusst t Trreeaat tmeennt t Syysst teem Swiitchiing to a Dryer wiith a Recllaiimer Approx. 80% You can reduce VOC emissions by collecting dry cleaning solvent evaporated while drying laundry. 2 M 3 M yen When a dryer without a reclaimer of dry cleaning solvent is used, dry cleaning solvent evaporated from laundry is emitted outdoors. You can reduce VOC emissions by adding a reclaimer to the existing dryer or replacing the dryer with a dryer with a reclaimer. Collecting and reusing dry cleaning solvent evaporated into the air lead to less use of dry cleaning solvent, resulting in cost reduction. <Description of a dryer with a reclaimer> No change (1) Hot air evaporates solvents (dry cleaning solvent) on laundry. (2) A cooling unit cools and liquefies solvent gas. (3) The water separator isolates liquefied solvents from water. (Solvents will be collected.) (Material purchase cost reduction effect) Reduction in dry cleaning solvent purchase cost by approx. 90% Less effective (4) Collected solvents are reused as dry cleaning solvent. Benefits The use of dry cleaning solvent will be reduced, resulting in cost reduction. It depends on the number of times you use a washer a day, but you can recoup the purchase cost of a dryer with a reclaimer in about one year. Estimates show that since dry cleaning solvent will be collected about 14,400 liters a year, the purchase cost of the dry cleaning solvent reduces by about million yen, and the total costs including lease payment reduce by approximately million yen/year. <Calculation conditions> Loaded laundry: 22 kg, washing frequency: 16 times a day, 25 days/month, solvent: 180 yen/l, electricity: 11.8 yen/kwh (only usage charge), steam: 5 yen/kg, lease payment rate (5 years): 0.02% (Source: Materials provided by the manufacturer) Newly required space 1 10 m 2 Smallest Largest Notes Static electricity, which can cause ignition/explosion accidents, can be prevented by throwing a specified amount of detergent into cleaning solvent. The concentration of detergent must be controlled to be 0.5% or more. Do not use special detergents (containing solvents with a low flash point such as thinner and alcohol). 98

Innt I trroodduucci iinngg VOC Exxhhaauusst t Trreeaat tmeennt t Syysst teem 44--33 Introduciing a Hanger Dryer wiith a Recllaiimer Approx.

15 Innt I trroodduucci iinngg VOC Exxhhaauusst t Trreeaat tmeennt t Syysst teem Introduciing a Hanger Dryer wiith a Recllaiimer Approx. 80% You can reduce VOC emissions by collecting dry cleaning solvent evaporated while drying laundry to be naturally dried. 3 M 4 M yen When washed laundry is naturally dried indoors, dry cleaning solvent evaporated from laundry is emitted outdoors after a while. A hanger dryer is used for laundry that cannot be dried in a tumbler and should be naturally dried times higher Dry cleaning solvent can be collected during the drying process. The indoor environment will also be improved. <Description of a hanger dryer> (1) Hang laundry in the cabinet using hangers. (Material purchase cost reduction effect) Reduction in dry cleaning solvent purchase cost by approx. 90% (2) Hot air evaporates solvents (dry cleaning solvent) on laundry. (3) A cooling unit cools and liquefies solvent gas. (4) The water separator isolates liquefied solvents from water. (Solvents will be collected.) (5) Collected solvents are reused as dry cleaning solvent. Highly effective Benefits The use of dry cleaning solvent will be reduced, resulting in cost reduction. The indoor environment will also be improved. Related section Newly required space Also see 2-4 Preventing Residual Solvent on Laundry m 2 Smallest Largest 99

16 Index (Dry cleaning) A P amount of laundry to be loaded 93 placement of containers 94 pretreatment 90 C changing and charging dry cleaning solvent 91 R charging pump 91 robustness of containers and their lids 94 collecting and reusing dry cleaning solvent 97,98,99 cooling dry cleaning solvent 92 S current VOC emission status 89 sorting laundry 93 spot removal 90 D T dry cleaning solvent residue 93 dryer with a reclaimer 98 tight closing of the lids of containers 94 Tokyo Metropolitan Government VOC control advisor drying temperature 93 dispatch service 89 drying time 93 V G VOC alarm 89 gas detector tube system 89 VOC concentration measurement 89 VOC measurement equipment 89 H hanger dryer with a reclaimer 99 W hot machine 97 water repellent treatment 95 water washing

III Metal Degreasing/Cleaning

III Metal Degreasing/Cleaning Metal Degreasing/Cleaning Contents (Printing) Checking Causes of VOC Emissions 60 List of VOC Emissions Control Measures 61 Details of Each Control Measure 1 Choosing Control Measures 63 1-1 Evaluating