Pre-cleaning for the CRC with Sponge Media Presented By: Ted Valoria Vice President, North America Sponge-Jet, Inc. Project TV

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1 Pre-cleaning for the CRC with Sponge Media Presented By: Ted Valoria Vice President, North America Sponge-Jet, Inc. Project TV

2 2 Overview: Empire Southwest LLC (Mesa, AZ US) Sells, rents and services heavy equipment, tractors and power generation equipment Evaluating cleaning technologies for their newly designed Rebuild Center Cleaning technology centered around 793D Mining Truck Objective: Select an effective, economical and environmentally-friendly cleaning solution which can: Remove dirt Degrease Remove failed coating layers CAT 793C

3 Cleaning Process Requirements: Quality Specs: Remove dirt,

Feather residual coating to remove layered look for like like

disposal Reduce initial cleaning of equipment (dirt, oil, etc.

washers Solution Specs: Allocated total space of 2,400ft²

3 3 Cleaning Process Requirements: Quality Specs: Remove dirt, oil and failed coatings for reconditioning and repainting Feather residual coating to remove layered look for like like new final painting finish No generated waste water or sewer disposal Reduce initial cleaning of equipment (dirt, oil, etc.) Reduce disassembly times Reduce need for in-line cabinet washers Solution Specs: Allocated total space of 2,400ft² (225m²) One bay for cleaning multiple parts One bay for cleaning engines

Ice Blasting Media vaporizes; no disposal of spent media Very good removing dirt and grease Can not remove multi-layered paint Produces very little

4 4 Considerations: Standard (Heated) Pressure Washer: Removes exposed dirt and grease Does not remove dirt and grease in crevices Does not remove layered paint 7-9 hours to clean the 3516 engine Requires two separate systems (one for each bay) Requires sump and drainage; larger footprint Dry Ice Blasting Media vaporizes; no disposal of spent media Very good removing dirt and grease Can not remove multi-layered paint Produces very little waste water; waste is oil/grease/dirt Requires onsite manufacturing of dry ice pellets Equipment can fit within allocated space Safety concern; ice burns

dirt and grease in crevices Removes layered paint 5-7 hours to clean the 3516 engine Other positive CAT dealer reference (frames/parts) Dry process;

5 5 Considerations: Plastic Media Blasting Can remove dirt and grease Media can get stuck in crevices Required the use of water (???) Generated a lot of debris/waste Equipment (for two bays) required larger footprint Sponge Media Blasting Removes exposed dirt and grease Removes dirt and grease in crevices Removes layered paint 5-7 hours to clean the 3516 engine Other positive CAT dealer reference (frames/parts) Dry process; no water used Equipment for the two bays fit within allocated space Other CAT dealer reported 6 to 8 recycles of Sponge Media Concern for noise (could be solved with sound doors)

6 6 Selection: Sponge-Jet Integrated System Silver Sponge Media abrasive (2) Sponge-Jet Feed Unit (2) 91E Sponge-Jet Recycler (2) Feed Unit Hopper (2) Recycler Hopper (2) Dust Collector (2) Vacuum

7 Sponge Cleaning Process: 1. Equipment Preparation / 2. Load Bay for Cleaning / 3. System Charge Up / 4. Sponge Blasting / 5. Cleanup 7

8 Sponge Cleaning Process: 1. Equipment Preparation / 2. Load Bay for Cleaning / 3. System Charge Up / 4. Sponge Blasting / 5. Cleanup 8

9 Sponge Cleaning Process: 1. Equipment Preparation / 2. Load Bay for Cleaning / 3. System Charge Up / 4. Sponge Blasting / 5. Cleanup Log Power Check Media Levels Air E-Stop Fill 9

10 Sponge Cleaning Process: 1. Equipment Preparation / 2. Load Bay for Cleaning / 3. System Charge Up / 4. Sponge Blasting / 5. Cleanup 10

11 Sponge Cleaning Process: 1. Equipment Preparation / 2. Load Bay for Cleaning / 3. System Charge Up / 4. Sponge Blasting / 5. Cleanup After blow-down, blasted parts are then transported for disassembly, inspection, etc, 11

12 12 Assembled Transmission (in/out): BEFORE Blast Cleaning AFTER Blast Cleaning

13 13 Wheel (in/out): BEFORE Blast Cleaning AFTER Blast Cleaning

14 14 Assembled Engine (in/out): BEFORE REBUILD AFTER REBUILD

15 15 Assembled Engine (in/out): BEFORE Blast Cleaning AFTER Blast Cleaning AFTER Painting

16 Thank you spongejet.com 16

17 Integrated System Selection and Design Presented By: Michael Merritt President Sponge-Jet, Inc.

18 18 Dust Collector & Vacuum are Smaller than with other abrasive types.

19 Typical Room for Steel Grit and other Ordinary Abrasives Sponge-Jet Media can be used in most blast rooms with by changing the Abrasive Blast Pot and the Abrasive

19 19 Typical Room for Steel Grit and other Ordinary Abrasives Sponge-Jet Media can be used in most blast rooms with by changing the Abrasive Blast Pot and the Abrasive Recovery/ Recycling system. Sponge-Media Rooms: 1/5 the Dust Collection Simplified Floor Recovery Less Capital Expense Substantial Energy Reduction Improved Reliability

20 20 Heavy Abrasives cost more to recover than lighter abrasives: 1) The lighter the abrasive the more easily the operator can move it to the pick up point. 2) Less operator fatigue and injury. 3) Sponge Media can be blown across large rooms in seconds to a pick up point. It can also be easily moved with brooms, pushers and shovels. 4) If active floor units are selected only some are capable of handling the weight of steel grit abrasives but all should work with Sponge Media. 5) Reliability, maintenance cost and process interruption should all be considered when considering an active floor system. 6) Active floors can save labor when dealing with heavy abrasives but they may also come at a high initial cost followed by high maintenance and downtime costs.

21 Common Reclaim and Recovery Method Traditional Screws and Bucket conveyors to recover abrasive will work with Sponge Media but are overkill as far as the

21 21 Common Reclaim and Recovery Method Traditional Screws and Bucket conveyors to recover abrasive will work with Sponge Media but are overkill as far as the initial investment and maintenance required. Simpler vacuum reclaim and recovery systems are more commonly installed in a Sponge-Jet system if new construction.

22 22 Some Floor systems use Conveyors to move the Abrasive Hoppers direct the abrasive to the center of the conveyor belt. The conveyor belt carries the abrasive to one end of the room and dumps into a receiving trough or collection bin. From there it can be collected and elevated by a variety of methods. This system has many mechanical parts with limited access for service.

23 23 Vacuum Pick: Lower Cost, Better Reliability Saved significant Capital cost compared to an active floor capable of supporting the heavy loads

24 24 Blast Rooms Designed for Sponge Media Active floors and mechanical bucket elevators are not required. The media is easily moved and collect with reliable vacuum components. The Blast Units and Recycling systems are unique to Sponge Media which can not be used with conventional abrasive pots. Air flow for Dust Collection is typically 20% of conventional blast rooms of the same size which may allow additional features such as HEPA filtration and recirculation of conditioned air. Sponge Media is compatible with sound absorbing wall systems, Glass viewing windows and Video monitoring for safety. Touch up next to intact paint coatings, work adjacent to mechanical assemblies, rotating equipment and electronic devices. New blast rooms can be built for a fraction of the cost of a conventional room Existing blast rooms can be easily reconfigured with just updating the Feed Unit (blast pot) and Recycler.

25 Room Design Establish the Basics First Room itself. How big? Where is it? What features? What is Ideal work flow in and out? Noise Will it be an issue? If so - how to manage it. How many blast nozzles? Dust Minimize it and manage its migration. How does airflow interact with adjacent work areas. Media Recovery Methods, Reliability, Labor cost spongejet.com 25

26 What to Keep in Mind Room Size Drives Cost Don t oversize the room. Lower Ceilings improve dust control and Reduces the size of Dust Collector. Must have continuous negative air pressure if connected to workshop Consider breeze way / air lock for dust and noise control. Otherwise Sound proof doors with interlock so doors can not be open on two sides at once and without negative air on. Blast Unit Configuration: One Media Type or more? How many operators and Nozzles (speed)? How Many Rooms? Hoppers and Pressure Vessels must be sized to the workflow. Larger units allow more blast time between clean up. Design Workflow, Air management and Sound Control. spongejet.com 26

27 Slide show of typical Systems

28 28 Existing French Railway Workshop with BVAC Added

29 29 Equipment Repair 2 blast units w/ Small Recycler Hopper

30 30 Note lighting and visibility

31 31 Blast room with small package HEPA Dust Collector

32 32 Heavy Equipment Remanufacturer Built two blast rooms with shared equipment room in the middle. Replaced conventional water wash down, mechanical cleaning and grit blasting with Sponge-Jet system. Each room is supported by two Sponge-Jet Feed Units, a Vacuum & Dust Collector. Centralized control panels provide status updates on Estops, Machine functions and open doors.

33 Typical system Cost Feed Unit, Recycler, Hoppers and Vacuum (Does not include Room, Doors & Dust Collectors)

34 34 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only No Vacuum No Integration No Hopper Most Basic 170 liter Feed Unit with minimal controls Basic Recycler

35 35 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only No Vacuum No Integration No Hopper Premium 470 liter Feed Unit all control features Basic Recycler

36 36 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only Integrated 3 Electric Vacuum Small Hoppers Premium 470 liter Feed Unit all control features 50 Series Recycler Closed Top

37 37 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only BVAC PRO 4 Standard Item Mobile in Lifting Frame Integrated 3 Pneumatic Vacuum Mid Size Hoppers Premium 470 liter Feed Unit all control features Upgraded Recycler Closed Top 50 Series Recycler

38 38 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only Shared Hopper over two Feed Units. Small hopper over recycler best if vacuum media recovery happens while blasting. 3 Electric Vacuum 50 series Recycler

39 39 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only Shared Hopper over two Feed Units. Large hopper over recycler. 4 Electric Vacuum. 90 Series Recycler

40 40 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only Shared Hopper over two stage Feed Units. Feeds two blast pots Large auger fed hopper over feed units. 3 Deck & 90 Series Recycler

41 41 Custom Engineered Solutions Feed Units, Recyclers, Hoppers and Vacuum only Shared Hopper over two stage Feed Units. Feeds three Nozzles Continuous Blast Medium hopper over 90 series recycler. Packaged frame for ease of transport. No Vacuum

42 42 Custom Engineered Solutions Over sized hoppers and blast pots. Client Required to blast two men all day with vacuum recovery during night shift. 90 Series Recyclers Dual 3 Pneumatic Vacuum u u u u u

43 43 What Else to Consider Compressor load: 450 CFM per nozzle dry air Dust Collector to create 20 ft per minute cross ventilation. Pulse purge filters (Paint room style and bag house won t last) Do doors need to be sound proof? Lighting Smooth Ceiling (no place for dust to set on) No connection with other HVAC systems Recessed floor pick up Door Interlocks. Remote Estops.

44 44 Summary Sponge-Jet builds Packaged and Custom Units to your specifications. We do not build rooms or install dust collection but are happy to work with your local supplier to match our systems to your local construction contractor or supplier. Our systems are in use in 6 continents and are designed for rapid global deployment to your specific needs and specifications.

Integrated System Selection and Design

Integrated System Selection and Design System Simplicity DUST COLLECTORS & VACUUMS ARE SMALLER THAN THOSE USING OTHER ABRASIVE TYPES 2 SPONGEJET.COM 2018 SPONGE-JET, INC. ALL RIGHT RESERVED Typical Room