Metalworking Fluid Recycling

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1 Metalworking Fluid Recycling and Management Equipment FB-106

2 A full line of fl uid management equipment CRS 300ST Customers who recycle their fluids enjoy a 40% to 80% reduction in coolant and fluid purchases 2 The acquisition of the HydroFlow Filtration and the Fluid Recycling groups from The Andersons, Inc. of Maumee, Ohio positions Eriez as a leader in comprehensive coolant and fluid management technology serving the metalworking industry. These industrial filtration systems and fluid recycling equipment maximize coolant effectiveness and longevity enabling companies to improve productivity and reduce disposal costs. Fluid filtering and recycling applications include parts washing, machining, grinding, honing, super finishing and EDM where fluids from water-based coolants to straight oil lubricants are required. These solutions include: Coolant Recycling Systems Solids-from-Liquid Centrifuges Liquid-from-Liquid Centrifuges Coalescers and Oil Skimmers Sump Cleaners Magnetic Chip Conveyors Magnetic Cleaners Drum Pumps Refractometers Water Purifiers Fluid Recycling Solutions Our metalworking fluid management solutions are specifically geared to the type and brand of fluid in use in your facility. Our filtration and recycling equipment are supported by more than one hundred years of engineering expertise, as well as a fully trained, veteran service department. Successful fluid recycling programs require: Stable, bio-resistant fluids able to withstand repeated recycling Management control and active supervision of the recycling program Properly designed and sized recycling equipment Systems capable of maintaining the fluid in consistently good condition Control of the mechanisms that cause coolants and cleaners to fail Key areas in fluid management include: Solids removal and filtration Tramp oil removal Concentration control Customers who recycle their fluids enjoy a 40% to 80% reduction in fluid purchases and a corresponding decrease in disposal costs.

3 Eriez CRS Coolant Recycling Systems Eriez CRS Fluid Recycling Systems are selfcontained coolant and fluid management systems capable of recycling any water-miscible fluid to its maximum potential. These units help minimize or eliminate disposal, reduce usage of the fluid concentrate, and improve plant profitability and productivity. Systems ranging from small to large feature low maintenance, unattended operation and fast return on investment. Eriez CRS Fluid Recycling System include: Separate dirty and clean tanks Automatic proportioner mixer coolant make up and control Oil removal device free-floating, non-emulsified tramp oil Coalescer tramp oil separator Liquid-from-liquid centrifuge clean coolant to < 0.5% emulsified tramp oil and 2-5 microns of particulate matter Pure water sources reverse osmosis systems or deionization systems Custom configurations can include systems that recycle a combination of both individual machine tools and central coolant systems. To facilitate the moving of fluids to and from the CRS recycling system, complete plant distribution and return header systems with pumping stations are also available. CRS 120SS side-by-side This modular, low-cost coolant recycling system provides the basic requirements of fluid recycling with water-miscible coolant and cleaner products that reject tramp oils. It has a convenient side-byside tank design and is equipped with a coalescer to remove free and mechanically mixed tramp oils. The CRS 120SS can be fitted with a high-speed centrifuge to address not only the free-floating and mechanically mixed tramp oil, but also remove partially emulsified, bacteriafeeding tramp oils. Systems range in size from small to large and feature low maintenance, unattended operation, and fast return on investment Far left: The CRS 120ST with standard highspeed disc bowl centrifuge and stacked tank design is ideal when fl oor space is limited. Left: The CRS 120SS is a feature-packed, modular and yet low-cost coolant recycling system. 3

4 CRS 120ST stacked This feature-packed system s stacked tank design reduces its foot-print and comes standard with a high-speed centrifuge for complete recycling of any metalworking coolant. The CRS 120ST s true high-speed centrifuge requires only one pass through the system to remove tramp oils, particulate matter and a substantial portion of the bacterial population. Cleaning the fluid to this degree eliminates the need for expensive, energy-intensive coolant pasteurization. CRS 300ST stacked The 300 series delivers an even larger centrifuge for higher processing rates and allows greater flexibility for adding optional equipment. An optional dual product design, referred to as the CRS 200/200 ST, features two dirty and two clean tanks for facilities using two different metalworking fluids. CRS 300SS side-by-side A complete, full capability, recycling system for medium-to-large sized metalworking plants equipped with machine tools using individual coolant sumps. In its standard design, the CRS 300SS easily meets the recycling requirements of facilities with up to 10,000 gallons of total sump capacity. For operations with greater flow rates or higher processing capacities custom configurations are also available from Eriez and HydroFlow, including systems that recycle a combination of both individual machine tools and central coolant systems. The CRS 300SS is a complete, full capability, single product coolant recycling system for the medium-to-largesized metalworking plant operating with machine tools fitted with their own coolant sumps. 4

5 Filtering and Removing Solids Eriez Solids-from-Liquid Centrifuges provide continuous MEDIA-FREE filtration Solids-from-Liquid Centrifuges Solids collect in individual machine tool sumps and in large central systems. It s important to efficiently remove these chips and fines as they have a detrimental effect on coolant performance and longevity as well as causing lost production and headaches during removal. Eriez Solids-from-Liquid Centrifuges provide continuous MEDIA-FREE filtration of both metallic and nonmetallic solids from industrial fluids. All Eriez Centrifuges are specifically engineered for heavy-duty industrial applications and will offer years of trouble-free operation. Typical solids-from-liquid centrifuges applications include: Machining, grinding and sawing High-speed centrifuge pre-filtration Rolling and tube mills Water jet cutting De-scaling operations Wire drawing Parts washers Quench tanks UF pre-filtration Precious metals recovery Solids-from-Liquid Centrifuges are available in either manually cleaned basket style (complete with reusable liner) or fully automatic self-cleaning designs to provide dependable, easy to maintain, media-free filtration solutions. Whether used on a single machine, a component or as a supplement to a complete paper media filtration/recycling system, the Solids-from-Liquid Centrifuge can remove solids typically missed by barrier filtration and reduces or eliminates costly filter paper, bags and cartridges all of which require disposal. Solids-from-Liquid Centrifuges offer dependable, easy to maintain, media-free solutions to filtration problems. Imagine no more filters to throw away! 5

6 Filtering and Removing Solids Sump Cleaners Filtering and Removing Solids Eriez offers the widest selection of sump cleaners in the industry. Solutions range from inexpensive drum top cleaners to the industry s widely recognized sump cleaner. Manufactured since 1974, these heavy-duty industrial wet/ dry vacuum filtration units clean virtually any machine tool sump, tank, or pit quickly and thoroughly. The Sump Cleaner continues to be the workhorse of the metalworking industry Eriez Sump Cleaner rapidly removes fluid, sludge and chips from the sump, filters the sludge and chips from the fluid via the reusable integral filter liner, and either returns the filtered fluid to the sump or transports the fluid to the CRS Fluid Recycling System. A polypropylene filter sleeve filters to a nominal 50 microns. For finer filtration, a single-use paper filter sleeve (to 20 microns nominal) can be inserted into the chip basket. The Sump Cleaner is fast! In just ten minutes, a cylindrical grinder sump with 120 gallons of coolant and 700 pounds of sludge can be completely cleaned, coolant filtered and returned to the sump. The 50 gallon, 120 volt electric Sump Cleaner is small enough to fit almost anywhere that fl oor space is at a premium. All of the features of our standard sump cleaners are available in easy-to-use, virtually maintenance-free, air-venturi powered models. 6

7 Eriez Sump Cleaners are available in: 50 to 1,000 gallon designs Single and dual compartment configurations Push, tow or truck mounted options Air venturi, single phase, 3 phase electric or liquid propane power Two inexpensive solutions for individual machines are Eriez drum top sump cleaner and the reversible liquid vacuum. Both drum top units draw up tramp oils, used oil and waste coolants quickly and efficiently. Eriez drum top sump cleaner is a vacuum unit that converts an open-top drum into a portable machine tool sump cleaner. In addition to fluids, this powerful vacuum removes chips and fines and is an economical alternative to a dedicated sump cleaner. The compact reversible liquid vacuum connects to a closed-head drum and is used to remove lube or hydraulic oils from reservoirs as well as many other fluid handling applications. For machine shops that work predominantly with ferrous metals, Eriez Magnetic Chip Conveyors and Magnetic Coolant Cleaners provide continuous removal of chips and swarf. This magnetic equipment can be submersed in the sump providing removal of large amounts of ferrous materials prior to filtering. Magnetic Coolant Cleaners Radial-design magnetic circuits extract ferrous particles from the coolant to help meet tolerances and improve surface finish in grinding and metal-cutting operations. Smooth-faced and extended-pole models extend life of coolant, cutting tools, grinding wheels and pumps. Magnetic Conveyors Eriez Tuf-Trac conveyors sit submersed in the sump and continuously extract ferrous turns. They re supplied with magnets on 12-inch centers, supported by twin roller chains that are powered by a shaft-mounted motor reducer. The roller chain rides on whisper-quiet Tuf-Trac engineered polymer guide track that requires no external lubrication. Conveyors feature heavy-duty construction for years of trouble-free operation. The drum top sump cleaner converts an existing open top drum into a powerful machine tool cleaning system. The reversible liquid vacuum is big enough for tough jobs, yet small enough to fit in your hand. 7

8 Removing Tramp Oil Self-cleaning high-speed disc bowl centrifuges keep central systems running clean and tramp oil free Reducing tramp oil is a high priority for all metalworking shops. Excess tramp oil leads to: Smoke, mist, and bacterial infestation of the metalworking fluids Adversely affect surface finish Reduces tool life and dimensional tolerance control Skin irritations such as dermatitis Partially emulsified tramp oils in coolants are the most dangerous and difficult to remove. Removing this type of oil requires an Eriez high-speed centrifuge which delivers exceptionally clean fluid with tramp oil levels below 0.5% and metallic solids in the 2 to 5 micron range. Portable Tramp Oil Separator This mobile centrifuge provides small metalworking plants with true, high-speed centrifugation. Eriez Portable Tramp Oil Separator recycles fluids at the sump by placing two hoses directly into the machine sump removing free and emulsified tramp oils from water miscible coolants and aqueous cleaners while the machine tool continues to operate. Eriez integrates larger, manually cleaned high-speed centrifuges into its CRS Fluid Recycling Systems. These systems are complete fully palletized packages used in conjunction with Sump Cleaners and often with fluid distribution systems. Self-Cleaning Centrifuges Typically, self-cleaning centrifuges are designed for central systems pulling the fluid, removing tramp oils and small fines, and returning cleaned fluid to the central system. This type of centrifuge package systems can be designed to handle any combination of central systems and individual machine tool recycling. The high-speed disc bowl centrifuges are available with either a manual clean, solid-wall bowl or a self-desludging two-part bowl design. The later automatic, self-cleaning bowl is preferred in high solids applications and on central system equipment. 8

9 Portable Coalescer Designed for plants with multiple machines needing a simple, effective, low-cost tramp oil separator able to be moved from machine to machine. Eriez Portable Coalescer uses an oleophilic (oil attracting) coalescing plate pack media to remove oils effortlessly and efficiently. The unit is equipped with a standard electric submersible pump, but can be upgraded with an optional air pump or a heavy-duty electric pump for deeper sumps. This portable coalescer is effective with high temperature fluids such as cleaners as well. Consult the factory for larger flow rate systems. Tank Side Coalescer (TSC) With a flow rate of 1.5 GPM, this small inexpensive sump-side coalescing unit allows oils to rise naturally by providing a quiescent area not available in a turbulent sump. The TSC comes standard with a submersible pump or with optional air pump. Surface Oil Skimmers The Surface Tramp Oil Belt Skimmer features an oleophilic belt and a unique method of stripping the separated oil from both sides of the belt without contact with a stationary scraper. This provides a great combination of performance and long belt life. The Standard Surface Tramp Oil Belt Skimmer uses a similar oil loving belt, but uses a more compact scraper blade to strip the separated oil from the belt. This low maintenance item can be equipped with a timer so that the unit runs only when the machine is idle and the tramp oils have risen to the surface. The Standard and Deluxe Surface Oil Belt Skimmers can be used even in applications with limited access. Tank Side Coalescer an effective yet economical unit. The Portable Coalescer accelerates the process of removing tramp oils with its unique plate pack coalescing media. Portable Tramp Oil Separators remove even the peskiest tramp oils and can be easily moved on its mobile platform 9

10 Controlling Concentration Proper concentration control increases fluid performance and longevity Keeping tight control of the fluid concentration ensures fluid never gets too lean or too rich. Eriez complete line of mechanical concentrate mixers meets the needs of all size metalworking shops. These mixers eliminate manual fluid mixing that often results in imprecise concentration control. Drum Top Mixer A compact, easy-to-use venturi mixer for combining water with coolant concentrates. Water, jetting through the unit, creates a vacuum that siphons concentrate from the drum. A needle valve offers infinite adjustment across the mixture range of 2% to 10%. The Drum Top Mixer is available in 3, 10, and 25 GPM versions and its all-metal construction provides maximum durability. The Drum Top Mixer is an economical, easy-to-use venturi mixer. The Proportioner is a water-driven, positive displacement proportioner which dispenses coolant on demand at the desired concentration. Eriez Proportioner When greater accuracy and automatic mixing are required, consider the Eriez Proportioner. This automatic unit is a water-driven, positive displacement proportioner dispensing coolant on demand at the desired concentration. The average flow rate is 5 GPM with mixing ranges from 1% to 25%. Special units are also available for highly alkaline parts washing fluids. The Eriez Proportioner provides consistent concentration at all times despite varying water pressures or fluid levels in supply containers. Because it is driven by the plant s water supply pressure, it can also supply properly mixed fluid through overhead piping to machine tools without a booster pump. 10

11 Eriez Industrial Fluid Testers feature automatic temperature compensation. Quickly determine coolant concentration with the Refractometer. Measurement Tools Fluid maintenance and concentration control programs must be checked on a regular basis. Eriez offers a number of different style refractometers to ensure accurate concentration. The Refractometer is a simple yet rugged device with a large, easy-to-read scale available in 0-10 Brix or 0-32 Brix models. This portable meter requires no batteries and quickly determines the concentration level of: coolants and cleaners heat-treating fluids water-based hydraulic fluids Pure Water makes better coolant Eriez advocates the use of pure water as pure water is key to excellent coolant, cleaner performance and longevity. Pure water sources include deionization and reverse osmosis. Eriez can provide you with a complete reverse osmosis system. Reverse osmosis (RO) is a process that removes up to 98% of dissolved minerals, and virtually 100% of colloidal and suspended matter. Compared to other processes, it provides excellent quality water at a low cost and does not require acids or caustics for regeneration. RO systems are available from 100 to more than 10,000 gallons per day. plating baths The temperature of certain fluids can affect the refractive index reading of the mix. In this case, an automatic temperature compensating refractometer is needed. Eriez temperature compensated Industrial Fluid Testers have large easy-to-read scales and are available in two ranges: 0-20 Brix, and 0-30 Brix. Eriez also offers an extremely accurate, hand-held, digital Refractometer with an easy to read LCD readout with 0-52 Brix. Proper concentration control increases fluid performance and longevity. 11

12 Complete Fluid Filtration Systems Fluid filtering applications range from individual machine tools or cells to complete plant-wide centralized systems supporting a variety of metalworking operations using water-based coolants to straight oil lubricants. To handle these types of applications, Eriez offers multiple HydroFlow Filtration solutions: Cartridge Filter Systems Provide positive inline filtration, to protect high pressure pumps, polish coolant or provide side loop filtration. Automatic Vacuum Filters CBN Vacuum Filter STAR Filtration System Centrifuge Filter System HydroFlow Centrifuge Filters Performance to 5 Microns Gravity Filter Systems Magnetic Drum Separators Hydrocyclone Separators Custom Transfer Equipment The STAR FILTER Element s unique design provides the maximum filtration area in the most economical use of space. Note: Some safety warning labels or guarding may have been removed before photographing this equipment Eriez, Eriez Magnetics, HydroFlow and STAR Filter are registered trademarks of Eriez Manufacturing Co, Erie, PA World Authority in Advanced Technology for Magnetic, Vibratory and Inspection Applications Headquarters: 2200 Asbury Road, P.O. Box 10608, Erie, PA U.S.A. Telephone: 814/ / Fax: 814/ International Fax: 814/ Web Site: eriez@eriez.com AUSTRALIA BRAZIL CANADA CHINA INDIA JAPAN MEXICO SOUTH AFRICA UNITED KINGDOM UNITED STATES 910-1M-AHA-MC ERIEZ MANUFACTURING CO 2010 PRINTED IN USA

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