All Cleaning Options for Parts Cleaning Rick Perkins Chemical Engineer / President Chem Logic Austin, Texas www.chemlogic.us 512-426-5728 rperkins@chemlogic.us
Our Experience 10 years in M&P working on high-reliability manufacturing of Space / Defense assemblies (Honeywell) 5 years on international projects replacing chemical processes that damaged the ozone layer (US EPA and World Bank) 20 years as a technical sales engineers working for multiple companies in equipment and specialty chemical sales Founded Chem Logic in 2009 as a one-stop resource for parts cleaning processes BS ChE University of Texas / MBA ASU
Cleaning Options Summary Water-based Hydrocarbon Immersion Solvents Hot Vapor DeFluxing / Distillate Rinse Re-deposition Plastic Compatibility Difficult for Tight Gaps and Blind Holes Non Volatile Residue Fast Process Slowest Process Flash Point Cleans Tight Gaps Solvent Maintenance No Water on Parts Only Option for Waterbased Fluxes Low Energy Cost Distilled Solvent Low Cost Equipment High Solvency Low Maintenance Nonflammable Drying / Moisture High Energy Costs Chemistry Monitoring Wastewater Treatment High Cost of Equipment
New Rule: Find the Right Cleaning Process for the Reliability Level of Your Product Not Everyone is Building Products for Outer Space.
Only 3 Types of Contamination In This World POLAR 3 Types of Contamination NON-POLAR PARTICULATE
Why is Cleaning Required? Prepare Surfaces for Coating or Bonding conformal coating, marking, or painting adhesive or rubber molding bonding anodizing or plating, etc Remove Contamination that can cause Corrosion or Ionic Dendrites Meet Quality or Customer Requirements
Cleaning Options Hydrocarbon Immersion Hot Vapor Condensation & Distillate Rinse No Clean Process Water-based Wash, Rinse, & Dry 6 CLEANING OPTIONS Bench Top Cleaning Co-Solvent Hydrocarbon & Vapor Rinse
Clean means different things to different customers And the Process of cleaning yields differing results.
Cleaning Optimization is the matching of the Solute (the contaminant) with the best Solvent (the cleaning chemistry), so to effectively remove it from the surface. We Use Hildebrand Solubility Parameters
How Do You Know it's Clean? Cleanliness is measured by... visual / ultraviolet light Easy water-break test ionics and ionic residue (ionograph) particulate counts gravimetric (weight change) surface analysis - Auger, EDAX FTIR / Gas Chromatograph Difficult
The Perfect Cleaning Process... High Solvency / Effective Solubility Removes the Contamination Cleans Blind Holes / Under Tight Gaps Distillable / Recyclable Easily Automated Relatively Small Physical Foot Print Non Hazardous Safe to Use Approved by US EPA and TCEQ Low Effect on the Environment Doesn't Exist
Hardest Parts to Clean First, the cleaning fluid must penetrate the small micronic gap under the component. Second, it must dissolve the unreacted flux, ionics, and paste and keep it in solution. Third, it must leave from under the component, with this new formula containing the contaminants. Not an easy job.
Residue Under Component www.process-sciences.com
Water-based Cleaning
Reciprocating Platform, Water Based Wash, Rinse, Dry
Dishwasher-style Water-based
Inline-style Water-based
Water-based Cleaning Great for Water Soluble Fluxes & Oils Requires 2 to 4 process tanks (floor space) Longer Process Times Difficult to Clean and Dry Blind Holes Parts May Require Demoisturization High Energy Usage (heating, drying of H2O) Chemical Maintenance / Monitoring Usually High ph (10 to 11) Uses a Large Amount of Water* Requires Water Treatment* *closed-loop processes exist
Immersion Solvent Cleaning
Immersion Solvent Cleaning Terpenator, Air-driven, No Heat, Low-cost
Immersion Solvent Cleaning MicroCel, Centrifugal Spinner
Immersion Solvent Cleaning Strong Cleaning Chemistry Neutral ph, Polar / Non-Polar Blends Requires 1 to 3 Tanks Lowest Energy Usage, No Heat But... Solvent is Contaminated Quickly Requires Frequent Changeouts VOC Evaporation Possible Solvent Exposure Issues
Hot-Vapor Condensation Solvent Cleaning (aka vapor degreasing)
Hot-Vapor Condensation Cleaning
Vapor DeFluxing / Degreasing
Vapor Degreasing / Cleaning Fast Cleaning Process 2 to 8 Minutes Vapor Condensation exhibits Low Surface Tension High Solubility Solvents (Fluosolv / Entron) Vapor Cleans Blind Holes / Intricate Parts No Waste Water for Disposal or Treatment Small Foot Print for the Equipment Safe Automated Process Very Low Solvent Emissions Recycles & Distills Solvent Continuously Low Maintenance / Moderate Equipment Costs
Particulate Removal Options Use of Ultra Sonics in the Clean Side Immersion Tank Cleans Blind Holes Combined with the ENTRON CE Solvent Azeotrope Reduces Ionic Charge Ionically Charged Particulates are Typically Eliminated Three Frequencies are Available Avoid Sweeping Frequencies
Two-Tank Solvent Vapor Cleaning Process Hot Vapor, Ultrasonics FreeBoard Vapor Trap Coils ~ Negative 25 C Primary Coils ~ 5 C Hot Solvent Vapor Condensate Return Immersion H-C Blend Boil Tank Distillate Solvent Particulate Filter Pump Heating Elements Ultrasonics (optional)
Two-Tank Vapor Degreasing Process FreeBoard Coils Vapor Condensing Coils Condensate Return Boil Tank Heating Elements High Purity Solvent Filter Pump
Two Tank Vapor Degreasing Steps Step 1: Condensation of Solvent Vapor on Parts and Removal of Oils, Grease, Ionics, and Other Residues FreeBoard Coils 1 Condensing Coils Condensate Return Heating Elements U/S Filter Pump
Two Tank Vapor Degreasing Steps 2. Immersion in Pure, Distilled Solvent FreeBoard Coils Condensing Coils 2 Heating Elements U/S Condensate Return Filter Pump
Dwell to Capture Solvent Emissions 3. Dwell at Cold Condensing Coils 4 3 4. Removal FreeBoard Coils Condensing Coils Condensate Return Heating Elements U/S Filter Pump
Vapor-Spray Process One Tank FreeBoard Refrigeration Coils Vapor Primary Condensing Refrigeration Coils Condensate Return Boil Chamber Heating Elements
Step 1: Basket is Placed in Hot Vapor; Solvent Condenses on Parts and Cleans Them; (Optional Pure Solvent Spray) FreeBoard Refrigeration Coils Primary Condensing Refrigeration Coils 1 Condensate Return Boil Chamber Heating Elements
Step 2: Dwells in Cool Vapor Trap Step 3: Basket is Removed 3 2 FreeBoard Refrigeration Coils Primary Condensing Refrigeration Coils Condensate Return Boil Chamber Heating Elements
Ultimate Vapor Cleaning Enhanced Vapor Degreaser Pre-Cleaning Stage with a Solvating Agent that can target specific contamination Rinsed by a Vapor Degreasing Cycle Also known as CoSolvent cleaning Uses a Nano-Still to remove the solvating agent from the vapor degreaser Recommended for Unusually Difficult to Clean Contamination
Ultimate Duo-Solvent Cleaning Process Immersion, Hot Vapor, Ultrasonics FreeBoard Vapor Trap Coils ~ Negative 25 C Primary Coils ~ 5 C Vapor Recycles Condensate Return Pre-Clean Ambient or Heat Immersion H-C Blend Boil Tank Distillate Solvent Particulate Filter Pump Particulate Filter Pump Heating Elements Ultrasonics
Ultimate 2-Dip 3-Tank Cleaning Process Double-Dip Immersion, Hot Vapor, Ultrasonics FreeBoard Vapor Trap Coils ~ Negative 15 F Primary Coils ~ 50 F Hot Solvent Vapor Condensate Return Pre-Clean Ambient or Heat Immersion H-C Blend First Immersion Dip Final Immersion Dip Particulate Filter Pump Particulate Filter Pump US Option US Option
M Series Front View Model MLR-216-LE Control Panel Electrical Enclosure Boil Sump Drain Boil Sump Cleanout Port
MSR216LE MLR216LE Programmable ATH35 2 axis lift Two Tanks, Each 18 x 12
Single-Axis Automated Basket Lift
PCH-75 Programmable Automatic Hoist Picks Up on Side of Machine Eliminates Solvent Exposure Best for Safety and Hands Free http://www.baronblakeslee.net/pch-dual-axis.aspx
Optional Exhaust System
Programmable Distillate Spray
Vapor Trap Freeboard Cooling
M Series Process Area Distillate Spray Wand Primary Condensi ng Coil Boil Sump Immersion / Ultrasonic Sump -20OF Freeboard Coil
M Series Side View Model MLR-216-LE Manual Sliding Cover Water Separator & Drain Freeboard Refrigeration Distillate Reservoir Still Inlet Filter Canister Primary Refrigeration Ultrasonic Transducer Coupling Distillate Spray Pump (transducer not installed) Immersion Sump Drain Distillate Reservoir Drain Water Separator Drain Filtration Pump
Solvent Options for Vapor Degreasing All Must Be Non-Flammable Brominated - N-propyl Bromide (EnTron) Fluorinated (FluoSolv, Solvex, Aerotron) Fluorinated Blends with 1,2 trans Dichloroethylene (FluoSolv, Aerotron) Chlorinated (most are Hazardous Air Pollutants) Most are Approved by US EPA's Significant New Alternatives Program (SNAP)
Benefits of Vapor Degreasing Equipment Very Low Emissions with Vapor Trap Continuously Recycles and Purifies the Solvent Fast Cleaning Process, 2 to 8 minutes Minimal Waste / No Wastewater Contamination Removed with Vapor Condensation Minimal Surface Tension Available in Many Sizes Compatible with All Vapor Degreasing Solvents
Cleaning Options Summary Hydrocarbon Immersion Solvents Hot Vapor DeFluxing / Distillate Rinse Re-deposition Plastic Compatibility Difficult for Tight Gaps and Blind Holes Low Cost Equipment Fast Process Slowest Process Non Volatile Residue Cleans Tight Gaps Flash Point No Water on Parts Only Option for Waterbased Fluxes Solvent Maintenance Distilled Solvent Low Energy Cost High Solvency Low Maintenance Nonflammable Water-based Drying / Moisture High Energy Costs Chemistry Monitoring Wastewater Treatment High Cost of Equipment
Please Feel Free to Contact Me to Ask Questions on Any Cleaning Process Consulting, Chemistry, & Equipment for Production Rick Perkins Chem Logic President / Chemical Engineer 512-426-5728 Austin, Texas www.chemlogic.us Agents for N-Propyl Bromide, Fluorinated Solvents, Other Specialty Solvents, Baron Blakeslee Equipment, Specialty Baskets, Advantage Water Chillers, Evaporators, CBG Recycling, and FloraChem CitraFlor and Solvex HD Solvents
Video Links of Solvent and Equipment in the Vapor Degreasing Process ATH-35 with an MLR216LE http://youtu.be/kbdnqcpdivc SMH50 Hoist in an MSR280LE https://youtu.be/ovr-imogo-w PCH-75 Automatic Hoist with a Small Vapor Degreaser http://www.youtube.com/watch?v=xcfud-ex6fg MSR-480LE cleaning metal parts: http://www.youtube.com/watch?v=k2mr41eujsg www.baronblakeslee.net