WIN 2016 Istanbul - Presentation Dürr Ecoclean (Tekeli-II)

CLEANING AND SURFACE PROCESSING
SELECTION OF THE OPTIMUM
CLEANING TECHNOLOGY
Ümit Tekeli, Global Area Sales Turkey
Forum: Surfaces in the metalworking industry, Istanbul, February 2016
www.durr.com
DÜRR GROUP
Dürr Ecoclean as member of Dürr Group
Since 1895
Global presence in
28 countries
50 production facilities
92 business locations
Employees
14.700 (per 9/30/2015)
Sales
≥ € 3.6 bn (2015e)
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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CLEANING AND SURFACE PROCESSING
Cleaning and Surface Processing
Cleaning Automotive
Cleaning Industrial
Cleaning systems for powertrain,
engine and transmission parts
Part cleaning systems for use in
machining
and
manufacturing
applications plus fine cleaning in the
production of medical and highprecision optical equipment
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
Surface Processing
Systems for activating
coating,
de-coating
conditioning of surface
before
and
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STABLE PART CLEANLINESS THROUGH…
…defined part type, complexity and contamination
Material
Geometry
Surface quality
Type and quantity of
contamination
Throughput
Part positioning:
Positioned
Single
Bulk
Part treatment before
and after cleaning
Cleanliness requirements
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…defined part type, complexity
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…appropriate cleaning fluid/media
Contamination
Hydrocarbons
Modified Alcohol
Watery Cleaner
organic, non polar
(e.g. oil, grease)
very good
good
moderate
organic, polar
(e.g. combined contamination)
moderate
very good
moderate
inorganic, polar
(e.g. salts)
moderate
moderate – good
very good
solid substances
(e.g. chips, particles, dust)
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
depending on machine type!
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STABLE PART CLEANLINESS THROUGH…
…defined range of part and contamination
Application example:
Cleaning of a wide part range in same machine!
Modified
Alcohol
Watery
Cleaner
10 min
15 min
Cleaning effect
in capillary
+
-
Cleaning result
in general
-
+
Corrosion
protection steel
parts
+
-*
Surface aluminium
parts
+
-*
Result
Throughput/
Cycle time
Piston rods (Steel)
Control block (Alu)
Cylinder block (cast parts)
Steel parts (misc. surface)
*without extensive machine technology
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…appropriate machine selection / equipment configuration
Cleaning fluid
Watery cleaner:
Organic solvents:
Machine type
neutral
Single chamber machine
acidic
Multi-chamber immersion cleaning system
alkaline
Belt washer/cleaner
hydrocarbons
Robot supported cleaning systems
modified alcohols
chlorinated hydrocarbons
Process
…
Periphery
Spraying
Injection flood washing
Automation level
Ultrasonic
Part movement
Part handling/logistics
Hot air drying
Vacuum drying
Environmental conditions
Infrared drying
Filtration
…
Treatment
…
…
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…appropriate machine selection / equipment configuration
Application example: Cleaning and preservation with assembly oil
Supplied parts
with
preservative oil
Cleaning
Preservation
with
assembly oil
Assembling
Magnetic valve
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…appropriate machine selection / equipment configuration
Application example:
Cleaning and preservation with assembly oil
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
Parts
Bearing bushes, armatures
Pole discs, pistons
2.4 Mio parts/a
Cleaning
method
(modified
alcohol)
FT1: IFW
FT2: US + IFW, 70°C
Vapour degreasing, vacuum drying
Cycle time = 540 s, 3 shifts/d
Contamination
Preservation oil, particle, dust
Cleanliness
requirement
Max. particle size 300 µm
(metallic), <0,2 mg / part
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STABLE PART CLEANLINESS THROUGH…
…control of quality influencing parameters
Parameter
Hydrocarbon
Watery
Control of watery based bath content with…
Standard methods
Pressure
Special methods
Temperature
− Acidic base titration
− online Tenside
measuring
Fill-/discharge times
− Photometric tenside
determination
− online particle counter
Particle content
− Conductivity
measurement
− Automatic dosing
Machine status
− …
− …
Filling volume
Bath quality:
• Concentration of
cleaner
• Quality of fresh water
• pH-value
• Conductivity
-
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…recovery of cleaning fluid
Task
Removal of contamination from cleaning fluid
Aim
Extension of life time of cleaning / rinsing bath
Maintenance of cleaning effect
Conductivity
Maintenance of rinsing effect (for aqueous systems)
without preparation
10 l/h (demand-given preparation)
100 µS
50 l/h (continuous preparation)
Bath life-time
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…recovery of cleaning fluid
Cleaning I
Input of
contamination
Cleaning II
Carry over of
contamination
Filtration
Filtration
Distillation (e.g. with oil discharge)
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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STABLE PART CLEANLINESS THROUGH…
…recovery of cleaning fluid
Rinsing I
Cleaning
Input of
contamination
Carry over of
contamination
Dosing of cleaner
Reiniger
+
Wasser
Carry over of
cleaner
Carry over of
contamination
Wasser
Dosing of
fresh water
Filtration
Rinsing II
Carry over of
cleaner
Carry over of
contamination
Wasser
Dosing of
fresh water
Filtration
e.g. oil separator,
Settling tank
Recovery of cleaner bath
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
Carry over of
cleaner
Dosing of
fresh water
Filtration
e.g. evaporator
DI device
Recovery of rinsing bath
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STABLE PART CLEANLINESS THROUGH…
Examples of recovery methods
Chemical methods
Thermal methods
Demulgation
Atmospheric Distillation (Evaporation)
Ion exchange
Vacuum distillation
UV-Oxidation
Gravity methods
Filtration methods
Bag filter
Cartridge filter
Micro-and ultra filtration
Reversible flow filter
Magnetic separator
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
Hydro cyclone
Settling tank
Centrifuge
Gravity oil separator
Support by e.g.
• Plate coalescence separator
• Direct gassing
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STABLE PART CLEANLINESS THROUGH…
…regular maintenance
The key points are e.g.:
Optimized maintenance concept
Qualification of personnel
Sustainable regular maintenance
Example: Watery based cleaning of steel parts
in case of too low dosing of cleaning media
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
Example: Accumulation of particles in tanks
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SUMMARY
Influencing parameters in the cleaning process
Appropriate
machine
equipment
Control of
process
parameter
Appropriate
cleaning media
Defined part
contamination
Defined part
range
Optimized
media preparation
Stable part
cleanliness
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
Regular
maintenance
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PART CLEANING IN THE FIELD OF
CLEANING AUTOMOTIVE
Technologies and Processes
Robotic cells
In-line transfer systems
High-pressure deburring machines
Belt-type washers
Multi-chamber systems
Single-chamber systems
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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PART CLEANING IN THE FIELD OF
CLEANING INDUSTRIAL
Technologies & Cleaning fluids
Single-chamber systems
Multi-chamber systems
Special application systems
Deburring of small parts
Iron/zinc/manganese phosphating
Automatic loading/unloading systems
Aqueous cleaning media
Non-halogenated hydrocarbons
Modified alcohols
(Chlorinated hydrocarbons)
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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PART CLEANING IN THE FIELD OF
FINE CLEANING
Technologies & Cleaning fluids
User-specific multi-chamber systems
Combined cleaning processes
Aqueous fine/ultra-fine cleaning
Cleaning of optical precision
parts & microsystems
Cleaning of mechanical
precision parts
Cleaning of medical
components
Cleaning before PVD/CVD
coating
Non-halogenated hydrocarbons
Modified alcohols
Chlorinated hydrocarbons
HFE (Hydrofluorether)
© Dürr Ecoclean, CSP, Selection of the optimum cleaning technology, February 2016
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CLEANING AND SURFACE PROCESSING
SELECTION OF THE OPTIMUM
CLEANING TECHNOLOGY
Ümit Tekeli, Global Area Sales Turkey
Forum: Surfaces in the metalworking industry, Istanbul, February 2016
www.durr-ecoclean.com