and paper industries because of the harsh fluids han- dled in those segments. The research house also points to the introduction of new and better-perform- ing pumps as a source of growth in the coming years. However, the emergence of longer-lasting pumps is expected to negatively impact demand for replace- ment parts.

Meanwhile, Freedonia tempers its prediction for the pump market, noting that value gains through 2006 could be somewhat restrained by international com- petition and new technology. Freedonia’s analysis of the pump market is part of a new study called Pumps. In it, Freedonia asserts that process manufacturing industries will remain the largest market for pump products over the next three years. Increasing output in the chemical and pharmaceutical industries is expected to assist growth. Among other major sectors, utilities are also expected to see above average gains

and quaternaries manufactured by the Industrial Specialties and Textile Care business lines.

IICTA Extends Scholarship Deadline The IICTA (Industrial Instrumentation and Controls Technology Alliance) has extended the application dead- line for its Fall 2004 Instrumentation Technology

15 to Apr. 1. Available to students who are planning to enroll in an ology two-year degree program, is sponsored by BP Exploration rough its collaboration with the

Stay reported this past month that a “toxic ud from a food plant” forced the evacuation and kept residents inside their homes in

expenditures by utility providers, particularly wat works and natural gas pipelines.

Hydraulic Institute’s ’04 Officers The Hydraulic Institute Directors and officers group’s annual meetin The appointments inclu Pasquale DePalma, pres Division, will serve as board Phillips, president and ch Shurflo Pump Mfg., will se Parrin, president of the La Sterling Fluid Systems, technical affairs; and R ITT’s Industrial Products ident, member services.

On The Fly Cleaning Paratherm Corp. (www.paratheum.com) LC system cleaner liquid allows large continuous operating hot oils systems to be cleaned without shutdown and over- haul. According to the company, simply replace 10% of the existing fluid with the LC liquid, install a 100 micron element in the sidestream filter (removing the screens from the Y-strainers) and restart the system. After the liquid circulates and sludge deposits are released into the flow, filtgr ekments should be reduced

to 50- and 25-micorn. When circulation continues for a day without the need to change the 25-micron element, the system is ready to be drained and recharged.

Goldschmidt Raises Prices Effective April 1, 2004 Goldschmidt Chemical Corp. (a subsidiary of Degussa corp.) is increasing prices by 5% in North America for all organic surfactants, fatty amines

huric acid were accidentally mixed, producing c acid, which exited the tank and blew the storage tank. The plant uses ferric chloride

uric acid to process wastewater.

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April 2004 www.cIeantechcentral.com 15

UF System Operation & Maintenance Checklist 10 Minutes (Daily) Permeate flowrate or flux measurements (container/ stopwatch) orator

*Visual inspection of permeate quality and pump seal leakage Daily inlet and outlet pressure checks

Five Minutes (Weekly) Inspect pump connection to bedplate and pump motor align-

Two Hours (Once every 3 4 weeks) Batch out process tank and transport oily waste to evap-

Exchange dirty membrane with a clean backup membrane Inject caustic solution into membrane with syringe and soak in Stage 1 cleaner tank.

ment

Dirty Stage 1

Bath Purification

The Turbo-Separator T14-3AQ Centrifuge Bath Purification System is designed to remove large volumes of solids, grease and free oil from aqueous bath solutions.

the solids are removed as a relatively moisture-free, easily disposed cake. The System is designed for the high pH and temperatures of washer solutions. www.sanborntechnologies.com

The removed oils are separated to an integrated tank and

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an 88% O&G removal rate while reju- venating the Stage 1 alkaline cleaner.

The O&G concentration average during the study was 70 percent below the baseline value of 250 mg/l found in the spent cleaner. Without being able to overflow Stage 2, Metcam could not allow O&G levels in Stage 1 to rise into the l , ~ Z , O O O mg./l range. Metcam's chemical sup plier claims that a proprietary compo- nent of the cleaner formulation prevents high O&G concentrations by encapsulating and dropping the oils out to the bottom of the tanks as a sludge. With the UF system installed, Stage 2 bath life was extended to six production days before reaching 1oml oil/lOoml rinse. After the rinse coun- terflow system was installed, Stage 2 did not reach loml oil/lOoml rinse

A certified independent laboratory analyzed cleaner samples using CTAS test method SM 5540 B, D. The neat cleaner formulation has a non- ionic surfactant concentration of 27 mg/l. The six-month old cleaner had a nonionic surfactant concentration of 66.8 mg/l and it is believed that a @e percentage was tied up with O&G and therefore unusable. The average concentration found in Stage 1 during the pilot study was 28.2 mg/l with only three grab samples exhibiting surfadants concentrations below 15 mg/l.

Recovery efficiency testing was also conducted in January and February 2003 to evaluate the per-

Before Project During Project After Project

tiveness of the alkaline cleaner stage.

Wastewater Reduction One of the most rewarding results of the project was the dramatic reduc- tion in Stage 2 wastewater generation. Metcam thought that if the rinse stage could be doubled to four production days the project would be a success. After the UF system was installed

~

M&cam also set a goal for extend- ing the life of their Stage 1 alkaline cleaner. Stage 1 was lasting an aver- age of six months and Metcam want- ed to extend the cleaner bath life to one year. The UF system helped them meet this goal by minimizing o&rG buildup. As of January 2004, Stage 1 was still operating effectively. Metcam now believes that they can get at least an additional six months out of the cleaner bath.

Alkaline Cleaner Usage Based upon the results of the pilot study, it was pjected that Metcam would rralize a 64 pemnt reduction in annual Stage 1 alkaline cleaner usage. A smaU impvesnent was made after installation of the UF sys- tern, with deaner usagein@Iom per lm ftzof parts processed going from 1.78 to 1.46, respectively. It wasn't until after the rinse COunterflOW SYS- tem was installed however, when

2.5

~

~'II 1111.. 1"11--. 0.5

Sept M kx Dec Jan k b Mu Apr May June July Aug Sept Oa blov Dec 2002 2002 2002 2002 2003 2033 1003 2003 2003 2003 2003 2003 2003 2003 2003 2003

Figure 4. Stage 1 alkaline cleaner usage before, during and after the pilot study.

20 April 2061 www.deantechcentral.com

Metcam noticed that cleaner addi- tions were decreasing substantially. For the remainder of the pilot study, Metcam used only 0.36 gallons of cleaner per 1,000 ft2.

Figure 4 shows a month-by-month profile of Stage 1 cleaner usage nor- malized to production from September 2002 through December 2003. Note that monthly cleaner usage was even lower in the six months following the pilot study with no chemical add required in December 2003, even though 34,800 square feet of parts were processed.

The cleaner usage reductions observed can be explained by a number of contributing factors. First, since the UF system i s remov- ing O&G and other contaminants from Stage 1 continuously while

ering cleaner chemistry, the alkalinity and surfactant package is not being consumed as quickly as it

and the percent s o h ained with less c

additions. Also, with the rinse coun- terflow system returning cleaner to Stage 1 that is carried into Stage 2 on the surface of the parts, the need to

add new cleaner as makeup for most likely prolonged the payback dragout losses is eliminated. period. Lastly, make sure to verify

with the equipment supplier that the Conclusion internal components of any recircu- The alkaline cleaner ultrafiltration lation pumps used with the UF sys- and rinse counterflow system exceed- tem are properly specified for high ed Metcam's goals and expectations. pH, oily solutions.

Additionally, by decreasing the This project represented a unique demand on the evaporator system, industry-government partnership Metcam can now save an additional within the Georgia Metal Finishing

ting the pollution ce. Metcam is con-

th P2AD in accel- ntation of the P2

red events.

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21

Get the

out Stop Corrosion in

/ ou have just installed an system - clean, silver

steel wash-water

process, confident that over. But, after several gelatinous substance in the sample flask. You open the sys- tem and the tank has a reddish deposit all over the inside. You open a pump and the impeller is red, the volute is red and the discharge is red. You look in the heat exchanger and see more red. The spray balls have red streaks around the orifices. What went wrong? Why i s good stainless turning red? To understand what is happening, we need to review the basics of stainless steel and corrosion.

Y

How Does Stainless Corrode? Stainless steel is iron with chromium added to give iron oxi- dation resistance. Other elements are added for specific physical properties or to give corrosion resistance in specific environments. The main point to remember is that stainless steel is mostly iron, about 70 percent for Type 304L and 69 percent for Type 316L.

There are five basic mechanisms that cause stainless steel corrwsion: uniform corrosion; intergranular corrosion; gal- vanic or general corrosion, whch includes pitting and crevice corrosion; stress corrosion cracking and microbiolog- ically influenced corrosion (MIC). In addition, there are sev- eral mechanical processes that accelerate the five basic mechanisms. These include erosion, cavitation, fretting, for- mation of concentration cells and changes in surface chem- istry by thermal or electrical forces.

All of these mechanisms have one characteristic in com- mon: the chromium oxide passive layer is breached and the unprotected iron component is oxidized. For an under- standing of the rouging phenomenon only two mechanisms will be considered: uniform or general corrosion and crevice

arts Uashing Systems T by John T'uerber-g I

Figure 1: An example of a weld beginning to corrode under the rouge deposit.

corrosion together with erosion, cavitation and concentra- tion cell formation.

Where Rouging Occurs Rouging of stainless steel is the result of the formation of iron oxide, hydroxide or carbonate-either from external sources or from destruction of the passive layer. Color variation is a result of the oxide/hydroxide/carbonate type and varia- tions in the water of hydration associated with the molecule. These colors range from orange to red to black.

Rouging can take place in pure water, ultra-pure water, steam, treated potable water or untreated process water. To date, the five mechanisms mentioned above have

_._

22 April 2004 www.cleantechcentral.com