GEA Mechanical Equipment

Treatment of wash liquids

Business Line Oil & Gas19 November 2013

GEA Mechanical Equipment / GEA Westfalia Separator Group GmbH

GEA Mechanical Equipment

Washing lye Mixture of water and washing detergents

Concentrate consists of Detergents Foam stabiliser Surface-active agents

pH-value 5 to 14 (new wash liquid)

Working temperature 40 C to 90 C

Problem Tramp oil and particle contamination

Definition | Washing lye

Treatment of Wash Liquids2

GEA Mechanical Equipment

withoutcleaning

Liquidchange

continuousseparatorcleaning

Time

max. tolerablecontamination

Con

tam

inat

ion

Continuous wash liquid cleaning

3 Treatment of Wash Liquids

GEA Mechanical Equipment

Reduced disposal volumes and disposal costs for waste liquids

Minimized washing lye consumption

Environmentally friendlysolution

Why washing lye cleaning?

Higher productivity

Less change intervals of wash liquid

Higher machine availability

Increasedproduct quality

Cleaner parts

Fewer rejects

4 Treatment of Wash Liquids

GEA Mechanical Equipment

Applications in the Automotive Industry

Increasingly stringent demands on thesurface quality of components in the automotive industry require effective cleaning with washing liquids.

Continuous treatment of the cleaning agents used (washing lyes, degreasing baths) results in significant cost savings.

Washing Lye

5 Treatment of Wash Liquids

GEA Mechanical Equipment

Spray Degreasing

Treatment of Wash Liquids6

Problem Particles in the washing lye lead

to clogging of pumps, valves andnozzles

Consequence: Production breakdown

Solution Separator keeps particles at a low

and constant level

GEA Mechanical Equipment

SludgeLight phase

7 Treatment of Wash Liquids

Spray Degreasing

GEA Mechanical Equipment

Problem Oil in the washing lye affects

product quality

Consequence Wash liquid has to be changed

- high disposal costs and volumes- machine downtimes- environmental impact

Solution Separator removes tramp oil and

solids from the washing lye in onesingle step

Immersion Degreasing

8 Treatment of Wash Liquids

GEA Mechanical Equipment

Dirty washing lye

Clean washing lye

Thin sludge

Operating water

Tramp oil

Washing Lye Treatment | Immersion Degreasing

9 Treatment of Wash Liquids

GEA Mechanical Equipment

Case story | Automotive industry

BMW AG

German (premium) car manufacturer

Installation for washing lye treatment:

One separator in continuous operation for bath 1

One separator in continuous operation treating alternately bath 2 and bath 3

Washing stepTank

volumeOil inlet per

car bodyRequired max. oil

content in bath

1. Brush degreasing 40 m 2,4 g/m 3 g/l

2. Spray degreasing 30 m 0,45 g/m 2 g/l

3. Immersion degreasing 185 m 0,15 g/m 1 g/l

10 Treatment of Wash Liquids

GEA Mechanical Equipment

Applications in the Steel Industry

In the cold rolling process, the surfaceof the rolled strip is contaminated by cooling oil or emulsion and other impurities that can considerably influence the end quality of the strip.

For a high quality of rolled material it is necessary that the surface is clean before further treatment processes(e.g. coating).

Washing Lye

11 Treatment of Wash Liquids

GEA Mechanical Equipment

Light phase Sludge

Washing Lye Treatment (Immersion degreasing)Example: Steel Rolling Mill

12 Treatment of Wash Liquids

GEA Mechanical Equipment

Case story | Steel industry

Nisshin Steel

Major Japanese steel manufacturer

Problem: Oil and particles contamination in

washing lye system (76 m total volume) Degreasing bath had to be cleaned by

changing 19 m every two weeks

Successful installation: Oil content is continuously kept below 5 g/l Metal particle content is continuously kept

below 400 ppm

IISI

13 Treatment of Wash Liquids

Result: Change interval for the 19 m was

extended from 2 weeks to 3 months

GEA Mechanical Equipment

Applications in the Metalworking industry

Due to increasing quality requirements, cleanliness of workpieces and components plays an essential role in the surface cleaning process.

To maintain the optimum cleaning effect of the cleaning agents, particles and tramp oil must be removed.

Continuous fluid cleaning ensures a highercleaning efficiency and a longer service life of the washing liquids.

Washing Lye

14 Treatment of Wash Liquids

GEA Mechanical Equipment

Case story | Metalworking industry

Miele

German Manufacturer of domestic appliances including laundry appliances (washing machines)

Problem: Oil and particles contamination in washing lye Degreasing bath had to be replaced with

some 800 litres every six weeks

Solution: At first: Use of manual cleaning separator

OTC 3 for washing lye treatment Now: Use of a self-cleaning separator OSD 6

15 Treatment of Wash Liquids

Result: Ten times increase in service life of the

washing lye

GEA Mechanical Equipment

Stationary compact unit with self-cleaning separator type OSD 18

Washing lye Treatment Systems

Treatment of Wash Liquids16

Also available in stainless steelfor ph-value > 9.5

GEA Mechanical Equipment

Significant lifetime extension of the washing lye

Constant high surface quality of the car body due to uniform cleaning effect

Reduced operating costs due to less purchasing and disposal costs

Increased machine uptime

Benefits of Washing Lye Treatment

Treatment of Wash Liquids17

GEA Mechanical Equipment

Short Payback Time

Treatment of Wash Liquids18

GEA Mechanical Equipment

Reference Projects | Washing lye treatment

Treatment of Wash Liquids19 Mechanical Separation / GEA Westfalia Separator