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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