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METALWORKING

» With the change to QUAKERCLEAN®BIO 1050 LH, the 1st stage in the waste water treatment was eliminated, which also eliminated any risk of the factory exceeding the parameters for the waste water laws

» There was improvement of safety of the operators since QUAKERCLEAN®BIO 1050 LH is a lower risk class than the previous technology used

CLEANINGQUAKERCLEAN® BIO 1050 LH

THE SOLUTION

Quaker introduced QUAKERCLEAN®BIO 1050 LH into the factory pre-treatment lines in 2-steps, and the following savings were achieved in step 1.

CHALLENGESThe Italian factory of a global home appliance company producing ovens was looking for a supplier to help reduce:

» Costs of the waste water treatment caused by surfactants from degreasing

» Temperature of cleaning baths in the pre-treatment stage

» General risk classes of the chemicals used in the enameling area

COMPETITIVE TECHNOLOGY QUAKERCLEAN®BIO 1050 LH

Consumption (g/m2) 1,5 1

Cost per m2 1,5 (g) x 2 (Euro/kg) X 4000 (m2)= 12.000 Euro

1,0 (g) x 6,79 (Euro/kg) x 4000 (m2) = 27.160 Euro

Waste water treatment cost to eliminate the Surfactant

18.000 Euro / Year 0

FINAL cost of the process 30.000 Euro/ Year 27.160 Euro / Year

Savings 2.840 Euro / Year

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METALWORKING

In the second step, by using QUAKERCLEAN®BIO 1050 LH there was a possibility to reduce the work temperature of the degreasing baths from 55°C to 35°C considering the quality of Cold Rolled Steel.

COMPETITIVE TECHNOLOGY QUAKERCLEAN®BIO 1050 LH

Calorific value of methane (η = 50%) 4,797 KWh / m3 4,797 KWh / m3

Starting Temperature 20°C 20°C

Energy to heat 1 m3 of bath 1000 x (55-20)/860 = 40,7 KWh 1000 x (35-20)/860 = 23,25 KWh

Methane quantity for 1 m3 of bath 40,7/4.797 = 8,5 m3 23,25/4,797 = 4,85 m3

Volume of the 2 degreasing baths 12 m3 12 m3

Cost of methane 0,8 Euro/ m3 0,8 Euro/ m3

Cost for start up temperature 8,5 x 12 x 0,8 = 81,6 Euro/day 4,85 x 12 x 0,8 = 46,54 Euro/ day

Temperature decrease for hour 10°C / h 5°C / h

Energy to improve 1 m3 of water 1000 x 10/860 = 11,62 KWh 1000 x 5/860 = 5,81 KWh

Cost for set-up work temperature 11,62/ 4,797 x 12 x 0.8 = 23,25 (Euro/h) x 12 h = 279,54 Euro/day

5,81/ 4,797 x 12 x 0.8 = 11,62 (Euro/h) x 12 h = 139,52 Euro/day

Total cost for a year (81,6 + 279,54) x 200 days = 72228 Euro/year

(46,54 + 139,52) x 200 days = 37212 Euro/year

Year Savings 72228 – 37212 = 35016 Euro x 2 pre-treat lines = 70032 Euro/ year

CLEANINGQUAKERCLEAN® BIO 1050 LH

THE EXPERTISE

Surface treatments represent a very minor part of the total steel processing cost, typically less than 1%. This case illustrates the importance of the correct selection of the surface treatment. The impact of the fluid can be a multiple of its costs, making the price of surface treatment insignificant. That is why Quaker focuses on developing fluids with the highest performance without compromise. Fluids that sharpen your competitive edge.

PROCESS AND EQUIPMENT

INDUSTRIAL PRE-TREATMENT LINE

Materials 100% CRS

Operation Cleaning

Pressure 1 bar

Temperature 55°C

Total Vol. of degreasing baths 12 m3

Water hardness 18°F

Concentration 5 g/l

THE PRODUCT

A water dilutable cleaner based on alginate technology combined with an alkaline-based degreaser, suitable for completely clean CRS/HDG/Aluminum components and for preparing the surface for the following pre-treatment conversion or enameling.

» Concentration range: 0,3 - 5 % depending on the condition of the surface

» Work Temperature 25 - 65 °C » Work Pressure 0,5 - 5 bar » Make-up water hardness:

very broad range

The product offers the following benefits:

» No class of Risk » Environmentally friendly

(complete and rapid biodegradability under AFNOR T90-312, ISO 7827 and OECD 301 tests.

» Possible use at room temperature

» No chemical treatment of the organic part in the waste water treatment

© 2016 Quaker Chemical Corporation. All Rights Reserved. 12.16-V003