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ECOTECH:
SUCCESSFUL APPLICATIONS
Surface
Treatment Success A
Surface Treatment Success B
Surface
Treatment Success A - A major manufacturer of high speed
end mills experienced corrosion on their steel parts after heat
treating in barium chloride baths. It was known that poor salt removal
during the subsequent water quench was the cause, resulting in an
unacceptable and costly level of re-work and scrap. Many chemical
additives from well known suppliers were tried in the quench water
with undesirable results. Even the salt bath vendor could not provide
a product to achieve adequate cleaning of the corrosive salt. The
existing quench/cleaning system consists of a 3-stage heated aqueous
soak with minimal ultrasonic activity in the second bath, and some
circulation from mechanical mixers in stages one and three.
Upon
referral from another of the manufacturer's facilities, Ecotech
was able to quickly develop a custom formulation, now known as Ecoprep®
2005, which not only resulted in much improved and acceptable levels
of salt removal, but provided in-process corrosion protection on
the parts after quenching and prior to steam tempering. Ecoprep®
2005 has proven to be cost effective as it operates at dilutions
of less than 5% v/v, and is capable of sustained cleaning under
heavy soil loads. Its ability to clean organic soils (oils) as well
as inorganic contaminants (salts), while providing rust protection
in the final rinse, has been established by its use in a belt spray
washer where parts are degreased prior to heat treat. As an added
benefit, Ecoprep® 2005 operates at a significantly reduced pH
from previous chemistries, thereby reducing worker safety and environmental
concerns. Ecoprep® 2005 is still in use to this day, and continues
to supply the quality results a world class manufacturer requires.
Surface
Treatment Success B- One of the world's largest manufacturers
of mining and construction equipment was facing a dilemma.Their
waste treatment facility received new wastewater discharge limits,
which would be very difficult, if not impossible, to meet without
significant changes to the effluent from their manufacturing
operations. Of particular concern was the high pH (and its propensity
to solubilize metals), and the chelants commonly found in the alkaline
cleaners, corrosion inhibitors, leak test additives, vibratory solutions,
and other chemistries used to process their ferrous and
non-ferrous parts. Of course, elimination of these undesirable components
had to be accomplished without decreasing the effectiveness or efficiency
of their surface treatment processes.
Ecotech formulated
a solution, Ecoprep® 2000, which is now effectively used
for a variety of purposes, while alleviating the waste treatment
concerns. This non-chelated, mild alkaline formula is utilized in spray
and agitating soak parts cleaning applications, plus non-heated
leak test tanks. Ecoprep® 2000 incorporates an effective,
non-nitrite corrosion inhibitor package which protects
even cast iron parts from rust during in-process storage and assembly.
Through the use of an Ecotech supplied central bulk storage
tank and a Dosatron proportioner, properly diluted Ecoprep®
2000 is fed to six different operations on the production floor. The
Ecoprep® 2000 formula and automated chemical feed setup have
resulted in positive contributions towards the customer's goals
in the following areas: improved quality, meeting their environmental
responsibilities, greater safety through minimal worker exposure,
reduced risk through exposure to milder chemistry, reduction of shipping
container handling and disposal costs, and minimizing their chemical
inventory.
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