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D 117 Cleaning for nitriding (A: main process) ( Date: 2004-05-25 )
Turned, punched parts from suppl. to carindustry made of steel and cast are cleaned from hardly known and changing dirts (e.g. cooling lubricant, chips, oxide, scales) in a vacuum plant by mod. alcohole and aq. agent; afterw. nitriding, back to customer
 


  Material  |  Dirt  |  Equipment  |  Agents  |  Process  |  Costs  |  Evaluate  |  Comparison  

Material:

Turned and punched parts for the automobile industry (hardening service provider) e.g. cog wheels, shafts, washers, bolts; D 117, 118, 119 are three processes run in the same company on the same plant. All consumption and utilization figures relate to all three processes together
METAL / NON METAL : steel, cast iron
Shape : porous surfaces, smooth surfaces, hollow spaces, small holes with metal chips inside, a complicated geometry
Utilisation of equipment (throughput,workload) in % : 95
Maximum possible throughput of parts per year : 65.700.000
Max. area which can be cleaned per year : No statement

Dirt:

drawing oil, mineral oil, grease, Metallic particles, cooling lubricants, mud/dust, corrosion protection layer, grinding agents, polishing agents, rust, sweat/fingerprints, oxides, mill scale
Previous process : Turning, punching
Dirt1: Oilsludge (95.00%), 5000.00 ltr. / Year
Dirt2: Particles, fines (5.00%)

Equipment:

Vaiocs
Vacuum Assisted Inorganic Organic Cleaning System. Single chamber plant, under vacuum and at elevated temperature hydro carbons, modified alcoholes, halogenated solvents and or aquieous agents can be used in all combinations; flooding, steam degreasing, drying and conservation can be applied (assisted by ultra sound and turning or rocking of charge)

Process:

Cleaning facilities with a vapour degreasing system,Multitask equipment,Central cleaning station,Facility combining solvent and aqueous cleaning

1. Flooding with mod. alcohol, 85┬░C, US, 2-8 min, 3┬░ rocking (turning only with big fixed parts); 2. vapour degreasing with mod. alcohol, 85┬░C; 3. vacuum drying

Duration of cleaning process for one part (min.) : 20.00
Duration of cleaning process for the charge (min.) : 20.00
Recycling : Step:1 The modified alcohol is used almost indefinitely, only minor evaporation and sludge losses have to be filled up. The oil sludge from the distillation is burned together with used oil. Amount 5 m3/a for the whole plant and the processes D 117, 118, 119
Step:2 No statement
Step:3 No statement

Quality:

free of oil and grease, dry, Precision cleaning

Ready for nitriding, ca. 38 mN/m

Subsequent process:

heat treatment, Hardening, Nitriding

Costs:

Total sum : 1.225.900,00 EURO / Year

Total costs per removed dirt: 245,18 EURO / kg


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