GUIDELINES ON SOLVENT

DEGREASING
Occupational Safety and Health Division
Ministry of Manpower
(Endorsed by the Working Group On Solvent Hazards Control)
Guidelines on Solvent Degreasing
1
Table of Contents
A. Definition of Terms 1
1. Introduction 5
2. General Guidelines 8
3. Liquid Degreasing 9
4. Open-Top Vapour Degreasing 10
5. Conveyorised Degreasing 12
6. Local Exhaust Ventilation 13
7. Protective Equipment 15
Guidelines on Solvent Degreasing
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A. DEFINITION OF TERMS
Solvent Degreasing Terms
AIR-SOLVENT INTERFACE is the interface between the exposed solvent and air.
AIR-VAPOUR INTERFACE is the interface between the exposed solvent vapour
and the air.
AIR-VAPOUR INTERFACE SURFACE AREA means the geometric surface area
of the open top of the open-top vapour degreasers.
REFRIGERANT FLOW SWITCH is a safety switch that turns off the sump heat if
the refrigerant in the primary cooling coils fails to circulate or rises above the design
operating temperature.
CONVEYORISED DEGREASER is any degreaser that uses an integral,
continuous, mechanical system for moving materials or parts to be cleaned into and
out of a liquid solvent or vapour cleaning zone.
DRAG-OUT is the solvent carried out of a degreaser that clings to or is trapped in
the part being removed.
FREEBOARD HEIGHT is the distance from the top of the solvent to the top of the
tank for liquid degreasers; or the distance from the air-vapour interface to the top of
the tank for open-top vapour degreasers.
FREEBOARD RATIO is the freeboard height divided by the smaller of either the
inside length or inside width of the degreaser.
HIGH VOLATILITY SOLVENT is a solvent that is not classified as a low
volatility solvent.
LIQUID DEGREASER is a degreaser that is designed to contain liquid solvent at a
temperature below its boiling point and is used for cleaning objects.
LOW VOLATILITY SOLVENT is a solvent which has an initial boiling point
greater than 120
o
C and whose initial boiling point exceeds the maximum operating
temperature of the solvent cleaning operation by at least 100
o
C.
OPEN-TOP VAPOUR DEGREASER is any boiling solvent degreaser.
PERMISSIBLE EXPOSURE LEVEL (PEL) is the time weighted average
concentration of a toxic substance to which persons may be exposed.
Guidelines on Solvent Degreasing
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PEL (Long Term) is the permissible exposure level over an 8 hour working day and
a 40-hour work week as specified in the Factories (Permissible Exposure Levels of
Toxic Substances) Order, 1996.
PEL (Short Term) is the permissible exposure level over a 15-minute period as
specified in the Factories (Permissible Exposure Levels of Toxic Substances) Order,
1996.
PRIMARY COOLING COILS is an emission control device consisting of coils that
carry a refrigerant to condense solvent vapour from the degreaser bath.
REFRIGERATED FREEBOARD CHILLER is an emission control device that is
mounted at the freeboard above the primary cooling coils, consisting of secondary
coils which carry a refrigerant to provide a chilled air blanket above the solvent
vapour to reduce emissions from the degreaser bath.
SOLVENT LEVEL CONTROL SWITCH is a safety switch that turns off the sump
heat when the solvent level drops below the designed operating level.
SPRAY PUMP CONTROL SWITCH is a safety switch that prevents the spray
pump from operating without an adequate vapour level.
ULTRASONIC means enhancement of the cleaning process by vibrating the
solvent with high frequency sound waves, causing the implosion of microscopic
vapour cavities within the liquid solvent.
VAPOUR LEVEL CONTROL SWITCH is a safety switch that turns off the sump
heat when the solvent vapour level rises above the design operating level.
WORKLOAD AREA means the plane geometric surface area of the top of the
submerged parts basket, or the combined plane geometric surface area(s) displaced by
the submerged part(s), if no parts basket is used.
Guidelines on Solvent Degreasing
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Local Exhaust Ventilation Terms
Duct Velocity

Slot Velocity
Plenum
Velocity
Capture
Velocity
CAPTURE VELOCITY is the air velocity in front of the hood opening necessary to
capture the contaminated air at that point by causing it to flow into the hood
SLOT VELOCITY is the air velocity through the openings in a slot-type hood. It is
primarily used as a means of obtaining a uniform air distribution across the face of the
hood.
PLENUM is the pressure equalising chamber of the exhaust hood.
PLENUM VELOCITY is the air velocity in the plenum.
DUCT VELOCITY is the air velocity through the duct cross section.
FLOW RATE is the rate of air flow in a duct usually measured in cubic metres per
minute
Guidelines on Solvent Degreasing
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1. INTRODUCTION
General
Solvent degreasing is the process where grease, oil, wax and other surface
contaminants are removed from workpieces with the use of organic solvents.
Solvent degreasing is commonly carried out in the electronics and metal
working industries.
Many degreasing solvents are harmful to health and therefore require some
form of control measures to minimise or eliminate the risk. The three most
common solvents used in degreasing and their properties are summarised in
Table 1
Solvent Boiling Point Vapour Pressure Density
Methylene Chloride 40
o
C 350 mmHg 1.326 g/cm
3
Perchloroethylene 121
o
C 14 mmHg 1.621 g/cm
3
Trichloroethylene 87
o
C 58 mmHg 1.462 g/cm
3
Table 1 Physical Properties of Some Common Degreasing Solvents
These guidelines spell out the design specifications and operating procedures
for degreasing that need to be taken to ensure a reasonably safe working
environment.
Health Effects
Solvents can enter the body through inhalation, skin absorption and by
ingestion of contaminated food or drink.
Inhalation of solvent vapours is the most common route of exposure as
solvents are usually volatile i.e. they have high vapour pressure and can
readily give off vapours even at room temperature.
Exposure to excessive solvents may cause short and long term effects as
indicated below:
* Short Term Effects
- Irritation to the eyes, nose and throat
- Headaches
- Nausea
- Giddiness
- Loss of consciousness and even death
* Long Term Effects
Guidelines on Solvent Degreasing
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- Dermatitis or skin disease
- Damage to the central nervous system
- Liver damage by certain chlorinated solvents
The permissible exposure levels of the major degreasing solvents are shown in
Table 2.
Solvent PEL (Long Term) PEL (Short Term)
Methylene Chloride 174 mg/m
3
(50 ppm) 870 mg/m
3
(250 ppm)
Perchloroethylene 170 mg/m
3
(25 ppm) 685 mg/m
3
(100 ppm)
Trichloroethylene 269 mg/m
3
(50 ppm) 537 mg/m
3
(100 ppm)
Table 2 Permissible Exposure Levels (PEL) of Some Common Degreasing
Solvents
Types of Degreasing Systems
1. Liquid Phase Degreasing
Liquid phase degreasing consists of a tank containing liquid
solvent that may be heated below the boiling point where parts
that need to be cleaned are immersed in the solvent. Surface
contaminants are then dissolved. The cleaning efficiency is
improved with agitation.
2. Vapour Phase Degreasing
a. Vapour phase degreasing consists of a tank containing
solvent that is heated to its boiling point and the solvent
vapour rises and fills the tank. When parts are lowered
into the vapour zone, the vapour condenses on the cold
parts and the surface contaminants are dissolved by the
condensing solvent that returns to the base of the tank.
The parts are removed when condensation ceases to
occur when the parts appear dry. Figure 1 shows the
schematic diagram of a vapour degreaser.
b. Another variation is the vapour-spray cycle degreaser.
The parts to be cleaned are placed within the vapour
zone as in the straight vapour cycle degreaser.
Condensing vapour is collected in a reservoir that is
pumped to the spray nozzle and is directed at the parts
whereby they are further cleaned and cooled to permit
further cleaning action by the solvent vapour.
c. In addition to the degreasers described earlier that are
designed for batch-type operations, conveyorised
degreasers are available for a greater cleaning capacity.
Guidelines on Solvent Degreasing
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Figure 2 shows the schematic diagram of a
conveyorised degreaser.
Cooling coils

Vapour Zone
Boiling Sump
Immersion Heaters
To Drain
FIGURE 1 - VAPOUR DEGREASER
Conveyor Track
Part to be
Cleaned Cooling
Coils
Spray Zone
Vapour Zone
Boiling Sump
FIGURE 2 - CONVEYORISED DEGREASER
Guidelines on Solvent Degreasing
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2. GENERAL GUIDELINES
The guidelines in this section are applicable to all types of degreasing
machines.
Basic Equipment
1. All degreasers shall be fitted with a cover that prevents escape
of solvent vapour when the degreaser is not in operation. One
of the following types of covers shall be used for open-top
vapour degreasers and liquid degreasers:
a. Roll-top cover;
b. Canvas curtain cover;
c. Guillotine (biparting) Cover;
d. Any other effective cover that slides off the degreaser in
a horizontal motion.
All covers shall be designed such that they can be opened or
closed without disturbing the vapour layer or the solvent
surface.
2. Suitable equipment such as perforated or wire baskets shall be
provided for draining cleaned parts such that the drained
solvent or drag-out is returned to the degreaser.
3. Means shall be provided for draining contaminated solvent
from the tank.
Basic Operating Guidelines
1. The degreaser shall be covered at all times except while
processing work or performing maintenance on the degreaser.
2. The parts to be cleaned shall be racked in a manner that will
minimize the drag-out losses (eg. cup shaped objects should be
inverted).
3. Parts shall be drained for at least 15 seconds immediately after
the cleaning within the degreasing tank and shall not be
removed until dripping of solvent ceases or the parts become
visibly dry.
4. Degreasing operators should avoid leaning over the tank.
Guidelines on Solvent Degreasing
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5. Drainage facility shall be used for removing the contaminated
solvent from the tank that minimises or eliminates contact by
persons in the surrounding areas. Sludge found at the bottom
of the tank shall only be removed once all the solvent is
completely drained off.
6. All waste solvents shall be stored in properly identified, sealed
containers and handled and disposed of in accordance with the
Ministry of the Environment regulations.
7. Solvent spray cleaning shall be done well within the vapour
zone. The spray shall consist of a liquid stream rather than a
fine, atomized, or shower-type spray. Solvent spray shall be
directed downward to avoid turbulence at the air-vapour or air-
solvent interface and to prevent liquid solvent from splashing
outside of the degreaser.
8. Degreasing of porous or absorbent materials, such as cloth,
leather, wood, or rope, is strongly discouraged.
9. Solvent agitation, where necessary, shall be carried out only by
pump recirculation, ultrasonic or by other mechanical means.
10. The vertical speed of a powered hoist, if one is used, shall not
be more than 3.3 meters per minute when lowering and raising
parts into/from the degreaser. This is to ensure minimal
disturbance to the vapour zone.
11. Degreasers must be located in well-ventilated areas and away
from strong draughts. The average draught rate in the
workroom shall not exceed 9.1 metres per minute when
measured parallel to the plane of the degreaser opening.
12. Ventilation fans shall not be positioned in such a way as to
direct airflow near the degreaser openings.
13. Standing fans shall not be used or positioned in such a manner
that solvent vapour is disturbed.
3. LIQUID DEGREASING
1. A degreaser loaded with a low volatility solvent must have a
freeboard ratio of at least 0.50.
2. A degreaser loaded with a high volatility solvent shall be fitted
with a drainage facility inside the degreaser and shall have
either:
Guidelines on Solvent Degreasing
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a. a water blanket over the surface of the solvent if the
solvent has a negligible solubility in water and has a
density greater than that of water; or
b. a freeboard ratio of at least 0.75.
3. Wire baskets should be used to hold small parts to permit
complete solvent drainage.
4. Should the air concentration level cannot be reduced to below
the PEL of the solvent, a local exhaust ventilation system
should be installed for the degreasing tank (see section on local
exhaust ventilation for details).
4. OPEN-TOP VAPOUR DEGREASING
Design Guidelines
1. Primary cooling coils shall be used to condense the solvent
vapour. The cooling systems must be designed such that the
temperature measured in degrees Celsius at the coldest point on
the vertical axis in the centre of the solvent container shall not
be greater than 50 percent of the initial boiling point of the
solvent.
2. The following safety switches shall be installed on the
degreaser:
a. Vapour level control switch;
b. Condenser refrigerant flow switch;
c. Sump heater thermostat;
d. Solvent level control switch with manual reset; and
e. Spray pump control switch, if solvent spray cleaning is
incorporated.
The control system shall be designed such that the safety
switches shall act exclusively without regard to other
conditions (eg. should the solvent level drop below the
designed operating level, the solvent level control switch will
shut off the sump heater. A decrease in the temperature sensed
by the sump heater thermostat shall not reactivate the sump
heater)
3. The degreaser shall have a freeboard ratio of at least 0.75.
Guidelines on Solvent Degreasing
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4. Open-top vapour degreasers which have an air-vapour interface
surface area of more than 1.0 square metre shall have a
freeboard ratio of at least 1.0 and shall be equipped with:
a. a refrigerated freeboard chiller, designed such that the
refrigerant temperature at the degreaser outlet does not
exceed 5
o
C or the temperature measured in degrees
Celsius at the coldest point on the vertical axis in the
centre of the solvent container shall not be greater than
30 percent of the initial boiling point of the solvent.
b. a hoist to facilitate movement of the workload into and
from the degreaser.
5. Should the air concentration level cannot be reduced to below
the PEL of the solvent, a local exhaust ventilation system
should be installed for the degreasing tank (see section on local
exhaust ventilation for details).
Operating Guidelines
1. When equipped with a lateral exhaust system, the exhaust fan
shall not be operational whenever the degreaser is covered.
2. The workload area shall not exceed more than half of the
degreaser's air-vapour interface surface area to prevent
emission of solvent vapour through displacement of the solvent
vapour by the workload (piston effect).
3. The vapour level shall not drop by 10 centimetres or more
when a workload enters the vapour zone. Introduction of heavy
workload will result in collapse of the vapour blanket and air is
pulled in and eventual re-establishment of the vapour blanket
will expel solvent laden air from the degreasing machine.
4. At start up, the primary cooling coils and the refrigerated
freeboard chiller, if any, shall be turned on before the sump
heater is turned on.
5. At shutdown, the sump heater shall be turned off before the
primary cooling coils and refrigerated freeboard chiller, if any,
are turned off. The degreaser must be covered whenever the
primary cooling coil is turned off.
6. The workload shall be degreased in the vapour zone until
condensation ceases.
Guidelines on Solvent Degreasing
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5. CONVEYORISED DEGREASERS
1. The following safety switches shall be installed on the
degreaser:
a. Vapour level control switch;
b. Condenser refrigerant flow switch;
c. Sump heater thermostat;
d. Solvent level control switch with manual reset; and
e. Spray pump control switch, if solvent spray cleaning is
incorporated.
The control system shall be designed such that the safety
switches shall act exclusively without regard to other
conditions (eg. should the solvent level drop below the
designed operating level, the solvent level control switch will
shut off the sump heater. A decrease in the temperature sensed
by the sump heater thermostat shall not reactivate the sump
heater)
2. The degreaser shall have a freeboard ratio of at least 0.75.
3. A drying tunnel or other effective means shall be installed to
reduce drag-out losses.
4. Entrances and exits to the degreaser shall have a clearance
between each workload and the edge of the degreaser of less
than 10 centimetres or less than 10 percent of the width of the
opening.
5. Conveyorised degreasers having an air-vapour or solvent-
vapour interface surface area of more than 1.0 square metre
shall have either:
a. a refrigerated freeboard chiller, designed such that the
refrigerant temperature at the degreaser outlet does not
exceed 5
o
C or -20
o
C if the air-vapour or solvent-
vapour interface surface area exceeds 2.0 square metres;
or
b. an enclosure that is connected to a exhaust system that
has a ventilation rate of 15.24 cubic metres per minute
per square metre of the air-vapour or air-solvent
interface surface area
Guidelines on Solvent Degreasing
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6. LOCAL EXHAUST VENTILATION
Local exhaust ventilation systems are designed to capture and remove the
contaminants from the source of emission before they escape into the
surrounding environment.
A lateral exhaust hood with a drying area shall be provided for large
degreasing tanks with a surface area of exposed solvent greater than 1 m
2
.
For degreasing tanks operating for more than 50 hours per week, the exhaust
air shall pass through an activated carbon recovery unit to remove the solvent
vapour.
d

Minimum 45
o
Duct Exhaust Hood
Hp Drying Area

Plenum
Wp Ld
Degreasing Lt
Tank
Wt
Figure 3 Lateral Exhaust Hood for Large Degreasing Tank
Design Specifications
Required Flow Rate Q 38.1 x (Length of Degreasing Tank , Lt +
Length of Drying Area, Ld) x Width of
Degreasing Tank, Wt (m
3
/min)
Required Slot Velocity Vs 610 m/min
Required Duct Velocity Vd 1220 m/min
Duct Diameter d (4Q / ( x Vd))

Length of Slot Ls (Lt + Ld)

Aspect Ratio of Slot (Ws/Ls) 0.25
Length of Plenum Lp > (Lt + Ld)
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Height of Plenum Hp Maximum Height of Workload
Plenum Velocity Vp 0.5 x Slot Velocity
Width of Plenum Wp = Q/ (Lp x Vp)
Example:
A vapour degreasing tank with length of 1.2 m and width of 0.9 m requires a
local exhaust system with a drying area to be installed to remove contaminants
from the source of emission. The height of the wire basket used is 0.1 m.
Preliminary design of exhaust system results in the following:
Length of Drying Area Ld = 0.3 m,
Length of Slot Ls = Lt + Ld = 1.5 m
Length of Plenum Lp = 1.6 m
Height of Plenum Hp = 0.12 m
Number of slots n = 4
Required flow rate, Q = 38.1 x (Lt + Ld) x Wt
= 38.1 x (1.2 + 0.3) x 0.9
= 51.44 55 m
3
/min
Total slot area, As = Q / Vs = 55 / 610
= 0.09 m
2
Area of a slot, As = As / 4 = (0.09 / 4)
= 0.0225 m
2
Width of a slot, Ws = As / Ls = 0.0225 / 1.5
= 0.015 m
Aspect ratio = Ws/Ls
= 0.015 / 1.5
= 0.01 < 0.25
Width of plenum, Wp = Q / ( Lp x Vp)
= 55 / (1.6 x 0.5 x Vs)
= 55 / (1.6 x 0.5 x 610)
= 0.112 0.12 m
Diameter of Duct, d = (4Q / ( x Vd))


= (4 x 55 / ( x 1220))

= 0.239 m 0.2 m
7. PROTECTIVE EQUIPMENT
Guidelines on Solvent Degreasing
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1 The following personal protective equipment shall be provided to
workers who operate degreasers:
a. Impervious PVC gloves if contact with the hands is likely
b. Chemical splash goggles or faceshields if there is a risk of
splashing.
c. Suitable respirators if the exposure is above half the PEL of the
solvent.
All protective equipment provided shall be solvent resistant.
2 The following provisions shall be made available and be readily
accessible for handling accidental contact with the solvent:
a. A wash basin and soap or soap solution to treat accidental
solvent splash on the skin.
b. Emergency eye wash to rinse the workers eyes should the
solvent come into contact with the eyes.
END