Seminar Report 2012 Dry Ice Cleaning Seminar Report 2012 Dry Ice Cleaning

1. INTRODUCTION
Dry ice is the solid CO
2.
Dry ice pellets are made by taking liquid carbon dioide !CO2"
#rom a pressuri$ed storage tank and epanding it at ambient pressure to produce sno%. &he sno%
is then compressed through a die to make hard pellets.
It is a process in %hich dry ice particles are propelled to supersonic speed' to impact and
clean a sur#ace. &he particles are accelerated by compressed air' (ust as %ith other blasting
systems.
&he micro)thermal shock !caused by the dry ice temperature o# )*+, C"' the kinetic
energy o# dry ice pellets and the air pressure break the bond bet%een the coating and the
substrate. It pops o## the coating #rom inside out and the air stream remo-es it #rom the sur#ace.
Industries can utili$e the dry ice blasting cleaning method through equipment that #ires
the pellets through a blasting gun. .pon impact the dry ice sublimates and remo-es the
contaminants #rom the sur#ace.
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2. DRY ICE
Dry ice is the solid CO
2.
&he phase diagram o# CO2 is sho%n belo%. &he triple point o#
CO2 is at 9.1+ bar')9:.:;C.&he sublimation temperature o# dry ice at atmospheric pressure is
)*<.9,C.It is clear #rom the #igure that dry ice sublimates #rom solid to gaseous state at
atmospheric pressure.
1ig. 1= Co
2
state diagram
2.1 DRY ICE CLEANING PROCESS
CO2 pellets are uni#orm in shape and the e##ecti-eness o# the pellets as a blast medium
is similar to abrasi-e blasting media. 3o%e-er' the pellets do not abrade the substrate>
there#ore' CO2 pellet blasting is technically not an abrasi-e operation. &his process can be used
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#or cleaning' degreasing' some de)painting applications' sur#ace preparation' and de)#lashing
!#lashing is the ecess material #ormed on the edges o# molded parts".
&he process starts %ith liquid CO2 stored under pressure !?<90 psig". &he liquid CO2
is #ed to a pelleti$er' %hich con-erts the liquid into solid CO2 sno% !dry ice #lakes"' and then
compresses the dry ice #lakes into pellets at about )110o 1. &he pellets are metered into a
compressed air stream and applied to a sur#ace by manual or automated cleaning equipment
%ith specially designed blasting no$$les. &he CO2 pellets are pro(ected onto the target sur#ace
at high speed.
4s the dry ice pellets strike the sur#ace' they induce an etreme di##erence in
temperature !thermal shock" bet%een the coating or contaminant and the underlying substrate'
%eakening the chemical and physical bonds bet%een the sur#ace materials and the substrate.
Immediately a#ter impact' the pellets begin to sublimate !-apori$e directly #rom the solid phase
to a gas"' releasing CO2 gas at a -ery high -elocity along the sur#ace to be cleaned.
&he high -elocity is caused by the etreme density di##erence bet%een the gas and solid
phases. &his kinetic energy dislodges the contaminants !coating systems' contaminants' #lash'
etc."' resulting in a clean sur#ace.
&o operate dry ice blasting equipment a #e% details need to be considered. 1irst' though
using dry ice is etremely sa#e' basic sa#ety matters need to be #ollo%ed including %earing
hand' eye and ear protection. 1irst' the process is noisy and ear protection should be used.
Second' the temperature o# dry ice is @10+ degrees 1ahrenheit. 7lo-es should al%ays
be %orn %hen %orking %ith it. &hirdly' in dusty areas' a mask is recommended #or eye and
nose protection. Other%ise' %earing standard eye and ear protection %ould be acceptable (ust
as %ith sand blasting or pressure %ashing. 1ourthly' the gun should ne-er be pointed at another
indi-idual or serious in(ury could occur.
4lso' blasting in an enclosed area is sa#e %ith proper -entilation. Aecause CO 2 is B0C
hea-ier than air' placement o# ehaust #ans at or near ground le-el is necessary %hen blasting
in an enclosed area. In an open shop en-ironment' eisting -entilation is su##icient to pre-ent
undue CO 2 buildup.
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1urther' though a large number o# applications using dry ice blasting equipment only
require bet%een <0 to 100 psi and 120 to 190 C12' an e-aluation o# your system air %ould be
necessary to determine i# your #acility has su##icient capabilities to run the equipment at le-els
desired #or your applications.

1ig. 2= Dry ice cleaning process
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The various steps in Dr i!e C"eanin# Pro!ess are$
2.1.1 STORAGE O% CO
2
CO2 is stored in storage tanks in liquid state. &he operating parameters o# storage tank are1B
bar')D0,C to 20 bar')20,C.
Options and 4dditions #or CO2 Storage .nits are=
Eapori$ers
Other electrical characteristics
6arger re#rigeration system
Dual sa#eties
6iquid le-el contacts
4uiliary #ill connection can be installed to rear head o# 2:)ton !2D9<* kg" units
or larger
Cold %eather gear
0o%er #ailure alarm
Alo% do%n -al-es
4dditional -al-es on auiliary outlets
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1ig. D= 6iquid carbon dioide container
2.1.2 &ANU%ACTURING O% DRY ICE
Dry ice manu#acturing starts %ith liquid carbon dioide held under high pressure in bulk
storage -essels. &o begin making dry ice' the liquid C02' is sent through an epansion -al-e into
an empty chamber %here under normal atmospheric pressure it #lashes into C02 gas. &his
change #rom liquid to gas causes the temperature to drop quickly. 4bout B:C o# the gas %ill
#ree$e into dry ice sno%. &he rest o# the C02 gas' 9BC' is released into the atmosphere or
reco-ered to be used again.
&he dry ice sno% is then collected in a chamber %here it is compressed into block' pellet
or rice si$e pieces to meet customers requirements. &he denser the dry ice is' the longer it %ill
last' the easier it is to handle' and the better it %ill per#orm %hen blast cleaning.
2.1.' PELLETI(ER
1ig. B= 0elleti$er
&he dry ice sno% #ormed during epansion is compressed to produce pellets in a special
machine called 0elleti$er.
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2.1.) LOADING AND CLEANING
Dry ice pellets are stored in %ell insulated containers #or transport to the cleaning site'
%here they are trans#erred to the reser-oir o# the dry ice blasting machine.
&here these pellets are dispensed in to a stream o# compressed air' %hich accelerates
them through a specially designed no$$le and pro(ects them at high speed against the sur#ace to
be cleaned. &he pellets are trans#erred to the reser-oir o# the dry ice blasting machine. &here the
compressed air #rom compressor accelerates the pellets to supersonic speed to impact the sur#ace
to be cleaned.
1ig. 9= 0ellets blasting machine
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'. PRINCIPLE O% DRY ICE CLEANING
O-erall' there are three steps in-ol-ed in dry ice blasting.
1. ENERGY TRANS%ER
Fith dry ice blasting' dry ice pellets are propelled out o# the blasting gun at supersonic
speed and impact the sur#ace. &he energy trans#er knocks o## the contaminant %ithout abrasion.
&he #orce o# this impact is the primary means o# cleaning.
2. &ICRO*T+ER&AL S+OC,
&he cold temperature during dry ice blasting o# the dry ice pellets hitting the
contaminant creates a micro)thermal shock !caused by the dry ice temperature o# )*+, C"
bet%een the sur#ace contaminant and the substrate. Cracking and delamination o# the
contaminant occurs #urthering the elimination process.
'. GAS PRESSURE
&he #inal phase o# dry ice blasting has the dry ice pellet eplode on impact' and as the
pellet %arms it con-erts to a harmless CO2 gas %hich epands rapidly underneath the
contaminant sur#ace. &his #orces o## the contaminant #rom behind. &he contaminant is then
relocated' typically #alling to the ground.. Since the dry ice e-aporates' only the contaminant is
le#t #or disposal.
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) CO&PARISON -IT+ OT+ER &ET+ODS
C"eanin# &etho. Co/parison
Issue Tra.itiona" Dr I!e 0"astin#
/quipment
Do%ntime
Cleaned in dedicated cleaning area>
DisassemblyGreassembly> Drying time
required
/quipment can be cleaned in
place> Dry process ) equipment
restart immediately a#ter cleaning
3a$ardous
Faste
Cleaner becomes and treated as a
secondary contaminant
5o additional contaminant> Dry
ice sublimates %ith contact %ith
targeted sur#ace
6abor 3ours
Intensi-e hand scrubbing> 6engthy
cleanings> 1ollo%)up cleaning)up can
be lengthy
Dramatically reduced ) o#ten
completed in a quarter o# time or
better
Huality o#
Cleaning
0oor to a-erage /cellent
0otential
/quipment Damage
7rit abrasions> 7rit contamination>
2o-ement o# equipment to and #rom
cleaning area
5o equipment damage>
0re-enti-e maintenance -ery
realistic as labor hours are
signi#icantly less
Sa#ety
3ealth threats #rom sol-ents> Fater)
based cleaning pose ha$ards around
electrical equipment> &hreats to
en-ironment
Standard sa#ety precautions> Dry
process ) sa#e around electrical
equipment
Cost
Cleaner becomes additional
ha$ardous %aste> epensi-e sol-ents>
4dditional labor
2inimal ) cost o# dry ice
Dr I!e 0"ast C"eanin# Co/parison Chart
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0"astin#
C"eanin#
Te!hni1ue
-aste 2or
Disposa" A3rasive To4i!
E"e!tri!a""
Con.u!tive
Per2or/an!e
Co/parison
Dr I!e No No No No E4!e""ent
Sand Ies Ies 5oJ 5o O8
7lass Aeads Ies Ies 5oJ 5o O8
Falnut Shells Ies Ies 5oJ 5o 6imited
Steam 5o 5o 5o Ies 0oor
Sol-ents Ies 5o Ies Ies 6imited
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5 AD6ANTAGES
Dry ice blasting bene#its can be broken do%n into si general areas. &hey are as #ollo%s=
5.1 DECREASED DO-NTI&E T+ROUG+ CLEANING IN*PLACE
&ypical cleaning procedures require that equipment be disassembled and mo-ed to an
assigned area #or proper cleaning. &hat is not the case %ith dry ice blasting. /quipment can be
cleaned in)place and hot in most situations. Aecause o# that' many time)consuming' labor)
intensi-e steps %hich %ere required %ith other methods such as sand blasting can be eliminated
including=
1. Cool do%n
2. Disassembly
D. &ransport o# the equipment to and #rom a dedicated cleaning area
B. Reassembly
9. Reheating time
6. Dry ice blasting can shorten the do%ntime #or cleaning #rom days do%n to hours.
*. Reduces time required #or cleaning processes by <0)+0C due to cleaning in place
5.2 %ASTER AND &ORE T+OROUG+ CLEANING
Fith dry ice blast cleaning' a superior clean can be achie-ed %hile reducing hours %hen
compared to scrubbing %ith abrasi-e pads or %ire brushes. 4 tremendous labor sa-ings is
accomplished. In addition' the CO2 blast method cleans in cre-ices that canKt be reached by
hand. 4s a result' equipment runs more e##iciently and potential leaks are re-ealed possibly
pre-enting ma(or system #ailures.
5.' ELI&INATION O% E7UIP&ENT DA&AGE
Dry ice blasting o#ten eliminates equipment damage. Cleaning methods such as
sandblasting lea-e an aggressi-e and abrasi-e e##ect on the sur#ace. &hey can actually remo-e
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part o# the sur#ace' changing the sur#ace structure considerably. Dry ice is non)abrasi-e to
sur#aces and does not change a sur#aceKs structure. It li#ts the contaminants a%ay. Secondly'
because equipment can no% be cleaned in place' potential damage #rom mo-ing equipment to
and #rom a dedicated cleaning area is also eliminated.
5.) REDUCTION OR ELI&INATION O% SOL6ENTS
Dry ice blasting uses no sol-ents' but instead uses harmless CO2 pellets. &his can be a
critical need #or certain companies in order to comply %ith en-ironmental regulations or to
impro-e %orker sa#ety. &here are no issues pertaining to toicity.
5.5 REDUCTIONS IN -ASTE DISPOSAL
Fith other cleaning methods' %hether it be %ith sol-ents' sand blasting or some other
means' the cleaning agent becomes a secondary contaminant and must be disposed o# as toic
%aste along %ith the primary contaminant. 3o%e-er' %ith dry ice blast cleaning because the
CO2 pellet -apori$es upon contact' the only %aste created is the contaminant itsel#. &his alone
can result in signi#icant %aste reduction.
5.8 INCREASED SA%ETY
Dry ice blasting pellets are non)toic' non)ha$ardous creating ad-antages to the
en-ironment' your employees' and production #acility=
5o secondary %aste
Sa#e #or the en-ironment
Sa#e #or employees
Sa#e #or end products
Sa#e #or equipment
5.9 DRY ICE 0LASTING IS E%%ECTI6E IN PRECISION CLEANING.
1or precision cleaning dry ice blasting is most suitable %hen compared %ith other methods
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8 DISAD6ANTAGES
1. CO
2
blasting is not al%ays a one)pass operation> an e##ecti-e blasting operation usually
requires multiple passes to achie-e the desired e##ect.
2. Requires operator training.
D. Can ha-e high capital costs.
B. 1ied position blasting operation can damage the componentLs sur#ace.
9. 7enerates solid %aste containing coating chips that are potentially ha$ardous> media
does not add to the -olume o# solid %aste.
:. Rebounding pellets may carry coating debris and contaminate %orkers and %ork area.
*. Some soils !in cleaning operations" may redeposit on substrate.
<. 5on)automated system #atigues %orkers quickly because o# cold temperature' %eight'
and thrust o# the blast no$$le. 4utomation !robotics" are required #or #ull aircra#t
stripping operations.
+. 0otential ha$ard #rom compressed air or high -elocity CO
2
pellets.
10. CO
2
blasting is not an e##ecti-e paint remo-al process #or aircra#t.
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9 APPLICATIONS
Dry ice blast cleaning applications are a-ailable to a multitude o# industries o##ering
tremendous -alue. In addition to the general bene#its mentioned' dry ice blasting has speci#ic
bene#its to some o# the #ollo%ing industries=
1. 4irlinesG4erospace
2. 4utomoti-e
D. Disaster Reco-ery
B. /lectrical
9. 1ood 0rocessing
:. 1oundries
*. 7eneral 2aintenance
<. 3a$ardous Faste
+. 3istoric Restoration
10. 2arine
11. 2ass &ransit
12. 0harmaceuticals
1D. 0lastics
1B. 0rintingG0lating
19. 0ulp M 0aper
1:. Rubber
1*. .tilities
9.1 AIRLINE:AEROSPACE
In addition to sa#ely and e##ecti-ely cleaning %iring' and hosing and similar materials'
dry ice blasting can reduce or remo-e the #ollo%ing contaminants #rom equipment=
Spray)on #oam insulation
Sealants and coatings
Carbons
7rease
Oil
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9.2 AUTO&OTI6E
Dry ice blasting can be used in a multitude o# %ays in the many #acits o# automoti-e
construction. &hey include=
1. Asse/3" P"ants
1. Robotics
2. Aody panel assembly
D. 2an #ans
B. Spray booths
9. 7eneral maintenance
2. %oun.ries
1. Core boes
2. 0ermanent molds
'. Ru33er an. P"asti! &o".ers
1. &ire molds
2. Seats and gasket molds
D. Sealing system molds
). En#ine Re/anu2a!tures
1. /ngine blocks and accessories
2. 0istons
D. Coils
B. Cylinder heads
9. 4lloy %heels
5. E"e!troni!s
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Sensors and computer components
8. Auto/otive Interiors * Urethanes an. P"asti! &o".in#
1ire %all
4ccoustic mats
Dashboards
Door panels
Seats and carpets
9.2 DISASTER RECO6ERY
0ro-iding commercial o%ners the ability to dramatically reduce do%ntime and' thereby'
reduce costs' dry ice blast cleaning is #ar superior to the cleaning methods typically used )
%ater or soda blasting. &his' o# course' is o# great interest to insurance companies also.
1ollo%ing is a list o# ho% CO2 blasting can be o# bene#it=
1. 1astest remo-al rate a-ailable ) 9 sq. #t per min. or greater
2. Remediation in days' not %eeks
D. Cleanest and most en-ironmentally #riendly mold remo-al process ) no secondary
%aste created
B. Drastic time sa-ings
9. 0enetrates behind and bet%een structural members to deli-er unparalleled co-erage
:. 2inimi$es demolition
*. /##ecti-e in industrial' commercial and residential en-ironments
<. Eersatile ) enables greater access to attics' roo#s' cra%l spaces etc.
+. Cleans #rom one position andGor plat#orm many angles and sur#aces )) including
di##icult corners and around nails
10. Cleans electrical ) outlets' conduit' ceiling #ans etc.
11. /limination o# sanding and scraping
12. 4 natural biocide
1D. Decontaminates your o%n equipment in minutes )) scrubbers' 3/04 -acs etc.
; CONCLUSION
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&oday' the dry ice cleaning method is quickly becoming #a-ored #or en-ironmental as %ell
as production reasons. Aecause o# tremendous en-ironmental regulations' industry has needed to
minimi$e %astes. 4lso' there is a gro%ing consciousness that many are placing no% on the global
en-ironmental impact o# their production practices. 3o%e-er' these bene#its are accentuated due
to the tremendous per#ormance gains through dry ice blasting )) little or no production do%ntime'
quality o# clean and minimi$ed damaged to equipment.
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< RE%ERNCES
1. Alasting 2ethod Comparison Chart @ Dry Ice Cleaning 4d-antages' 2id%est Dry Ice
Alasting
2. 2oore' Da-id /.' .S patentsNB':1*'0:B and NB'*BB'1<1
D. 1ood Standards 4gency Report' 2icrochem Aioscience 6imited' 1+ September 200B
B. /04) &/C35IC46 14C& S3//& 1OR 1'1'1)&RIC36ORO/&345/ !&C4"
34O4RDS 45D 46&/R54&IE/S
9. Dry Ice Alasting #or 7enerators and &urbines' Cryogenic Institute o# 5e% /ngland' 2010'
accessed 2ay 10' 2011
:. Dry Ice Alasting #or 0rinting 0resses' Cryogenic Institute o# 5e% /ngland' 2010'
accessed 2ay <' 2011
*. Dry Ice Alasting 1ire and Soot Damage' Cryogenic Institute o# 5e% /ngland' 2010'
accessed 2ay +' 2011
<. Dry Ice Alasting #or 2old Remediation' Cryogenic Institute o# 5e% /ngland' 2010'
accessed 2ay 10' 2011
+. Dry Ice Alasting 1or &he 0lastic and Rubber 2olding Industry' Cryogenic Institute o#
5e% /ngland' 2010' accessed 2ay <' 2011
10. Dry Ice Alasting #or 0aint 0reparation' Cryogenic Institute o# 5e% /ngland' 2010'
accessed 2ay 10' 2011
11. 1riedman' Daniel. P&oicity o# Carbon Dioide 7as /posure' CO2 0oisoning
Symptoms' Carbon Dioide /posure 6imits' and 6inks to &oic 7as &esting
0roceduresP . Inspect40edia.
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