Cleaning Systems
Which molten salt cleaning system fits my parts and process?
It depends on your parts and process. Batch systems process discrete loads under your existing hoist or with handling we supply; Unitized™ systems are smaller batch units pre-assembled on a common base; and electrolytic salt baths use direct current, commonly for sand, graphite, and scale on iron castings. Kontinuous™ systems strip racks in-line on paint and powder lines, metal descaling systems are laid out around strip, tubing, pipe, or wire, and Recover® equipment strips reject parts. Send us your part sizes, load weights, and hourly throughput, and we will lay out a system and send a quotation.
Most Kolene® cleaning processes operate at elevated temperatures and require specialized equipment for proper operation and safety. We have designed and engineered purpose-specific process equipment since our start in 1939. Today the emphasis is on environmental, health, and safety, with energy efficiency and ease of use close behind.
We start each design by discussing your process with you. Key questions include:
- What are the objectives of the process?
- How many / how large are the parts to be cleaned?
- What materials are involved?
- Will the system be manually operated or fully automated?
- Do you need a minimal configuration or a complete process line?
From your answers, our engineering group, applications lab, and sales team specify the system using process parameters we have developed.
With more than 85 years of experience, we have produced a wide variety of cleaning systems. The salt bath cleaning units below are a few examples.
For the molten salt chemistry these systems run, see Cleaning Chemicals.
Thermochemical Cleaning Systems
Used for: Alloy Scale & Oxide Conditioning, Cast Iron & Sand Casting Cleaning, Investment Casting Cleaning, and Engine Core Cleaning & Overhaul
Batch Systems
Batch cleaning units are designed to process discrete loads or batches of parts. These units can be placed under an existing rail and hoist or we can supply various types of manual or automated handling systems. Floor, roof, or unit-supported handling systems are available.
Minimal Configuration
For molten salt (thermochemical) systems, a minimal cleaning system configuration consists of the molten salt cleaning furnace, a by-product removal zone, and at least one water rinse tank. Ventilation of the system is also included. Optional stations include hot water rinses, brightening or neutralizing stations, and additional salt bath furnaces as required.
Unit size is determined by the size and volume of parts to be cleaned.
Unitized Systems
Unitized systems are typically smaller batch systems that can be pre-assembled before shipment to speed up the on-site installation at your location. All components – molten salt bath, water rinse tank(s), by-product removal zone, etc. – are mounted on a common I-beam base. Where possible, all components are pre-piped and pre-wired to reduce on-site installation work.
For larger systems, we can also provide modular systems that can be readily field-joined on your plant floor.
Electrolytic Salt Baths
Our electrolytic molten salt baths are used exclusively for direct current activation of molten salt chemistries. These systems are commonly used for sand, graphite, and scale removal of iron sand castings. The electrolytic activation is also used for conditioning and/or removing tenacious metallic and ceramic compounds from high-value components for rebuild and remanufacturing.
Sacrificial wear surfaces in the operating bath can be readily replaced as required, increasing the service life of the furnace.
Electrolytic salt baths are variants of Batch and Unitized salt bath designs.
Integrated Lines
Used for: Hook, Rack & Fixture Stripping and Alloy Scale & Oxide Conditioning
Kontinuous™ Paint Stripping Systems
Kontinuous paint stripping systems are custom-designed to install in your paint and powder coating conveyor lines. They are located after your curing oven and rack unload, and before your unpainted parts loading station. Stripping racks in-line keeps them clean for good grounding and uniform film build. Treatment time depends on the coating.
Kontinuous™ Plus Paint Stripping Systems
At the same time that racks and hooks are being stripped through the Kontinuous system’s dedicated pass-line (red zone), a second independent pass-line lets you strip reject parts. With a manually operated hoist, the “Plus” option (blue zone) lets you use the same salt bath that strips your hooks and racks. With its own water rinse tank, the manual stripping operation is completely independent of the in-line maintenance stripping activity.
Metal Descaling Systems
We custom engineer molten salt scale conditioning systems for stainless steels, nickel alloys, titanium, and select refractory alloys such as tungsten and molybdenum. The salt chemically converts the scale to residual surface oxides that are easy to pickle, which gives brighter, more uniform products after pickling. Unnecessary metal loss is kept to a minimum. The physical shape of the products dictates the equipment layout:
For Continuous Anneal and Pickle (CAP) lines for strip, we design systems that are installed after the annealing furnace and jet cooler. Strip passes under a dunker roll to immerse the strip into the salt, where only a few seconds are required to properly condition the scale. It then immediately passes over a carry-out roll and travels to an immersion rinse tank where any conditioning salt residues are removed.
If you produce tubing, pipe, profiles, shapes, or wire, our systems are rated based on your tons/hour throughput needs. Overall lengths or coil diameters are carefully considered in our engineering specifications. Units with usable work zone lengths of 50 feet or more are commonplace. Due to thicker, more tenacious production scales formed on these shapes, process cycle times in the bath typically run several minutes.
By-Product Management Systems
Sludge Management System
Our SMS™ (Sludge Management System) was developed to offer an alternative processing method for the reaction products that are formed in our processes. As various contaminants are added to the bath – sand, investment ceramics, metal oxides, paints, etc. – and react with the chemicals, by-products (sludge) are formed and settle to the bottom of the bath. Once removed, they must either be sent off-site or managed internally. The SMS dissolves the sludge in water so the pH can be adjusted and heavy metals precipitated. See Support Products.
Recover® Reject Part Stripping Equipment
The Recover process uses an organic fluid to strip reject or defective coatings from a wide variety of components. For best results and process life, we have developed process equipment that heats the fluid to its 250–325 °F operating range. Once stripped, the parts are cooled and rinsed in an adjacent water tank.
Used for: Reject & Salvage Stripping
Planning a new line or upgrading an old one? Send us your part sizes, load weights, and hourly throughput, and we will lay out and quote a system.