of Acetone, MEK, Lacquer Thinner & Toluene

This guide examines the recycling of solvents to reduce hazardous wastes, expenses
and the burden of regulatory requirements. Various recycling methods, including
refrigeration machine distillers, are compared.

HOW TO RECYCLE INDUSTRIAL SOLVENTS

Many industries utilize onsite solvent recycling to reduce hazardous wastes and
solvent purchase expenditures. Through solvent recycling, most of the solvent is
recovered and environmental liabilities are reduced. This guide reviews four popular
solvents: acetone, methyl ethyl ketone (MEK), lacquer thinner and toluene. It also
examines the solvent recycling process, environmental and regulatory considerations,
safety precautions and best practices.

WHAT IS SOLVENT RECYCLING?

Solvent recycling is a process that reclaims used

solvent. Simply put, a solvent is a substance that
can dissolve or extract other substances without
causing chemical changes to itself or the other
substances.

Solvent recycling works by means of distillation,

which involves boiling a mixture to extract pure
solvent vapors. The vapors are then condensed
and converted back into a liquid, ready for reuse.

Many facilities are choosing to implement solvent

recycling due to the fact that most of the solvent is
regained, thus making the process cheaper than
purchasing brand-new solvents.

In addition, recycling helps reduce the output of

hazardous materials and minimizes regulatory
burdens. In many instances, waste generation
represents an inefficient use of materials.
Although used solvents can be transported away,
recycling is a much more efficient use of solvents.
SOLVENTS THAT CAN BE RECYCLED

Solvents are often used in industrial operations as degreasing cleaning agents or

reaction media. Usually the solvents are not consumed, but become contaminated by
other substances. When the contaminate level exceeds predetermined criteria limits,
the solvent is considered unsuitable for its intended purpose and either discarded,
reused for a less critical application, or, ideally, recycled.

Common solvents, such as acetone, MEK and toluene, are organic chemical
compounds, meaning they are all carbon-based. These are manufactured chemicals
that are also found naturally in the environment. Acetone, MEK and toluene are
singular solvents with their own distinct chemical makeup. Lacquer thinner is a
combination of solvents that is made up of organic and/or synthetic solvents. Many
other cleaning solvents can also be recycled.

Acetone is used to dissolve rust and other metal

contaminants, and to protect metals from corrosion.
(For more on this topic, read Substrate Surface
Preparation for Corrosion Prevention.) It is commonly
used to clean things in laboratories and as a
denaturant in denatured alcohol. It has also been
used as a selective solvent for vegetable oils and
electrospinning poly fibers.

Methyl Ethyl Ketone (MEK) is primarily used as an

industrial solvent. These industrial processes mainly
involve resins, gums, cellulose acetate, nitrocellulose
coatings and vinyl films. In turn, MEK finds use in the
manufacture of plastics, textiles, in the production of
paraffin wax, and in common items such as cleaning
agents, paint remover, lacquer, varnishes and glues,
and as a denaturing agent for denatured alcohol.
 Lacquer Thinner lacquer is a liquid that hardens to
form a coating that protects various materials. Lacquer
thinner is used to dissolve plastics and resins found in
modern-day lacquers and to break the bonds of strong
adhesives, greases and oils.

Lacquer thinner is also used in the fields of structural

engineering and metallurgy. The most common
ingredient in these thinners is acetone, and most
producers of this solvent mixture must now abide by
low VOC output regulations, resulting in healthier
environments. (For more on low VOC coatings, read
Waterborne Coatings: Environmental and Health
Regulations Meet Coatings Technology.)

Toluene is commonly used as a solvent in silicone

sealants, chemical reactants, paints, thinners,
permanent markers, contact cement, rubber, printing
ink, adhesives, leather tanners, disinfectants and
lacquers. It is also used chromatographically, and in
the field of composite material developments.

General User Classifications

Solvent users can be classified into the following groups:

• Commercial paint and finish contractors

• Industrial and government paint, finish and coating
users
• Automotive paint and finish users
• Fiberglass, plastics and composites users
• Metal finishing and resin tire fill users
 HEALTH AND ENVIRONMENTAL CONSIDERATIONS

Unfortunately, many solvents are volatile and evaporate rapidly, giving

off vapors that may be toxic, flammable and explosive, especially in
confined spaces. When ingested or making contact with the skin,
these substances may produce human health hazards, including
carcinogenicity. Incinerating these wastes contributes to degraded
air quality as the smog contains volatile organic compounds (VOCs).
Discarded solvents are a major contributor to air and water pollution.
A medical review in 2000 summarized the harmful effects solvents can have on the
central nervous system, peripheral nervous system, renal system, liver, cardiovascular
system, dermal system and reproductive system, among others. The best course of
action to prevent health problems caused by solvents is to replace highly toxic solvents
with less toxic ones and ensure that proper ventilation and respiration protection are
used when working with solvents.

Recycling and waste minimization are one of the few areas where environmental goals,
industries economic interests and public health and safety issues coincide.

There are several interconnected environmental benefits of recycling hazardous

solvent waste, including:
• Reducing the amount of waste that must be transported and disposed of
• Reducing the consumption of raw materials that would otherwise be used to
manufacture more solvents
• Reducing energy use
• Reducing pollution
Extracting, refining, transporting and processing raw
materials have a significant impact on the environment.
When hazardous waste is recycled, there is less air,
water and soil pollution generated from these activities.
Recycling means that less hazardous waste is sent offsite
for treatment and eventual disposal. This avoids dumping
them into hazardous waste landfills or burning them in
incinerators. Less energy is needed for transportation
and incineration, which ultimately leads to less air
pollution.

Additionally, recycling can reduce greenhouse gas

emissions. By recycling solvents, less energy is used to
obtain raw materials or to manufacture virgin solvents.
As energy demand decreases, fewer fossil fuels are
consumed, thus reducing the quantity of greenhouse
gases and pollution being released into the atmosphere.
 REGULATORY CONSIDERATIONS

Hazardous waste generators have a “cradle to grave” responsibility for

the safe disposal of hazardous wastes. United States federal law says
that the generator is responsible for the waste they create, regardless of
who hauls it away or where it is stored. The generator’s name is on the
barrel, and if it is spilled or otherwise causes pollution, the generator is
responsible for the cleanup.

Recycling for waste generator benefits include

reduced liabilities and regulatory burdens associated
with hazardous waste management. For the
general public, waste minimization improves our
environment. Environmental and safety regulatory
agencies have an interest in minimizing the overall
amounts of hazardous waste being transported on
our highways and stored at hazardous waste sites.
Other countries, such as Australia, have similar
concerns and recommendations.

To accomplish these goals, the US Environmental Protection Agency (EPA) tailors

rules and regulations to encourage onsite recycling and reuse. The EPA purposely
developed hazardous waste recycling regulations to promote the reuse and
reclamation of useful materials in a manner that is safe and protective of human health
and the environment. Over time, the agency has shifted from a waste management
approach to a sustainability approach.

RESOURCE CONSERVATION AND RECOVERY ACT (RCRA)

The Resource Conservation and Recovery Act (RCRA) creates what the EPA
considers a framework for the proper management of hazardous and non-hazardous
solid waste, and gives the EPA the authority to control hazardous waste from “cradle
to grave”, including the generation, transportation, treatment, storage and disposal of
hazardous waste.

These RCRA regulations can be found in title 40 of the Code of Federal Regulations,
parts 239 through 282. The regulations specifically governing hazardous waste
identification, classification, generation, management and disposal are found in title 40
CFR parts 260 through 273, and the regulations specific to transporters of hazardous
wastes can be found in title 40 CFR part 263.
 THE PROBLEMS OF USED SOLVENT WASTE DISPOSAL

According to a study on waste management, household hazardous

waste, including common solvents, generally comprises only one to
four percent of municipal solid waste, but the potential risks to the
environment and health are disproportionate to its size. (Note: In this
content, the EPA’s definition of solid waste includes liquid, sludge and
slurry.)

Most hazardous waste is inevitably disposed along with municipal solid waste at
municipal waste landfills. This mixing can increase the hazard to the local community
because not only are these substances potentially dangerous to the environment
and human health, but solvents can also prompt unintended changes in other waste
streams when they react with the waste or alter the redox environment.

BENEFITS OF SOLVENT RECYCLING

Beyond the obvious benefits of reducing

environmental and community health
concerns, by recycling solvents a business
may be able to greatly reduce or eliminate
the generation of hazardous waste and avoid
RCRA regulatory requirements altogether.

A business may also benefit financially and

from a marketing perspective by presenting
a positive or “green” image associated
with hazardous waste recycling efforts. For
example, a company can distinguish itself
from its competitors and increase customer
goodwill and shareholder value by exhibiting
strong corporate environmental stewardship.
 SOLVENT RECYCLING METHODS

In general, the solvent recycling process consists of placing waste

within a chamber, heating it, and allowing the solvent to vaporize. The
vapors then re-condense into the original pure solvent. The condensed
solvent is then collected through vapor tubes, while the waste stays
behind within the original chamber. (For more information, see The Best
Process for Distilling Waste Solvents.)

A solvent recycling machine reduces the volume of hazardous materials onsite and
helps eliminate the need to transport liquid hazardous waste on streets and highways.
There are several solvent recycling methods to choose from, each with their own
advantages and disadvantages.

Gravity Separation facilitates the simple settling of

solids and water for reuse of solvents. Centrifuges
may also be used to accelerate the process.
Generally, this method is only suitable for paint
thinners that may be reused if solids are allowed to
settle.

Forced-air Units heat the dirty, contaminated

solvent until it turns into a vapor that is then collected
and cooled by circulating ambient temperature air
in a condenser. However, this method is inherently
inefficient in warm climates.

Water-cooled Condensing Systems operate

similarly to forced-air units, but use water to cool
the solvent vapor in a condenser. This method can
waste large amounts of water (about 180 gallons of
water per 1 gallon of recycled solvent), is messy, and
special consideration must be given to plumbing,
water storage, water treatment and wastewater
disposal. Operation in freezing temperatures may
introduce additional concerns.

Refrigeration Machine Distillers use refrigeration

condensing system as an attractive alternative to the
forced-air and water-cooled methods. These units
are discussed in detail in the next section.
REFRIGERATION MACHINE DISTILLERS ARE
THE OPTIMAL RECYCLING METHOD

The use of a refrigeration condensing system instead of

a forced-air or water-cooled system is a more resourceful
choice, especially where water conservation is important.
Additionally, special plumbing, water treatment and freezing
weather considerations are unnecessary.

Specifiers should exercise great care and caution when

deciding on a solvent recycling machine, as they are not
all made the same. Some solvent recyclers require special
installation planning and must be restricted to limited areas
within the facility, whereas other solvent recyclers can be
plugged in almost anywhere and operate with the press of a
button.

The sealant on the lid of the machine must be able to hold

up despite extreme temperatures. Corrosion-resistant
materials, such as Teflon, should be used to construct the
vapor tubes. Safety features, such as pressure relief valves
and redundant plumbing are highly suggested, as well as a
mechanism to perform an automatic shutdown if necessary.

A well-designed machine will not require servicing for

replacement seals, O-rings or gaskets. These machines are
intended for use in commercial and industrial applications
only by trained personnel. Strict adherence to the cautious
handling of hazardous materials must always be maintained.
SAFETY PRECAUTIONS

When choosing a solvent recycler its safety features need to be taken

into consideration. The distillation process should be continuously
monitored by an electronic logic printed circuit board. Automatic
shutdown should commence in the unlikely event of an overheat
situation. These safeguards should not only shut off the unit, but also
disable it until a service representative can evaluate the problem and
help with repairs.

As with most products, there are some pitfalls to avoid. Only

knowledgeable persons should be allowed to operate a solvent
recycler. Never process unidentified compounds. Know what you
are processing and check the material safety data sheets (MSDS)
for the resulting waste contaminants as well as for the solvent being
recycled for compatibility before processing.

UL LISTING

A solvent recycler should be considered for use in normal, non-

hazardous locations, and listed by Underwriters Laboratories. The
United States electrical standard for distillation is certified by the
requirements of UL 2208. Current codes state that as of 1997, the
Uniform Fire Code requires that a solvent recycler be listed by a
nationally recognized board third-party testing agency and that it be
certified by the testing agency to meet the requirements of the UL
2208 Standard for Solvent Distillation Units.

According to the standard and codes, a solvent distillation unit

must be either compliant for use in non-hazardous areas or must
be located in either a Class 1, Division 2 or Class 1, Division 1
hazardous location. The machine should comply in all instances for
use in non-hazardous locations. An ozone-safe refrigerant should
also be used.
SUCCESS STORIES AND BEST PRACTICES

Onsite recycling is often the most cost-effective and environmentally

friendly option for dealing with used solvents. A 1989 study
examining the onsite recycling and reuse of solvents highlighted two
success stories:

1. A recycling machine, used at the Naval Shipyard in Portsmouth,

Virginia to recycle paint thinners and mineral spirits, was paid off in
less than six months and cost savings were estimated at $15,000 per
year.

2. Robbins Air Force Base experienced a savings of over $600,000

per year using several recycler machines to process over 50,000
gallons of various solvents.

The study also found that segregating the solvents and processing
each type in individual batches significantly improved the quality
of the end product. Mixing solvents together makes recycling
problematic, so temporary holding containers should be clearly
labeled with their contents. Segregation is the best way to optimize
recovery and minimize costs.

Another good management practice is known as downgrading, where

the (expensive) virgin solvent is used for critical procedures and the
recycled solvent is used for less demanding applications that can
tolerate some contaminants. In this way, the same solvent can be
recycled and reused several times.

CONCLUSION

Used waste solvents can pose an environmental and human health

hazard if improperly stored or handled. Solvent waste producers
have several alternatives to help them comply with environmental
regulations and save money by reusing expensive solvents.
Refrigeration machine distillers offer several advantages over other
types for recycling common solvents, such as acetone, methyl ethyl
ketone (MEK), lacquer thinner and toluene.