tinted Statat ' dUr and
EnvtoraiMntafPreuctton Radiation
A0*ncy (ANFV44S)
EPAMOOn41J017
Jum1Q91
Conservation And Recycling
Practices For CFG-1i3 And
Methyl Chloroform
X
i.' £
MO
PrintKl on R*cyd«d Paper
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r
CONSERVATION AND RECYCLING PRACTICES
FOR CFC-113 AND METHYL CHLOROFORM
by
ICOLP Technical Committee*
John Thome (Chairman)
Ray Alien
Jonathan Andell
Kenneth Bench
David Hey
Stewart Holm
Jim LaiKtoirs
Dara O'Rourke
Robert Ramsey
Bill Rtehard»on
Farzan Riza
Richard Szymanowski
Peter Thoratenaen
Stephen O. Andersen
U.S. Environmental Protection Agency
ICOLP n the IndusuyCoopentive for Ozooe Layer ProuctkMt ICOLP corporate member compute include AT&T, Boeing Company,
British Aerospace, Compaq Computer Corporation, Digital Equipment Corporation, Ford Motor Company, General Electric, Hitachi
Limited, Honeywell, IBM,, Matsushita Electric Industrial Company, Mitsubishi Electric Corporation, Motorola, Northern Telecom,
Sundstrand, Tens Instruments, and Toshiba Corporation. Industry association «fnii«t»« include American Electronics 'Association,
Electronic Industries Association, Japan Electrical Manufacturers AseocJaiiion, and the Hatogenated Solvents Industry Alliance (US.).
Government organization affiliates include the City of Irvine, California, the State Institute of Applied Chemistry (ILS.S.R.), the Swedish
National Environmental Protection Agency, UJ5. Air Force, and US. Environmental Protection Agency (EPA).
John Thome, Ray Alten, Jonathon Andell, and Jim Landers are employed bjr Motorola; Kenneth Beach it employed by Honeywell; David
Hey is employed by ICI (UK); Stewan Holm is employed by the Halogenatel Solvents Industry Alliance; Dan O'Rourke and Farzan Riza
are employed by ICF Incorporated; Bill Richardson is employed by Digital Equipment Corporation; Robert Ramsey is employed by
DuPont de Nemours & Qx; Richard Szymanowski is employed by Northern Telecom; and Peter Thorstensen is employed by Manchester
Corporation. We would like to **|»n*r the many individuaht and companies tiiat provided """gt" and infomatibn that hflpr^l produce »*»«
This -manual was funded by the US. EPA and ICOLP. j
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Disclaimer
Hi
The US. Environmental Protection Agency (EPA), the Industry Cooperative for Ozone Layer
Protection (ICOLP), the ICOLP committee members, and the companies that employ the
ICOLP committee members do not endorse the cleaning performance, worker safety, or
environmental acceptability of any of the technical options discussed. Every cleaning
operation requires consideration of worker safety and proper disposal of contaminants and
waste products generated from cleaning processes. Moreover, as work continues, including
additional toricity testing and evaluation under Section 612 (Safe Alternatives Policy) of the
Clean Air Act Amendments of 1900 and elsewhere, more information on the health,
environmental and safety effects of alternatives will become available for use in selecting
among alternatives discussed in this document ;
EPA and ICOLP, in furnishing or distributing this information, do not make any warranty
or representation, either express or implied, with respect to its accuracy, completeness or
utility; nor do EPA and ICOLP assume any MabiJity of any kind whatsoever resulting from
the use of, or reliance upon, any information, material, or procedure contained herein,
including but not limited to any claims regarding health, safety, environmental effects or fate,
efficacy, or performance, made by the source of the information.
Mention of any company or product in this document is for informational purposes only, and
does not constitute a recommendation of any such company or product, either express or
implied by EPA, ICOLP, ICOLP committee members, or the companies that employ the
ICOLP committee members.
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Table of Contents
List of Exhibits
................. . .... . .... . vjj
Foreword.
Cooperative Efforts
r
Economic Benefits ' ..
U.S. Clean Air Act Amendments
.......6
Excise Tax .. -... ?.................
Other International Phaseout Schedules .............. ...'.'.'. " " 6
7
Structure of the Manual
- - t- - - - - - - -. ,-'«..,.......... y
Conservation and Recycling Advantages .....,.. ........ ..... 11
........... 13
Process Characterization i<
" ~ ' : / ' . . ' «'«,........»... ID
Sources of Potential Savings !....' 15
Extent of Usage .; ..'.'..!*! i ] i'i i ° *"" * 15
Solvent Loss Mechanisms :'...<.....'.'.'.'.]'.'.'.'.'.] " 20
Measurement and Monitoring ..........!!.!!..].] 22
Recap on Program to this Point .........;............. 23
Conservation Practices and Strategies .......... ....... 25
Best Practices in Operation .;. - 26
Operator Training Curriculum ..., .'!]"""" 26
Handling Practices for CFC-113 and MCF ....... ...... 26
Pumping Practices '..... . 29
Equipment Strategies ..... .'.....' '..'.'.'.'.'.'.'.'.'.'.'.'.'"'29'
Batch aeaning Operating Practices 30
Process Description ......;[:]! i i *'" ];.! {. 1 30
Convection ..i................;!!" °'" * °' *"" 30
Superheated Vapor Drying . \. .."!'!:!!!!!!;!!!!! 30
Dragout -'. ......!! ][ !!!!!;'*"* " 32
Maintenance .....'.'.''"" 32
Piston Effect > ."'."...... *..... 32
Vapor Blanket Collapse ... ^ ............ 1 !!*]!]]*!]] 33
Programmable Hoists ...... '....... °...... 33
Start-Up and Shut-Down Procedures !!" * 34
Idle Time Management >....,'..'. .' ;.. '..'..,' 34
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Vi
Table olf Contents (Continued)
In-Une Cleaning Practices ....... , ................... ....... ..... 35
Process Description ......... ---- ..... ..... ....... ...... 35
Convection .............. : ...... ..... ......... ...... *J
Dragout ...... . ......... ........... ........ ---- ....... 37
Maintenance ........... ? ............... ...... fj
Superheated Vapor Drying . * ............. ...... ....... '"":*'
Start-Up and Shut-Down Procedures ------- ...... ........ ---- . . 38
Idle Time Management .... ...... « . .......... ...... ---- . . 38
39
Cold Cleaning ............... .......... -. ..... ...... ..... ;"
Process Description ........ ............. ..... '"'"'" Z
Qeaning Methods and Emission Reduction .......... . . ----- ..... 3*
40
Reclamation ........... .................. .*.. ....... '""
On-site Recycling
Off-site Recycling
Other Control Technologies ......... ............ ...... ....... ---- 45
Carbon Adsorption .......... . . . . * ............ ............. 45
MCF and Carbon Adsorption . . ---- ..... ........ ---- ..... 4^
Air Stripping ............ ...... .............. i ----- ... ........ 45
Thermal Destruction . . ....... . . ..... ---- ....... ....... ---- ««
Recap of the Manual ............ ........ ................. ....... ... 49
Case Studies of Industrial Practices ......... . ......... . ....... ---- ...... 53
Case Study #1 - CFC Reduction/EKmination in Electronics Qeaning ...... . . 55
Case Study #2 - Using Industrial Hygiene Techniques to Monitor
and Reduce Solvent Losses ......................... « ............ 59
Case Study #3 - Solvent Equipment Selection - A Case Study of Errors ..... 60
Case Study #4 - Emissions Monitoring and Reduction . . ........ ........ 62
Case Study #5 - History of Equipment Upgrades ...................... 63
Case Study #6 - Solvent Conservation and Recycling ...-..............,.'»
1 ' ' ' ' ' 67
References .................................. ........... ....... ....
List of Solvent Recyclers and Equipment Manufacturers ............ ----- ---- . 69
Glossary ........................... ; ; ;' ..... ° ' « 75
Appendix A - Industry Cooperative for Ozone Layer Protection . . . ; . ..... ... : ---- 77
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vii
List of Exhibits
Exhibit 1 Montreal Protocol Participants 1
Exhibit 2 Corporate Policies on CFC-113 Reduction Schedule . 2
Exhibits Phaseout Dates for CFC-113 and Methyl Chloroform Under the
US. Clean Air Act and the Montreal Protocol .. ... .....'. . 4
Exhibit 4 Relative Solvent Emissions From Representative Industrial
Situations ........ 12
Exhibit 5, CFC-113 and Methyl Chloroform Usage Profile ....... .....* 17
Exhibit 6(a) An Example of a Printed Circuit Hoard Cleaning Equipment
Profile .... :. :......... ig
Exhibit 6(b) An Example of a Metal Cleaning Equipment Profile ....... .. 19
Exhibit 7 Solvent Losses in a Typical Printed Wiring Assembly Plant ...... 21
Exhibit 8 Training Curriculum for Solvent Reduction Program . .'. 27
Exhibit 9 Solvent Refill Procedure ....... 1.. . ....-,............. 29
Exhibit 10 Basic Vapor Degreaser-Batch Cleaning .. . ......... 31
Exhibit 11 Schematic of Piston Effect ] ]'; [ 33
Exhibit 12 Schematic of Vapor Blanket Collapse 33
Exhibit 13 In-Line Solvent Cleaning System 36
Exhibit 14 Orientation of Parts for Maximum Drainage . ..... ..... 37
Exhibit 15 Factors Influencing the Decision to Recycle Solvent Wastes On-
Site ................................ . .....; 41
Exhibit 16 Continuous Steam Stripping .......... ." ... 43
Exhibit 17 Facility Considerations in Choosing an Off-Site Recycler 44
Exhibit 18 Point-Of-Use Carbon Adsorption Process Schematic 46
Exhibit 19 Rotary Carbon Adsorption System .....'., 47
Exhibit 20 Thermal Destruction FlowTDiagram 1 »-..* 48
Exhibit 21 Emissions Reductions: Problems and Solutions Checklist .........]] 50
Exhibit 22 Solvent Usage Reduction Program 1, 57
Exhibit 23 Solvent Usage Profile for a Conveyor Degreaser ...... ....... 62
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VU4
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FOREWORD
The 1987 Montreal Protocol on Substances that
Deplete the Ozone Layer, and subsequent 1990
amendments and adjustments, restricts the
production and consumption of ozone-depicting
chemicals. Two such chemicals, chlorofluoro-
carbon l,l,2-trichloro-l,2,2-trifluoroethane
(commonly referred to as CFC-113) and 1,1,1-
trichloroethane (commonly referred to as methyl
chloroform or MCF), will be completely phased
out in developed countries by years 2000 and 2005
respectively, and ten years later in developing
countries.
Exhibit 1 lists the countries that are Panics to the
Montreal Protocol as of April 1991. In addition,
many companies worldwide have corporate policies
to expedite the phaseout of ozone depleting
chemicals. Exhibit 2 presents the corporate
policies on CFC-113 reduction for some of these
companies.
In addition to providing regulatory schedules for
the phaseout of ozone-depleting chemicals, the
Montreal Protocol established a fund that will
finance the incremental costs of phasing out
ozone-depleting substances by developing countries
that are Party to the Protocol
U.S. Clean Air Act
Amendments
The ILS. Clean Air Act (CAA) was amended in
1990, and contains several provisions pertaining to
stratospheric ozone protection. Section 602 of the
CAA presents a list of ozone-depleting substances
that are restricted under the CAA. These ozone-
depleting substances are defined as Class I and
Class II substances. Class I substances include all
fully halogenated chlorbfluorocarbons (CFCs)
including CFC-113. three batons, MCF, and carbon
tetrachloride. Class II substances are defined to
include 33 hydrochlorofiuorocarbons (HCFCs).
The sections of the CAA that are of importance to
users of this manual are discussed below.
Exhibit!
MONTREAL PROTOCOL PARTICIPANTS
Argentina
Australia
Austria
Bahrain
Bangladesh
Belgium
Brazil
Bulgaria
Burkina Faso
Cameroon
Canada
Chile
Czechoslovakia
Denmark
Ecuador
Egypt
European
Community
Finland
vFiji
France
Germany
Ghana
Greece
Guatemala
Hungary
Iceland
Iran
Ireland
Italy
Japan
Jordan
Kenya
Libya
Liechtenstein
Luxembourg
Malawi
Malaysia
Maldives
Malta
Mexico
Netherlands
New Zealand
Nigeria
Norway
P3H3013
Poland
Portugal
Singapore
South Anica
Spain
Sri Lanka
Sweden
Switzerland .
Syrian Arab Rep.
Thailand
The Gambia
Trinidad and
Tobago
Tunisia
Uganda
USSR (includes
Byelorussia and
Ukraine)
United Arab
Emirates
United Kingdom
United States
Uruguay
Venezuela
Yugoslavia
Zambia
Non-Ratifying Signatories: Congo, Indonesia,
Israel, Morocco, Philippines, Senegal, Togo
Date: April, 1991
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Exhibit 2
CORPORATE POLICIES ON CFC-113 REDUCTION SCHEDULE
Company
American Electronics Association Member
Companies, U.S.
AT&T, U5.
Canon, Japan
Digital Equipment Corporation, U.S.
Hitachi Corporation, Japan
HoneyweU, U.S.
IBM, US.
Intel Corporation, U.S.
Matsushita, Japan
Motorola, Inc., U.S.
Nissan Motor Corp., Japan
Northern Telecom, Canada
Seiko-Epson, Japan
Sharp Corporation, Japan
Texas Instruments, ILS.
Toshiba Corporation, Japan
Volvo, Sweden
Reduction Schedule
CFC-tl3
Phaseout2000
Phaseout 1994
Phascout 1994
Phaseout 1995
Phaseout 1993
Phaseout 1997
Phaseout 1993
Phaseout 1992
Phaseout 1995
Phaseout 1992
Phaseout 1993
Phaseout 1991
Phaseout 1993
Phaseout 1995
Phaseout 1994
Phaseout 1995
Phaseout 1994
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Section 604 and Sect/on 605:
Phasmout of Production and
Consumption of Class I and Class II
Substances.
These provisions of the CAA present phaseout
schedules for Class I & Class II substances. The
phaseout dates for ozone-depleting substances
listed in the CAA are more stringent than the
Montreal Protocol. Exhibit 3 presents the
phaseout schedule for CFC-113 and MCF. Other
substances with ozone-deleting potential are also
regulated under the Montreal Protocol and the
CAA. While they are not used in solvent cleaning
applications, these substances are used in other
applications. Section 605 of the CAA presents
provisions for the phaseout of HCFCs. The CAA
freezes the production of HCFCs in 2015 and
phases them out by 2030. Since these restrictions
focus on production limitations, to the extent that
these chemicals can be recovered, recycled, and
reused, they may continue in commerce past the
applicable phase-out dates.
Sect/on 608; National Emissions
* Reduction Program
This section calls for EPA to promulgate
regulations by July 1992 requiring emissions from
all refrigeration sectors (except mobile air
conditioners that are covered in Section 609) to be
reduced to their "lowest achievable levels."
Regulations affecting emissions from all other uses
plClass I and Class II substances including solvent
cleaning are to take effect lay November 1995.
This section also prohibits any person from
knowingly venting any of the controlled substances,
including HCFCs, during servicing of refrigeration
or air conditioning equipment (except cars)
beginning July 1, 1992, and requires the safe
disposal of these compounds by that date.
Section 10: Nonessentlal Products
Containing Chlorofluorooarbons
this provision directs EPA to promulgate
regulations that prohibit the sale or distribution of
certain "nonessential" products that release Class I
& Class II substances during manufacture, use,
storage, or disposal. In the CAA, Co- £-
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Exhibits ' , .
PHASEOUT DATES FOR CFC-113 AND METHYL CHLOROFORM
UNDER THE U.S. CLEAN AIR ACT
AND THE MONTREAL PROTOCOL
CFC PHASEOUT
Clean Air Act
Reduce from 1986
levels by:
1991 -15%
1992-20%
1993-25%
1994 - 35%
1995-50%
1996-60%
1997 - 85%
1998-85%
1999-85%
2000-100%
METHYL CHLOROFORM PHASEOUT
Montreal Protocol
Freeze at 1986 production and consumption levels by July
1989
20% reduction from 1986 levels by January 1993
50% reduction from, 1986 levels by. January 1995
85% reduction from 1986 levels by January 1997
100% reduction from 1986 levels by January 2000
Also call for future assessment to determine if an earlier
complete pbaseout by January 1997 is achievable
Montreal Protocol
Freeze at 1989 production and consumption levels by
January 1993 '
30% reduction from 1989 levels by January 1995
70% reduction from 1989 levels by January 2000
100% reduction from 1989 levels by January 2005
Clein.AliLAct
Freeze at 1989 levels
by 1991
Freeze at 1989 levels
continues in 1992
Reduce from 1989
levels by:
1993-10%
1994-15%
1995 - 30%
1996-50%
1997-50%
1998-50%
1999-50%
2000-80%
2001-80% '
2002-2004*
2005 - 100% \
* New authority would be given to EPA to authorize, to the extent consistent with the Protocol, the
production of methyl chloroform in an amount not to exceed 10% of baseline per year in 2002,2003.
and 2004 for use in essential applications for which no safe substitutes are available.
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environment, and (c) are currently or potentially
available. If EPA temporarily exempts products
manufactured with Class I substances from the
labeling tequirement based on the lack of
substitutes, the products must be labeled by
January 1,2015; and
No later than January 1, 2015, products
containing or manufactured with j Class II
substance must be labeled. EPA may require
such products to be labeled as early as May 15,
1993 if it determines, after notice and
opportunity for public comment, that there are
substitute products or manufacturing process
available. .
The CAA allows for petitions to be submitted to
EPA to apply the requirements of Section 611 to
products containing Class II substances or a
product manufactured with Class I or II substances
which are not otherwise subject to the
requirements. This petition process will operate
between May 15, 1993 and January 1. 2015. For
products manufactured with Class I substances, a
successful petition would result in, the labeling of
a product previously determined by EPA to be
exempt For products containing or manufactured
with Class II substances, the petition process could
lead to labeling of a product that had been left
unlabeled by default
Sect/on 612: Safe Alternatives Policy
Section 612 establishes a framework for evaluating
the environmental impact of current and future
potential alternatives. Such regulation ensures
that the substitutes for ozone-depleting substances
will not create environmental problems themselves.
The key provisions of Section 612 require EPA to:
Issue rules by November 15,1992 which make
it unlawful to replace any Class I and Class H
substances with a substitute that may present
adverse effects to human health and the
environment where EPA has identified an
available or potentially available alternative that
reduces the overall risk to human health and
the environment
Publish a list of prohibited substitutes,
organized by use sector, and a list of the
corresponding alternatives;
Accept petitions to add or delete a substance
' previously listed as a prohibited substitute or an
acceptable alternative;
Require any company which produces a
chemical substitute for a Class I substance t<*
notify EPA 90 days before any new or existing
chemical is introduced into commerce as a
significant new use of that chemical In
addition. EPA must be provided with the
unpublished health and safety studies/data on
the substitute.
To implement Section 612 EPA will (1) conduct
environmental risk characterizations for substitutes
in each end use and (2) establish the Significant
New Alternatives Program (SNAP) to evaluate the
future introduction of substitutes for Class I
substances. EPA has also initiated discussions with
NIOSH, OSHA, and other governmental and
nongovernmental associations to develop a
consensus process for establishing occupational
exposure limits for the most significant substitute
chemicals.
The environmental risk characterizations for the
substitutes will involve a comprehensive analysis
based on the following criteria: ozone-depleting
potential, flammability, toricity, exposure effects,
energy efficiency, degradation impacts, air, water
and solid waste/hazardous waste pollution effects,
and global-warminj; potential. Economic factors
will also be considered. EPA will organize these
assessments by use sector (Le. solvents,
refrigeration, etc). The risk characterizations will
result in risk-management strategies for each
sector and substitute. EPA will then categorize a
substance as unacceptable, acceptable with
limitations on use or quantity, acceptable without
comment, or delayed pending further study.
Petitions will be allowed to change a substance's
status with the burden of proof on the petitioner.
The SNAP program, effective November 15,1992,
will review future substitutes not covered in the
initial risk characterization process. SNAP will
evaluate a substitute based on the criteria
established for the risk characterization and will
classify it similarly.
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Excise Tax
Congress has abo placed an excise tax on ozone-
depleting chemicals manufactured or imported for
me in the United States. This tax provides a
further incentive to use alternatives and substitutes
to CFC-113 and MCF. The tax amounts are based
on each solvent's ozone depleting potential
Calendar Year
1991
1992
1993
1994
1995
Tax Amount
Per found
CFC-113 MCF
$1.096
S1336
52.120
S2.120
$2.480
$0.137
$0.167
$0.265
$0.265
$0310
The tec will increase by $0310 per pound
for CFC-113 and $0.045 per pound for
MCF each year after 1995.
Other International Phaseout
Schedules
European Community Directive
Under the Single European Act of 1987, the twelve
members of the European Community (EC) are
now subject to various environmental directives.
The members of the EC are Belgium, Denmark,
Germany, France, Greece, Great Britain, Ireland,
Italy, Luxembourg, the Netherlands, Portugal, and
Spain. Coundl Regulation number 594/91 of
March 4,1991 provides regulatory provisions for
the production of substances that deplete the
ozone layer. The EC phaseout schedule for CFC-
113 production is more stringent than the
Montreal Protocol It calls for a 50 percent
reduction of CFC-113 by the end of 1993, a 67,5
percent reduction by the end of 1995, an 85
percent reduction by the end of 1996, and
complete phaseout by June 30,1997. For MCF,
the production phaseout schedule is as follows: 30
percent reduction by the end of 1995, 70 percent
by the end of 2000. and a complete phaseout by
the end of 2004. While all members must abide by
these dates. Council Regulation number 3322/88 of
October 31.1988 states that EC members may take
even more extensive measures to protect the ozone
layer. , .
Other Legislation
Several other countries have adopted legislation
that is more stringent than the terms of the
Montreal Protocol. Environment Canada, the
federal environmental agency responsible for
environmental protection in Canada, also has a
reduction program in place that is more stringent
than the Montreal Protocol All production and
import of CFCs. for use in Canada, must be
eliminated by no later than 1997. Environment
Canada has also announced a series of target dates
for the phaseout of CFCs in specific end uses. For
solvent cleaning applications, such as metal and
precision cleaning, it mandates a phaseout of CFC-
113 by the end of 1994. Pending final
consultations with end-users and producers of
MCF, the target date for the phaseout of MCF wfll
be 2000.
Japan has ratified the revised Montreal Protocol
The recent Ozone Layer Protection Act gives the
Ministry of International Trade and Industry
(MITI) the authorization to promulgate ordinances
governing the use of ozone-depleting compounds.
MTTI and the Environmental Agency have
established the 'Guidelines for Discharge
Reduction and Use Rationalization.' Based upon
these guidelines, various government agencies
provide administrative guidance and advice to the
industries under their respective jurisdictions.
Specifically, MITI, the ministry overseeing several
aspects of Japanese industry including the
production and trade of controlled substances,
prepares and distributes manuals, and encourages
industry to reduce ozone-depleting compounds
consumption through economic measures such as
tax incentives to promote the use of equipment to
recover and reuse solvents.
The EFTA (European Free Trade Agreement)
countries (i.e., Austria, Finland, Iceland, Norway,
Sweden, and Switzerland) have each adopted
measures to completely phaseout fully halogenated
ozone-depleting compounds. Some of the EFTA
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countries have sector-specific interim phaseout
dates for certain solvent uses. Norway and Sweden.
will phaseout their use of CFC-113 in all
applications except textile dry cleaning by .Jury 1
and January 1, 1991, respectively. Furthermore,
Austria will phaseout CFC-113 in some solvent
cleaning applications by January 1,1992 and 1994.
Austria, Finland, Norway, and Sweden will
completely phaseout their use of CFC-113 in all
applications by January 1,1995. Sweden also plans
an aggressive phaseout date of 1995 for MCF.
Cooperative Efforts
The U.S. Environmental Protection Agency (EPA)
has been working with industry to disseminate
information oh technically feasible, cost effective,
and environmentally sound alternatives for ozone-
depleting substances. As part of this effort, the
U.S. EPA is working with the Industry Cooperative
for Ozone Layer Protection (ICOLP*) to prepare
.a series of manuals to provide technical infor-
mation on alternatives to CFC-113 and MCF. The
manuals are based on actual industrial experiences
that will serve as a guide to users of CFC-113 and
MCF worldwide. These manuals will be updated
periodically as technical developments occur.
first manuals in the series are:
Conservation and Recycling Practices for CFC-
113 and Methyl Chloroform.
Aqueous acid Semi-Aqueous Alternatives to
CFC-113 and Methyl Chloroform Cleaning of
Printed Circuit Board Assemblies.
Inert Gas Soldering/Low Residue Flux and
Paste Alternatives to CFC-113 and Methyl
Chloroform.
Alternatives for CFC-113 and Methyl Chloro-
form in Metal Cleaning.
Eliminating CFC-1 13 and Methyl Chloroform in
Precision Cleaning Operations.
Riveting Without CFC-113 and Methyl Chloro-
; form. 1 '.''.
This particular manual presents a simple structured
program to help you reduce use and emissions of
CFC-113 and/or MCE The manual:
« Guides you through a characterization of your
existing process;
Helps you identify sources of emissions from
| your process;
Outlines the selection criteria for appropriate
conservation and recycling measures for your
operations;
Introduces several conservation and recycling
technologies;
Presents detailed case studies of solvent
conservation and recycling measures.
! '"''.'
The conservation measures for CFC-113 and MCF
cleaning will help to reduce losses from:
Convection and diffusion
Dragout
« Maintenance
;« Miscellaneous sources.
This manual will be helpful to all users of CFC-
113 and MCF in solvent cleaning. However, the
success of your CFC-113 and MCF reduction
'strategies will depend upon how effectively you can
coordinate your conservation and recycling
programs. The reduction of CFC-113 and MCF in
solvent cleaning presents a demanding challenge
for your organization. The rewards for success are
the contribution to global environmental
protection and the increase in your company's
industrial efficiency.
' Appendix A presents more detailed information
about ICOLP.
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8
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9
STRUCTURE OF THE MANUAL
This manual is divided into four sections:
CONSERVATION AND RECYCLING ADVANTAGES
This section outlines some of the advantages of conservation and recycling
practices.
PROCESS CHARACTERIZATION
This section helps toc assess and understand the use of solvents in manufacturing
processes. ' . i
CONSERVATION PRACTICES AND STRATEGIES
'" f
In this section, conservation practices specific to batch cleaning, in-line cleaning,
and cold cleaning are discussed with examples and ideas for reducing losses from
these systems. Reclamation and recycling processes are also discussed.
- ' ', '
CASE STUDIES OF INDUSTRIAL PRACTICES
i 'i
This section presents case studies of several companies that implemented
conservation and recycling programs.
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10
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11
CONSERVATION AND RECYCLING
ADVANTAGES
There are a number of compelling reasons to
conserve and recycle CFC-113 and MCF solvents.
Controlling solvent emissions from vapor
degreasers has been important to reducing
occupational exposure and minimizing solvent
losses. With the added incentive of protecting the
stratospheric ozone layer and mitigating the
greenhouse effect, it is now imperative that your
company reduce emissions of these chemicals
through conservation and recycling.
Solvent conservation and recycling
protects worker health and protects
the local environment.
Solvent conservation and recycling
improves operating practices.
Understanding and controlling
emissions of cleaning solvents
supports the optimization of
manufacturing processes.
Reducing waste streams and chemical
losses during operation saves money
and can help your company comply
with environmental requirements.
In all but the most efficient systems, vapor
degreasing and cold cleaning systems emit
relatively high amounts of solvents when compared
to solvent emissions when proper engineering
controls are implemented. Exhibit 4 shows typical
emission factors in industrial practices. The results
are based on a standard load, keeping variables
such as thermal mass constant for the different
operating settings.
In Exhibit 4, "base* represents the minimal amount
of solvent emissions from a process unit that is
idling with its cover on. The amount of solvent
loss during this idling period is arbitrarily given an
emission factor of 1.0.
"Good" represents solvent loss rates for a property
operated unit with a representative load. The
general procedure is a 30-second vapor rinse, 30-
second ultrasonic immersion, 60-second vapor dry,
and a 30-second residence in the freeboard zone
(just above the vapor zone but still within the
cooling coils). This emission factor represents a
high level of conservation of emissions through
strict adherence to proper procedure.
"Poor" represents solvent loss rates when some
common shortcuts are taken in violation of "good"
procedure. For example, when no freeboard
residence is used and the vapor dry is reduced
from 60 seconds to 30 seconds. As shown in
Exhibit 4, these seemingly minor violations in
procedure dramatically increase emissions by a
factor of five compared to the "Base" case.
"Industry* represent!) a value that is representative
of what is commonly found in industry. This value
incorporates losses associated with liquid dragout,
drafts, rapid entranos and exit speeds, uncontrolled
sprays, and other procedural violations. This case
represents an increase in emissions by a factor of
eight compared to the "Base" case. This
consumption level is generally found in high
production situations where throughput is
emphasized over soltvent savings.
Identifying the sources of emissions is the first step
in reducing emissions. In our discussions of the
various technologies, we examine specific sources
of emissions and elite actions which will help to
reduce these losses.
-------
12
Exhibit 4
RELATIVE SOLVENT EMISSIONS FROM
REPRESENTATIVE INDUSTRIAL SITUATIONS
10
8
ft
t
l)
1
.;
BASE
GOOD POOR
Industrial Practices
INDUSTRY
Source: Halogenated Solvents Industry Alliance
FUMU
-------
13
The three main sources of emissions are: .
Diffusive and convective losses of
solvent vapor from the equipment;
Leakage from the equipment and its
associated piping;
Liquid and vapor dragout on the work
being processed.
Recent improvements in machine designs address
the main sources of emissions. Solvent losses can
be reduced either by replacing old machines with
new equipment or retrofitting older machines with
improvements. A partial list of vendors of
equipment appears at the end of this manual
Occupational Safety and Health regulations which
are in place in the U.S. and Europe also motivate
companies to reduce emissions of solvents.
Permissible exposure limits require companies to
monitor and control emission of certain solvents.
Economic Benefits
The U.S. tax on CFCs and MCF, and product
shortages, will continue to improve the economics
of recycling and conservation. As production cuts
go into effect and prices continue to rise, the
efficient use of solvents will become more
profitable.
The elimination of waste streams in a
manufacturing process increases the efficiency of
the process and reduces costs associated with
complying with state and local regulations on
hazardous waste minimization and auditing
requirements. Reclaiming and recycling solvents is
one way to reduce both waste streams and the
virgin use of expensive ozone-depleting solvents.
It is important, however, to avoid mixing solvents
in the recovery process. The quality of recovered
solvents should be examined for suitability for
intended future uses. -'..,
Solvent recycling can occur both on-site and off-
site. While the magnitude of on-site recycling is
difficult to quantify, it has been a significant
component in the increased solvent efficiencies
that have been achieved in recent years. Over 100
off-site solvent recycling organizations exist in the
U.S. and Europe. Over the last several years these
companies have proven that recycling is
economical for both themselves and those who use
solvents. As more companies perform solvent
recovery, the recycling organizations are now
poised to serve the needs of the industry. A
partial list of solvent recyclers appears at the end
of this manual.
Older equipment is generally less efficient and
more likely to emit solvents than new equipment
-------
14
-------
PROCESS CHARACTERIZATION
The first step in reducing use and emission of
ozone-depleting chemicals is identifying them in
your processes. CFC-113 and MCF are marketed
as cleaning solvents under a variety of names and
labels. They are also found in smaller concen-
trations in a variety of mixtures. The following is
a partial list of these solvents by their trade names,
and the companies that manufacture them:
,
CFC-113
Trade Name
Algofrane 113
: ArkloneP
: Asahifron 113
Daiflon 113
Daiflon S3
Flugen 113
FreonPCA
Freon TMS (94%)
Freon 113
Freon TF
Frigen 113
Frigen 113A
Frigen TR
Genetron 113
GenesolvD
Manufacturer
Montecatini
ICI
Asahi Glass
Daikin
Daikin
Atochem
DuPont
DuPont
DuPont
DuPont
Hoechst
Hoechst
Hoechst
Allied Signal
Allied Signal
Nomenclature/Chemical Names
1,1,2-Trifluorotrichloroethane
R113
F113
Methyl Chloroform
Trade Name "
Genklene
Propaktone
AerotheneTT
Chlorothene SM
DowcleneEC
DowcleneLS
Proact
Prelate
Solvent 1,1,1
Manufacturer
ICI
ICI
Dow
Dow
Dow
Dow
Dow
Dow
Vulcan
Nomenclature/Chemical Names
1.1.1-Trichloroethane
MCF
TCA
Sources of Potential
Savings
There are five steps Involved in reducing emission
of solvents. Incorporating these five steps in your
evaluation process will significantly reduce
emissions. The savings associated with each step
can vary widely, a representative range is presented
in the discussion below.
These five steps can be summarized as the
following actions:
Eliminate
Isolate
Automate
Educate
Maintain.
Eliminate. Eliminating solvents results in a 1 GO
percent reduction in emissions. The first step in
reducing the use and emission of solvents is to
assess the need to employ solvent cleaning at each
existing ,stage in the manufacturing process.
Redundant or unnecessary cleaning of parts is
common in manufacturing systems. Any stage in
a process where cleaning can be eliminated will
automatically reduce emission of the chemicals,
while saving money.
i
If parts are cleaned a number of times before final
assembly, consolidation (or centralizing) of
cleaning processes and equipment will reduce
unnecessary steps in the manufacturing process. It
also concentrates activities to fewer machines -an
advantage in both maintenance and operating
costs.
Isolate. Isolating open sources of emission and
enclosing them can reduce emissions from 50 to 80
-------
percent Open-top vapor degreasers can be
retrofitted easily to Include a shroud or cover.
Sealed doors and covers should be added where
access is necessary but where emissions occur.
Dedicated vents that can account for up to .75
oercent of emissions should be turned down or ofi,
if other measures can be taken to limit worker
exposure.
At&malt. Automating a vapor degreasing process
can reduce emissions by 40 to 60 percent Manual
operation of vapor degreasing equipment often
leads to unwanted emissions. Opening and dosing
covers, lids, and doois as well as moving the work
pieces in and out of the solvent can cause
emissions. Employing automatic hoists and
transport systems will reduce operation emissions.
Automated operation also minimizes operator
error. Manufacturers should consider retiring
older equipment and replacing it with modem
systems which have been designed with emission
redactions features. It is important to note that
retrofitting a degreaser may require a permit
modification. Replacing an old degreaser with a
new one wfll likely require repermittrog. A
sifdScant cost savings can be achieved with such
investments, but plan ahead by purchasing
equipment that can use the new solvents that are
replacing CFC-113 and MCF. In many cases,
faowsver, different equipment designs will be
required to use alternative solvents.
Fffo**** Education programs can lead to
procedure changes, which in turn can reduce
emissions by 20 to 30 percent Training workers to
be aware of the need to reduce, emissions wfll
ensure that programs are instituted correctly and
that accidental emissions are reduced. Information
sessions addressing emission issues of sun-up, shut
down, and idle time procedures should be included
in basic operator training. Incentives for
conservation should also be explained to the
. workers, including their own health and safety,
environmental concerns, and company benefits.
Jtfa&tfgfc- Improved maintenance procedures can
result in 20 percent reduction in emissions.
Maintenance of vapor degreasing equipment is
essential to preventing potential emissions. Leak
testing and usage logs can be used to track the use
and emissions of solvents. Improving solvent
change and boil down procedures will also reduce
emissions. General equipment maintenance is
important for proper operation. A critical
maintenance issue is the associated chiller package,
.where failures can result in the toss.of excessive
amounts of solvent overnight
Extent of Usage
An effective program to reduce CFC-113 and MCF
use requires a good knowledge of your plant
operations, including quantities of solvents used
for each process and areas *toere losses occur.
The following questions will help you understand
your plant operations:
. Who purchases CFC-113 and MCF?
Who takes delivery?
How is the CFC-113 or MCF handled from
arrival to ultimate use?
. How is CFC-113 or MCF used?
' . Where do losses take place?
Have the manager of your solvents elimination
program start with a survey. A copy of
questionnaires that can be'used are shown in
Exhibits 5 and 6. This survey form should be sent
to individuals in each plant location who are
responsible for Material Safety Data Sheets
(MSDS). All MSDS should be checked for 1,1,2-
trichloro-lA2-trinuoroethane (CFC-113) and
11,1-trichloroethane (methyl chloroform) to help
identify the trade name. The MSDS sheets should
be cross-checked with the trade names listed
previously in this section. Identify the quantities
bought in the previous calendar year and start
reporting on a regular basis (monthly or quarterly).
Some solvent losses wfll inevitably occur during
operation. However, it is impossible to determine
the extent of your emissions and potential
reductions until a process assessment is performed.
Monitoring your operations is also the best way to
determine the success of your conservation
programs.
-------
.17
,
Exhibits
CFC-113 AND METHYL CHLOROFORM USAGE PROFILE
A. Identification
Name of Product: ' .' '.- ':
Manufacturer:
Purchase Number:
CFC or MCF Components:
1.
2.
3.
Chemical Name
Percent or Concentration
B. Quaatyication of Usage Patterns
Quantity Purchased: (specify units)
1989: ". 1991:
* 1992:
C. CFC and MCF Disposal Practices
Annual quantity shipped as waste
for disposal: (specify units)
Annual disposal costs:
Annual quantity shipped for
reclamation: (specify units)
Annual cost of reclamation:
Annual quantity lost to the
environment: (specify units)
Through leakage:
Through spillage:
Through testing:
Through drag-out and
evaporation:
By other means (specify)
Unaccounted:
1989
1990
1991
1992
Source: U.S. EPA 1990
-------
Exhibit 6(a)
AN EXAMPLE OF A PRINTED CIRCUIT BOARD
CLEANING EQUIPMENT PROFILE
Equipment Name:
Model Number _
Manufacturer. __
Year Purchased: __________
Tilde Name of
Chemicals Used: __________
Annual Quantity of CFC or MCF
Purchased for use in this
Equipment (specify units): -
Annual Quantity of CFC or MCF Waste
Requiring Disposal or Off-site
Recycling: .
& Equipment Usage Pattern
..is *
Annual Board Production
(specify units):
Average Board Area:
(specify units):
Check appropriate blanks:
Single sided
Double sided
Multilayered
Number of layers
Average Number of Solder
Connections per Board:
C. Emission Controls
Do you practice the following? If you do, briefly describe the procedures:
Leak Testing:
Alternate Testing Methods:
On-site Recovery/Recycling:
Improved Loss Control Procedures:
Operator Awareness/Guidelines:
Source: US. EPA 1990
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19
Exhibit
AN EXAMPLE OF A METAL CLEANING EQUIPMENT PROFILE
*"'('- :-
A. Identification ' - '
* * ;
Equipment Name: '' ' !' - '
Model Number -"'"'' ' '. .
Manufacturer: .
Year Purchased:
Trade Name of
Chemicals Used:
Annual Quantity of CFC or MCF
Purchased for Use in this
Equipment (specify units): ,
Annual Quantity of CFC or MCF Waste
Requiring Disposal or Off-site
Recycling: .
B. Equipment Usage Pattern
Annual Quantity of Parts Cleaned
(specify units): "
Type of Pan Cleaned: .
TVpe of Cleaning Equipment:
Cold cleaner/dip tank
Open-top vapor degreaser
In-line vapor degreaser
C Emission Controls
Do you practice the following? If you do, briefly describe the procedures:
Leak Testing:
- - . |
Alternate Testing Methods:
On-site Recovery/Recycling: >
Improved Loss Control Procedures: j
OperatorAwareness/Guidelines:
Source: US. EPA 1990
-------
20
The following two steps should be
followed for printed circuit board
processes:
« Determine total production of boards
in square meters of surface area for a
given time period (year, quarter,
month). Only measure the area of
one side of the board regardless of
whether it is single sided, two sided,
or multiple layer in configuration and
regardless of whether any components
are mounted on it
^ Divide total quantity of CFC-I13 or
MCF purchased by total manufactured
board area for the same period to
determine the ratio of pounds solvent
used per square feet of board
produced, expressed as Ibs/fr.
In North American industry, this ratio is on the
ordsr of 0.41 lbs/ft2 (2.0 kg/m2> for a production,
facility operated with today's technology and with
minimal attention to chemical handling.
Determine your use ratio before beginning your
conservation and elimination programs.
For metal cleaning, this ratio can be
determined by the following step:
« Divide total quantity of solvent
purchased by total units or weight of
parts cleaned for a given time period.
Repidless of the cleaning process used, calculate
thii ratio and report it on a.regular basis -
monthly is recommended. This step is important
because it enables you to monitor success as your
conservation programs go into effect. It will also
stimulate your employees to take an interest and
participate in the drive to reduce solvent use.
Keep a log book for solvents used in each of your
machines. The log tracks the amount of solvent
used and product cleaned and gives you
information to compare machines. Log books will
add incentive and a feeling of ownership to
operators of the machines.
At this point, you have to make the following
decision:
If you have already reduced use by 75 percent,
you probably have good conservation practices
in place and will be ready to focus more time
and effort on exploring alternate processes and
technologies.
If your usage has reduced by less than 75
percent of original, you can probably benefit
from additional conservation programs.
1 ,'
Next, do an assessment of where you are losing
solvents. Do this for the whole plant beginning
with the delivery of solvent You may wish to
develop a simple flow diagram as in Exhibit 7.
This will give your project manager and your
technical staff an understanding of the areas to
focus on first If you have more than one cleaning
machine, you should do an analysis of each, since
solvent losses may vary significantly from machine
to machine.
With knowledge of solvent use and where losses
are occurring, you can now select the appropriate
conservation programs described in the next
section.
Solvent Loss Mechanisms
Losses from convection, diffusion, dragout,
maintenance, and spills occur in all solvent
cleaning systems. Knowing which losses are the
most significant in your operation and which can
most easily be reduced will help improve your
success.
In a vapor degreaser, there is a layer of relatively
stagnant gas in the freeboard zone of the machine
that is sandwiched between the layer of 100
percent solvent vapor at the bottom of the
condenser and the layer of 100 percent air exiting
at the top lip of the machine.
-------
Exhibit?
21
SOLVENT LOSSES IN A TYPICAL PRINTED WIRING
ASSEMBLY PLANT
Evaporallv* LOSMS, Drag Out Evaporative LOSMS,
S«al«,«tB. 12% 40% Seals,«tc, 2%
Evaporative LOSMS
Solvent
15% Evaporative LOSMS
Holding
Tanks
Source: Northern Telecom
-------
Under these conditions, the solvent molecules tend
to migrate or diffuse from the region of high vapor
concentration at-the condenser to the region of
low vapor concentration at the top of the
degreaser. The rate of diffusion is a function of
the freeboar*1 depth (the deeper the depth, the
slower the diffusion rate) and the condenser
temperature (the lower the temperature, the slower
the diffusion rate). Auxiliary refrigerated
condensers (-20*F/-29*C) located in the freeboard
zone help to reduce the diffusion rate.
Diffusion, however, is an. insignificant process of
solvent toes compared to other loss mechanisms.
Convection is the most significant physical loss
process. Drafts or other air currents blowing
across the top of the degreaser, referred to as
convective losses, can be eliminated by locating the
unit in a draft-free environment Consider that
moving a degreaser or installing a hood may
subject some operations to repermitting
requirements, depending on the regulatory
requirements. Where excessive air movement is a
problem, consider installing baffles or partitions on
the windward side to divert the air currents away
from the degreaser. Losses from drafts can also be
reduced by using hooded enclosures in conjunction
with automated work-handling facilities.
Insertion and withdrawal of the workload can lead
to losses due to disruption of the vapor blanket, as
well as dragout losses. Manual insertion and
withdrawal tend to increase these losses.
Mechanical devices to insert and withdraw the
Work load can result in significant savings. Such
devices can range from inexpensive hoist motors to
sophisticated, programmable systems.
Emissions during maintenance of a solvent
cleaning machine are also common and can be
reduced through increased training and awareness
on the pan of maintenance personnel. Emissions
from spills will also be diminished through user
awareness and care.
Measurement and Monitoring
Several simple measurement and monitoring
methods can be used effectively to determine
sources of losses. Leak detectors sold as
refrigerant detectors wfll identify leaks of solvents.
Air currents which may cause diffusion should be
monitored with smoke generation tubes.
Operators or system analysts should be given the
time to verify the performance condition and
calibration of solvent monitoring equipment To
be effective, the monitoring equipment must be
both accurate and responsive in the range in which
it is expected to perform. Below is a partial list of
instruments that can be used for leak detection and
vapor concentration monitoring. A partial list of
vendors for monitoring equipment appears at the
end of this manual
MEASUREMENT/MONITORING EQUIPMENT
Infrared
Infrared
Flame lonization
Detector Tube
Electronic
Thermal Printer
Paper
1-40,000 ppm
100-9900 ppm
1-10,000 ppm
50-1400 ppm
Ounces/yr
Concentration Monitoring
Leak Detection/Concentration Monitoring
Leak Detection/Concentration Monitoring
* . - '
Concentration Monitoring
i '
Leak Detection
Leak Detection
-------
23
RECAP ON PROGRAM TO THIS POINT
If the recommendations presented above are followed, the program will have laid the
groundwork for reducing solvent emissions, including: ;
« Commitment by management and workers to reduce emissions;
Better understanding of the costs and benefits of reducing emissions;
Recognition of CFC-113 and MCF under their various trade names and chemical
names; t
Characterization of cleaning processes to identify the extent of usage and the
need for a conservation and recycling program;
Identification of the primary sources of emissions and means of reducing them.
-------
24
-------
25
CONSERVATION PRACTICES AND
STRATEGIES
This section of the manual begins by discussing conservation practices in general and then
presents specifics of different cleaning operations (e.g., batch, in-line, and cold cleaning).
Finally, the section concludes with an overview of reclamation and recycling procedures.
The section is organized in the following manner:
Best practices to operate solvent cleaning equipment;
Causes of emissions and reduction strategies for batch cleaning operations;
*, Emissions during in-line cleaning and techniques to reduce ithem;
' ' . ,|
Cold cleaning practices and emissions reductions;
Reclamation and recycling practices;
Other control technologies;
» _ A summary of emission causes and solutions.
-------
26
*BMMI
Best Practices in Operation
Once current use of solvents is characterized, a
conservation strategy can be developed. An first,
choose conservation options that are easy to
implement in the short-term. These will offer
immediate results and will encourage employees to
continue and accelerate their efforts. The
following options for savings are typical for open-
top3wpor degreasers that do not have some of the
more'advanced control techniques, and that may
differ for conveyorized equipment
Operator Training Curriculum
Operator training is the second largest
conservation opportunity, second only to control of
air currents. Operating losses due to dragout
average 40 percent of the total losses. Other
practices such as basket overloading, vapor blanket
distnrbances,sprayingabovecondensingzone,poor
racking habits, and solvent removal for hand
cleaning can increase total losses from operating
habits to over 80 percent
Operator induced losses obviously are reduced with
increased automation. Fully automated systems,
including part racking, are controlled by the
programmed operation of the equipment >
Therefore, production programmers should also be
trained in good conservation practices.
It has been found that operators are generally
unaware of the financial and environmental costs
associated with the use of ozone-depleting
chemicals. Increased operator awareness can
translate into a reduction in consumption, since
operating practices and methods can usually be
improved. . .
' Operator awareness of the ozone-depletion issue
and training in the handling of solvents is
recommended. Operators can change their
methods and practices, such as keeping lids and
windows closed, turning off the cleaner when not
in use, conducting maintenance regularly, and
exercising care while working with machines and
equipment
Access to CFC-113 and MCF can be restricted to
strengthen management control
Part basket designers, production scheduling
managers, and equipment maintenance personnel
should also be involved in training programs.
Parts must move slowly through the cleaning cycle.
Racking and basket design are critical fectors in
preventing or minimizing vapor blanket collapse
and solvent dragout Maintenance practices can
contribute to losses from poor cleaning and
handling techniques. On a warm day up to five
gallons of solvent can be lost from an open
< container due to evaporation.
A training curriculum for most solvent vapor
decreasing processes is shown in Exhibit 8. The
training is most effective if given over a four* to
six-week period and in at kast four separate
meetings. Any single training period should not
one hour.
Handling Practices for CFC-113 and
MCF
With more stringent production and emissions
controls on ozone-depleting chemicals, it is
imperative that solvents containing CFC-113 and
MCF be handled with the utmost care. These
solvents should be stored in secure drums to
prevent evaporation during storage and transfer
and should be clearly marked. You should also
store drums with the bung end up to eliminate the
possibility of solvent spillage through a leaking
bung.
If large quantities of solvents are used, consider a
bulk storage system and delivery of the solvent
through a piping system to the batch cleaners.
Solvent should be sampled periodically and tested
for acidity, moisture content, azeotropic imbalance,
and other signs of degradation. Solvent
degradation is often symptomatic of a flawed unit
which in turn can generate excessive solvent waste.
Follow solvent manufacturer's instructions for
proper testing methods and guidelines to
determine acceptable conditions for continued use
of the solvent If solvent cannot be used, be sure
to follow appropriate procedures for off-site
reclamation and disposal.
-------
27
Exhibits
TRAINING CURRICULUM FOR SOLVENT REDUCTION PROGRAM
/. OWNERSHIP
Encourage operator 'ownership' of environmental concerns
Operator tracking mechanism
- Meter with calibrated'solvent dispensing pump
- Solvent log book j
- Solvent usage graph
- Volume/area of work run
- Report usage to management
Understanding degreasing process
- Condensing of solvent on cold part
- Evaporation of solvent from warm part
Introduction to types of losses
Evaporative
- Vapor blanket collapse
- Dragout
« Demonstration of vapor degreaser in operation
~ Start up and shutdown procedures
- Condensing coil/distillation
- Vapor blanket smoke tube highlighting
//. MANAGER/SUPERVISORY SUPPORT
Training all operators
Control of operators
Reduce number of operators
- Reward mechanism
- Monitor performance
Provide sufficient equipment
- Stills, filters
- Hoists
Properly designed parts basket
Degreaser placement
Controlled ventilation
-------
28
Exhibit 8 (continued)
Maintenance program
- Chiller package
- Leaks
Cleaning
Demonstration
Ventilation disturbances
- Basket design
- Insufficient cooling
HI. VAPOR DEGKEASER OPERATIONS
Pan racking
Pan cupping ,
- Cohesion of solvents between parts .
Part/basket mass vapor blanket collapse
Slow pan submersion and withdrawal
- Piston effect
- Vertical rate less than 10 ft/min
Drying in condensing zone
Spraying techniques '
Low pressure
Below condenser area .
Fixed spraying zone
Solvent addition/removal .
Utilization of open-top unit as a still .
- Add below vapor and liquid levels
- No removal for .hand or cold cleaning
Disposition of still bottoms, handling empty drums
Demonstrations* '
- Vapor blanket collapse due to mass
Piston effect
Insufficient drying time
~ Solvent addition
* Demonstrations are an important tool in training. Artificial smoke from smoke-generating tubes
can provide an excellent media for observing air currents and vapor blankets. Dry ice can also be used
in a container to provide a nonsolvent demonstration. To minimize exposures to trainees and to limit
solvent emissions, dry ice may be preferred Either method provides a hands-on demonstration of
operator control
-------
Pumping Practice*
Carefully add solvent to the cleaner to minimize
disturbing the vapor blanket Solvent should be
pumped into the cleaner through a submerged
outlet Makeup solvent should be added to a rinse
compartment or better yet, to the cleaner's
condensate collection tank. In either case, it
should be added below the solvent surface. Cold
solvent definitely should not be added to a boiling
sump: it may stop the boiling and cause the vapor
blanket to collapse (see Exhibit 9).
Avoid pouring solvent with buckets or drums into
an open-top degreaser because:
Solvent foiling through air evaporates rapidly,
causing significant losses before entering the
unit;
The pouring action creates turbulence in the
vapor blanket, leading to convection losses.
This effect will be exacerbated if the cold
solvent causes the vapor blanket to collapse;
Spillage is increased; and
« Increased worker exposure may occur.
Exhibit 9
SOLVENT REFILL PROCEDURE
YES
Sauna: DuPont
Equipment Strategies
System optimization will improve the efficiency of
your manufacturing process as well as reduce
unnecessary emissions. Solvent cleaning units
should be used to their maximum potential C^e
large unit costs less than two small units and is
much more efficient
r
Vapor emissions can be reduced by consolidating
operations of several open-top units into a single,
enclosed unit designed for continuous operation.
Production scheduling, involving linear
programming or other methods, can help
streamline your process and reduce unnecessary
steps as well as associated labor and process costs.
Ideally, you should size a machine to your required
capacity. But if necessary, yon should oversize
your system rather than buy two machines. It is
important to consider the ability of the unit to
accept scale down. System operation at 20-30
percent of maximum capacity can be important
-------
90
Batch Cleaning Operating
Practices
P/oc*cs Description
Bitch cleaning systems (also called open-top vapor
decreasing) are used primarily-in metal working
operations, and defluxing operations. They can
also be used for maintenance cleaning of electronic
components, small equipment parts, and aircraft
pans where a high degree of cleanliness is needed.
A bitch cleaner is a tank with a heat source to bofl
solvent and a cooling zone to condense the vapor
in the upper section. Hie soiled pans are
suspended in an air-free zone of solvent vapor.
The hot vapor condenses onto the cool parts,
dissolving oils and greases and providing
continuous rinsing with clean solvent This process
also warms the parts, thus decreasing the rate of
condensation.
As the condensed solvent drains from the part,; it
carries off the soils and returns to the boiling
liquid reservoir. This vapor treatment is often
augmented by mechanical action such as liquid
immersion, ultrasonic agitation, or spraying the
with liquid solvent beneath the vapor level (as
shown in Exhibit 10).
Conviction
Because solvent losses result from air currents,
batch cleaners should be placed .in an area that is
as draft-free as possible. Turbulence caused by
drafts from adjacent windows, doors, fens, unit
heaters, ventilators, or spray booths will greatly
increase emissions of solvent vapor.
To avoid excessive air movement, consider
installing baffles or partitions on the windward side
to divert drafts away from the cleaning unit You
can reduce the velocity of the air flow over the top
of the unit by eliminating dedicated exhaust
ventilation. Air velocity over the top of the
machine should not exceed 6 meters per minute
(20 ft/min). However, it should be noted that in
order to minimize worker exposure to high
concentrations of solvent vapor, sufficient
ventilation should exist around the vapor degreaser
work areas.
For open-top equipment, problems with drafts can
be avoided or corrected by* using hooded
enclosures with automated work-handling facilities.
Hinged covers, if opened too quickly, tend to drag
some of the solvent vapor with them. Consider an
alternate design such as a cover that slides or rolls
open.
Most machines have covers or lids to limit solvent
losses and contamination during downtime or idle
time. Control of the solvent is also provided by
the freeboard, which is pan of the tank wall
extending from the top of the vapor zone to the
tank lip. The freeboard ratio (FBR), or ratio of
freeboard height to machine width, usually ranges
from .75 to 1.0, depending on the manufacturer's
'design.
It is sometimes possible to dramatically reduce
convection losses by adding a supplemental water-
cooled or refrigerated freeboard. The original
covers should be abandoned and replaced by
sliding covers on this new freeboard, which should
be as deep as practically possible.
Superheated Vapor Drying
Superheated vapor drying is a relatively new
technology that can be quite effective in
minimizing or eliminating losses from dragout la
this process, the parts being cleaned come in
contact prior to their withdrawal into the unit's
freeboard zone, with solvent vapor that is
superheated to a temperature above the normal
boiling point of the solvent The superheated
vapor provides the heat needed to evaporate the
equilibrium film of liquid and any additional
solvent trapped due to work configuration.
The savings associated with superheated vapor
drying are on par with that of automation. There
are two procedures for effecting the contact of the
work using superheated vapors. In one, the "static"
method, the vapor zone of die degreaser is
superheated using heat exchangers situated at an
elevation below the condenser. In the other, the
"dynamic" method, solvent vapor is recycled by a
blower through a heat exchanger and then
discharged through distributor nozzles onto the
work prior to its withdrawal into the freeboard
zone.
-------
31
Exhibit 10
BASIC VAPOR DEGREASEIR - BATCH CLEANING
SPRAY
TUBE
LIP VENT
WATER
sSEPARATOR
\
CLEAN OUT
DOOR
BOILING SUMP
HEATING ELEMENTS
WATER OUTLET
SOLVENT RETURN
SUMP THERMOSTAT
Source: PPG Industries
t1M06.1t
-------
32
«MHM
Dmgout
Dra'fout is primarily a function of the geometry of
the pan being cleaned and the type of basket being
uscdT You can reduce dragout losses if the work
being cleaned is always positioned in baskets or on
books, racks, or conveyor belts to permit maximum
liquid drainage. Solvent trapped in pockets and
recesses results in excessive dragout losses.
Baskets containing a random fill of parts should be
routed during cleaning to facilitate drainage.
If possible, hold the workload in the-vapor zone
after the final cleaning step until its temperature
equals that of the vapor zone and vapor stops
condensing on the part. Work taken out earlier
wfll emerge wet with solvent condensate. Ten feet
per minute is an effective maximum speed for work
entering/leaving a degreaser in batch operations.
Dwell times - the time spent in the vapor zone -
that are too short are most often seen in open-top,
units where the work is manually moved in and out
of the unit A freeboard dwell of the workpart just
above the vapor line is suggested until all solvent
on the workpart has flashed off. Automatic hoists
can help reduce excessive dragout due to
insufficient dwell time. They can also reduce the
piston effect and free the operator to perform
other tasks.
often occur around corners and joints, where two
seals meet. ' . .
Equipment should be fabricated from materials
that are chemically compatible with the solvent
employed. Aluminum should never be used as a
material of construction for storage and use
equipment with halogenated solvents. Type 300
stainless steels are the preferred materials of
construction for vapor degreasers and defluxers
employing CFC-113 and MCF. They are also the
preferred materials of construction for use with the
new HCFC solvents. It is difficult to obtain leak-
free joints in threaded stainless steel piping.
Welded or soldered joint piping with flanged
connections for removal of accessories (pumps,
filters, dryers; etc) is recommended to minimize
leakages.
Without an effective cooling system, more solvent
would escape, and these systems would evaporate
dry. This is another maintenance area requirement
When possible take advantage of services offered
by the machine manufacturers; they have
experience in fine tuning the cleaner to minimize
losses. You may wish to supplement this
assistance with services offered by solvent suppliers
who often have programs and information that can
help operators manage the process better.
Maintenance
Solvent losses during maintenance are common
and can be remedied relatively easily. Training
maintenance personnel is critical. Although the
design of vapor degreaser units can vary greatly,
some problems are common to all systems.
Leakage losses are primarily a reflection of the
quality of construction of the cleaning unit and of
the attention paid to its subsequent maintenance.
Pump seals deteriorate when not in contact with
solvent A "running dry" condition erodes the seal
surface and the seal prematurely fails. Systems
should be equipped with gaskets that are suitable
for contact with the solvent and mechanical burden
they face. Note that CFC-113 and MCF may
require different materials.
The design and maintenance of cleaners and stills
requires special attention to the seals and gaskets
on covers, lids, and panels. High volume leaks
Piston Effect
The loss of solvent vapor can be decreased by
avoiding the processing of workloads that exceed
the cleaning system's design capacities.
A workload that is too large in physical size can
displace vapor from the vapor degreaser by the
piston effect." Such losses can be minimized by
making sure that the workload area is not greater
than 50 percent of the horizontal cross-sectional
area of the sump into which it is being introduced.
You should also use baskets which minimize the
area of the workload perpendicular to the surface
of the solvent baths (see Exhibit 11).
Proper placement of baffles to contain the vapor as
well as an increase in the freeboard ratio within
the tank reduces losses from the piston effect
-------
E&ibitll
PISTON EFFECT
t.
Wkto
Workload
Sown: DuPont
Wkte
Workload
Vapor Blanket Collapse
The rapid introduction of a workpiece with a large
thermal mass will condense too moch of the vapor
blanket This will cause air to infiltrate the cleaner
and cause the vapor blanket to collapse. When the
vapor blanket is restored, the infiltrated air
saturated with solvent vapors will be expelled from
the vapor degreaser (see Exhibit 12). If this occurs
on a regular basis, contact the equipment
manufacturer to determine if additional heating
and condensing utilities can be incorporated into
the vapor degreaser.
Avoid spraying work pieces by spray lance or spray
headers. If you must spray in this way, spray deep
within the vapor zone, to avoid excess disturbance
of the vapor/air interlace.
Avoid liquid solvent ricochet into the freeboard
zone or out of the machine when lance spraying.
Do not spray cold solvent because its vaporization
consumes heat from the vapor blanket, which
s the risk of collapsing the vapor blanket
.' -. '. ... .' 33
Use of solvent at a (temperature near the solvent's
boiling point minimizes the potential for vapor
blanket collapse and the loss of solvent when the
vapor blanket is reestablished. Typically this is
pan of the machine design.
Vapor Blanket Collapse
V S. Condmalanm
Waft Stop*
6. Vapor BtankM
Programmable Hoists
A recommended maximum speed for work entering
and leaving the cleaner is less than 3 meters/min
(10 ft/min). Higher throughput rates can cause
disturbances at the vapor/air interface that result in
high vapor tosses. Automatic hoists and
programmed work transporters are recommended
because controlled speeds are difficult to sustain
manually.
The inclusion of an integrated degreaser cover and
hoist design is effective in reducing working
isolvent losses. The presence of a motorized,
horizontal sliding, two-piece lid can be integrated
wth an automated programmable hoist As the
iboist lowers the workload to the degreaser, the lid
-------
slides open to allow .the product to enter into the
vapor zone. When the workload clears the lid on
its downward descent, the lid doses. Subsequent
losses doe to the "piston effect" or sprayers
disturbing the vapor blanket are reduced.
Shortly after vipor condensation ceases, or
spraying is terminated, the workload can be raised
into the cooling coil zone of the degreaser with the
lid still closed to minimize disturbance to the
vapor zone and workload dragout tosses. When
the solvent has vaporized and the product is free
ofliquid solvent (dry), the hoist raises the product
out of the degreaser. The lid opens to allow the
product to exit, and then closes.
Such designs can be purchased as an integral pan
of many, new degreaser designs. Retrofit kits
consisting of a lid, hoist, or a combination of the
two are abo available to convert existing
degreasers. Retrofitting degreasers may require
repermitting.
Start-Up and Shut-Down Procedures
Start-op always results in some loss of solvent
vapor as air is purged from the system. When the
cleaner is used on an intermittent basis, emissions
caused by frequent start-ups and shut-downs can be
minimized by deferring cleaning until there is a full
day's worth of work to process. Thus, there will
only be one start-up of the cleaning equipment If
such scheduling is impossible, the unit should be
left on with the lid closed when not in use.
Solvent emissions during start-up can be
minimized through the following steps in the order
shown:
Start up the condenser cooling system and make
sure that it is operating property;
' Start up any auxiliary emission control
equipment;
Check and adjust solvent levels in all
compartments;
Torn on heaters;
Start up the spray, pumps once a stable vapor
blanket is established; and
Process work pieces only after the vapor blanket
has been established. In order to determine if
the vapor blanket has been established you must
look inside the unit. Best practice is to do this
only once. Time how long the blanket takes to
form, and incorporate that time into the
procedure.
When shutting down the system, use the following
steps in the sequence shown:
Stop work processing and clear the machine of
all work;
Close the cover on open-top units;
Turn off the heaterr,
Activate sump cooling coils wiiere provided;
water-cooled sump cooling coils can be easily
installed in many cases;
Allow the vapor blanket to collapse completely.
As before, time this step;
Turn off the condenser cooling system where
applicable. However, some units do not have
sump cooling coils. In this case, the condenser
cooling system should be kept on, on an
intermittent basis.
Note: If cooling condenser is left running for
extended periods after shut-down, it could cause
moisture condensation on the coils from room air.
The moisture would. drip into she sump and
contaminate the solvent However, this can be
prevented with the use of a water separator or
desiccant dryer.
Id/0 Time Management
Simple procedures such as putting the unit on
"cool* mode or turning it off whenever it is not in
use can help reduce losses during idle time.
However, start-up and shut-down losses must be
factored into scheduling decisions. Each
installation may warrant its own, customized plan.
Using rigid covers with tight seals is essential when
a machine is not operating. Make sure covers are
not discarded or lost
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35
In-Line Cleaning Practices
Process Description
In-line cleaning systems (also referred to as
conveyorized cleaners) transport the work through
the machine on an automated continuous basis.
Most of the in-line cleaners that use halogenated
solvents are vapor cleaners. In-line cleaners are
used in many different industrial applications.
However, they are most common in processes
where production volumes are large enough to
justify the higher capital costs of such equipment
Except for the parts/conveyor inlet and exit opmi
ngs, in-line cleaners are usually enclosed. Althou
gh this helps to control solvent losses from the s
ystem, it does not eliminate them. Most in-line s
ystems have significant emission. In-line cleaning
systems are usually custom made for ah applicati
on.
There are five main types of in-line cleaning syst
ems that use CFC-113 and MCF: cross-rod, mon
orail, belt, strip, and printed circuit board proces
sing equipment These systems differ in their met
hods of loading and unloading parts and in their
methods of transporting materials through the cl
eaning process. Systems are chosen based on the
needs of the manufacturing process, including th
e type of part to be cleaned, type of cleaning req
uired, and speed and space requirements. Exhibit
13 shows one type of in-line cleaning system.
Convection , ,
Excessive air currents around in-line solvent
cleaners disturb the vapor blanket' within the
equipment which causes solvent losses. When
excessive air movement is a problem, remove the
source or install baffles or partitions on the
windward side to divert the draft away from the
cleaning unit
In applications in the electronics industry, solvent
cleaning units are often placed immediately
following wave solder machines. This reduces the
cooling time before cleaning. If the boards are
entering the cleaner at a temperature greater than
the vapor temperature, the heat will be transferred
to the vapor and liquid solvent. This results in ah
additional heat load which may exceed the
condenser's heat adsorption capabilities, resulting
in vapor discharge or machine shutdown by the
vapor safety thermostat
Mounting small fans above and below the conveyor
to cool the boards before they enter the cleaning
, machine is one, solution to the problem. To
prevent disturbing the vapor blanket within the
machine, which coultd result in increased solvent
loss, fans should be directed away from the
openings of the equipment
You may wish to consider a , number of
enhancements to the solvent cleaner. These are
hardware add-ons or modifications that require
capital expenditures; and are not pan of the
machine optimization aspects previously described.
System enhancements include:
Increased freeboard height
Increased cooling system compressor
capacity
Additional cooling coils on inlets and
outlets.
Cleaner manufacturers and experts in
chilling/refrigeration should be consulted for their
expertise. Consider reviewing the condensing
effectiveness of your chiller/refrigeration system
with the assistance of a knowledgeable contractor.
Improved condensing efficiency through additional
cooling coils at the entrance and exit of the wash
and perhaps through compressor resizing will
reduce evaporative and dragout solvent losses.
Keep in mind that refrigerant changes can result in
losses of other CFCs.
Use gas detectors to give accurate information on
the location of emissions and to determine how
effective your efforts, are.
-------
Exhibit 13
IN LINE CLEANING SYSTEM
Hood
eLJgvaL.^._ I
.« I
Dogrcasad
Part
Condensing
CbH
"i m Water
Jacket
Condensate
Trough
Boiling Sump
Heat
V-Solvent Spray
Reservoir
Source: Halogenated Solvents Industry Alliance
F1KNO-5
-------
37
Drmgout
Orientation of the pan and pan design plays a key
role in the volume of solvent dragged out of the
cleaners. For example, in many instances in the
electronics industry, it has been found that solvent
adheres to the underside of components and
collects in pools in connectors. This could be
minimized through reoriehtation (see Exhibit 14).
Exhibit 14
ORIENTATION FOR
MAXIMUM DRAINAGE
NO
YES
Soum: OuPont
tiam.7
Reorientatioh can be as simple as changing the
method by which the pans are processed. This
may require an intelligent controller interfaced
with a turntable located after the wave solder
machine. The turntable may require a faster cycle
time to reduce the adverse effects on production.
In a less sophisticated operation, the operator can
load the parts to optimize cleaning.
In optimizing the machine, examine the potential
for reducing the conveyor belt speed. This keeps
the board in the vapor zone longer for more
complete evaporation of solvent, thus reducing
dragout to a minimum. A recommended maximum
speed for work entering and leaving an open-top
cleaner is 3 meters/min (10 ft/min). For
conveybrized belt in-line systems, consider 3 to 5
ft/min conveyor spied. Higher throughput rates
can cause disturbances at the vapor/air interface
that result in high vapor losses.
Maintenance
A bulk solvent handling system reduces solvent
losses due to drum handling, transferring to small
containers, and filling the cleaners. With
appropriate real time alarms, personnel are alened
to possible leak conditions by monitoring
consumption or toss in each cleaner as solvent is
supplied. Careful visual inspection should
supplement the use of alarm systems.
Solvent is delivered by bulk tanker and is then
pumped into a bulk storage tank where it is held
until needed. The tank is not pressurized and is
commonly placed within the plant Distribution to
the cleaners is provided through a series of pumps
and pipes. These pipes, valves, etc, should be
made of appropriate materials. Therefore, the
system eliminates all manual handling of solvents
and minimizes losses. Control is provided by float
switches within individual washer units.
A microprocessor am be used to monitor solvent
consumption. This provides consumption data and
activates an alarm in case consumption levels
become excessive in the case of a leak.
Pump seals deteriorate when not in contact with
solvent A "running dry* condition erodes the seal
surface and the seals fail prematurely. Pumps and
seals are typical sites for leaks.
The design and maintenance of cleaners and stills
require attention to the seals and gaskets on
covers, lids, and panels. High volume leaks often
occur around cornets and joints where two seals
meet Check that new and replacement materials
are compatible with the solvents in use.
Take-advantage of services offered by the machine
manufacturers; they liave experience in fine tuning
the cleaner to minimize losses. This can be a
supplement to the services offered by solvent
suppliers who often have programs and
information that can help operators better manage
the process. _
Check all temperature-measuring devices and
controls. Correctly calibrated instruments will
-------
38
MHMM
optimize machine performance and reduce solvent
lotsec.
Under normal operating conditions, original filters
reach the limit of their usefulness relatively
qufckry. Using more effective filters results in
fewer changes over time and less solvent loss.
Consider adding filters to extend machine solvent
lifie.
-*5i
For example, the use of a common motor vehicle
oil inter and a pump can filter out additional
impurities to the solvent distillation process. This
filter can increase the time between preventative
maintenance requirements which In turn de
solvent losses.
Do not use solvent appearance as the only tool for
deStier drain and refill. Boil temperature should
also be analyzed. Solvent/oil specific gravity can
also be an easy method to determine the
contamination level of the solvent
Superheated Vapor Drying
Superheated vapor drying, as discussed under batch
cleaning operations, can also be used with in-line
cleaning operations.
the unit Best practice is to do this, only pnce.
Time how long the blanket takes to form, and
incorporate that into the procedure.
When shutting down the system, use the following
steps in the sequence shown:
Stop work processing and clear the machine of
all work:
Close the cover on open-top units;
Turn off the heaters;
Activate sump cooling cons where provided;
Allow the vapor blanket to collapse completely;
Turn off the condenser cooling system where
applicable. However, some units do not have
sump cooling coils. In this case, the condenser
cooling system should be kept on, on an
intermittent basis. >
Note: If cooling condenser is left running for
extended periods after shut-down, it could cause
moisture condensation on the coils from room air.
The moisture would drip into the sump and
contaminate the solvent
and Shuf-Down Procedures
Solvent emissions during start-up can be
minimized through the following steps in the order
shown:
Stan up the condenser cooling system and make
sure that it is operating property;
Stan up any auxiliary emission control
equipment;
Check and adjust solvent levels in all
compartments;
4
Turn on heaters;
Start up the spray pumps once a stable vapor
blanket is established;
Process work pieces only after the vapor blanket
has been established. Determine if the vapor
blanket has been established by looking inside
Idle Time Management
Consider using one vapor degreaser to handle the
boards from two or more soldering machines.
Permitting requirements should be verified. Large
losses are seen in degreasers that are under utilized
and have an extended idle mode or that cycle as a
result of frequent start-ups and shut-downs.
Idle time management could require reworking
equipment placement conveyor lines, controllers,
and other features. Benefits include not only
reduction of losses of solvent but also removal of
extra equipment with a reduction in operating and
maintenance costsl Well designed in-line systems
are provided with covers for controlling emissions
during idle times. .
-------
Cold Cleaning
Process Description
Cold cleaners use solvents at room temperature for
parts cleaning. CFC-113 and MCF have been used
extensively in cold cleaning because of their
relatively low toxicity and resulting high workplace
exposure limits. Cold cleaners are usually small
maintenance cleaners or pans washers.
Cold cleaning operations can include brush or wipe
cleaning, spraying, flushing, and immersion. Hie
most common machines which use CFC-113 and
..MCF are of a type called carburetor cleaners.
Cleaning Methods and Emission
Reduction
Wiping. The major sources of emissions from
wiping operations are the disposal of used solvent
during the cleaning operation and the disposal of
solvent-soaked rags. Solvent evaporation and
spillage from the solvent container can also result
in substantial solvent emissions.
The best way to reduce emissions from wiping
operations is to use covers for solvent containers,
fo dispose of used solvent-containing rags in closed
containers, and to store used solvent in well sealed
containers. Used solvents may be reclaimed or
recycled. Several companies, listed on pp. 63-65,
operate solvent reclamation and delivery services
that may be suitable for your organization. Used
solvents and spent rags can also be disposed of by
incineration as a way of reducing solvent emissions.
This should occur only in facilities that have been
designed for and authorized to perform
incineration.
Spraying «r nuking. When solvents are used in
spraying and flushing systems, they are usually
recycled because of their high cost Distillation
equipment for these solvents is relatively
inexpensive and can be justified in terms of solvent
savings alone. Containment systems and covers
must also be employed during operation and
downtime. Spraying equipment should be operated
at low pressure (less than 10 psi), and air-agitation
must be avoided. In addition, spray droplets
should be as large as practical to minimize
evaporation from the droplet surface.
39
Immersion Claming. Consumption of a large
volume of solvent is (oommonrwhen immersion cold
cleaning systems also known as dip tanks are
used as pan of a manufacturing process. If
alternative solvents can replace CFC-113 and
MCF, emission reductions can be significant (See
the other manuals in this series for alternatives to
CFC-113 and MCF.)
Although air-agitation systems may be used to
increase the cleaning efficacy of immersion
systems, they also cause a higher evaporative
emission rate. The use of covers and increased
freeboard ratio are both effective means of
reducing evaporative emissions. Covers can reduce
emissions by between 20 to 40 percent Increasing
the freeboartr ratio to 1.0 may reduce evaporation
by up to 70 percent The area around and above
the cleaner should be kept free of drafts.
Removing and replacing covers horizontally (rather
than lifting them off) will reduce air currents and
thus reduce evaporation losses.
Dragout and cany-out losses can be reduced by
requiring operators to allow the pans being
cleaned to drain for 15 seconds and rotating pans
to ensure that soivenit is released from recesses and
blind holes in the work pieces. Proper storage and
reclamation of used solvent can also reduce vapor
emissions. .
' . ,
Parts that have been sprayed, dipped, or wiped may
be drained on an inclined rack that is attached to
the degreaser. Automatic hoists can also be used
to drain parts over the degreaser.
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40
Reclamation
External reclamation and recycle services are often
available to purify contaminated solvent and return
it to the original customer or to sell it to other
users.
Reclamation and recycling can also be performed
cm-site. Several such systems are discussed below.
Where recycling solvent waste is viable, the choice
between on-site versus off-site recycling must be
made. Major factors that may influence a decision
are shown in Exhibit IS. In addition to these
factors, Title VI of the dean Air Act Amendments
of 1990 has imposed recycling requirements. In all
cases, the quality of the reclaimed solvents is an
important consideration. ASTM currently is
developing standards for recycled CFC-113 and
MCF.
On-s/fe Recycling
On-site recycling is currently economical if at least
approximately 8 gallons of solvent waste are
generated per day. The simplest form of solvent
reuse is termed downgrading,* which is using a
solvent that has become contaminated through
initial use for a second cleaning process. For
example, precision bearings need very high purity
solvents for cleaning. The solvent acquires very
little contamination in usage and can be
downgraded for use in less demanding cleaning
operations.
Because more effort is required a> recycle solvent
that is heavily contaminated, on-site and off-site
recycling or reclamation should be explored. In
vapor degreasing and cold cleaning, the soil re-
moved accumulates in the equipment Eventually,
the solvent still bottoms become too contaminated
for farther me and must be reclaimed or disposed
through incineration. For on-site recycling, many
different separation technologies are available.
Commonly used separation technologies for
contaminated solvents include gravity separation,
filtration, batch distillation, fractional distillation,
r evaporation, and steam stripping.
Crtrity Stfontion. The use of settling to separate
solids and water from solvent often permits the
reuse of solvent. For example, paint solvents may
be reused many times if solids are allowed to
settle.
Filtration. Filters can be used to remove solids
from many solvents, thus extending solvent life.
Batch Distillation. A batch still vaporizes the used
solvent and condenses the overhe^i vapors in a
separate vessel. Solids or high boiling residues
(>400*F) remain in the still as a .residue. Solvent
stills range in size from 5-gallon to 500-gallon
capacity. A vapor degreaser can be used as a batch
still for recycling solvent by employing proper boil-
down procedures. Detailed discussion of these
procedures is available from major solvent
suppliers.
In many applications, it is necessary to keep the
water content of the recovered solvent to less than
100 ppm. This can be accomplished by distilling
the solvent-water azeotrope, decanting the water,
and then drying the remaining solvent with a
molecular sieve or other desiccant The water
removed in this operation must then be either
treated or drummed for disposal
Fractional Distillation. Fractional distillation is
carried out in a reflux column equipped with either
trays or packing. Heat is supplied by a reboiler
located at the bottom of the column while heat is
removed at the top of a column by a condenser.
Fractional distillation allows for separation of
multi-component mixtures or mixtures of solvent
and oils with similar boiling points.
Evaporation. Evaporation can be employed for
solvent recovery from viscous liquids, sludge, or
still bottoms resulting from distillation. Scraped or
wiped-film evaporators utilize revolving blades,
which spread the liquid over a heated metal
surface. The vapors are recovered by means of a
condenser. Another type of system, a drum dryer,
employs two heated counter-rotating drums
through which the liquid feed must pass. White
both systems can handle viscous wastes, the drum
dryer is more tolerant of porymerizable
contaminants.
Steam Stripping- Steam stripping is a solvent
, reclamation enhancement process commonly used
for the processing of CFC solvent still-heels
generated in one-plate distillations. These still-
heels often can. contain as much as 40 to 50
percent (by weight) of solvent. In general, steam
stripping should not be used for MCF.
-------
41
Exhibit15
FACTORS INFLUENCING THE DECISION
TO RECYCLE SOLVENT WASTES ON-SITE
Advantages
Less waste leaving the facUity.
Owner controls reclaimed solvent's
purity.
Reduced liability and cost of transporting
waste off-site.
Reduced reporting (manifesting).
Possible lower unit cost of reclaimed
solvent
Perceived Benefits
Favorable economics for recovery (e.g.,
reduced solvent requirements).
Reduction in disposal costs.
Lower liability.
Disadvantages
Capital outlay for recycling equipment
Liability for worker health, fires,
explosions, leaks,, spills, and other risks.
Need for operator training.
Additional operating and maintenance
costs.
Reported Difficulties ,
May be a need to restabflize the
reclaimed solvent
Installation problems.
Maintenance problems.
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42
The vapor/liquid equilibrium associated with steam
stripping permits a further separation of volatile
solvent from relatively nonvolatile impurities. This
is done" at distillation temperatures lower than
thcc? encountered in the one-plate distillation of
a contaminant-rich solvent mixture.
Steam stripping can be carried out either as a
batch process or as a continuous process. Batch
processing is more common, but continuous
operation offers a number of advantages if the
contaminants are liquids (e.g., lubricating oils) of
low to moderate viscosity and the cleaning fluids
arc quickly contaminated.
Batch steam stripping is usually performed in the
same still as was used for still-heel generation.
However, in some high-volume solvent use
applications, the provision of a separate still
dedicated solely to the processing of heels from
other one-plate stills can offer significant
advantages in maintaining a high level of
productivity in the cleaning system. An example of
a steam stripping system is shown in Exhibit 16.
wastes and product outputs of individual industries
and firms. ' .
Both before and after recycling, solvent should be
monitored for acceptability, including thermal
breakdown (acidity) and azeotropic imbalance. It
is important to ensure that solvents are not mixed
at any time during the recovery process.
Off-site recycling services are offered by a number
of licensed commercial operators. A partial listing
of these firms is provided later in this document.
After the maximum amount of solvent is
recovered, the still bottoms and other residues
from degreasing operations are destroyed
thermally, generally through fuel blending.
Off-site Recycling
If recycling of waste solvent on-site is impractical,
several off-site recycling schemes are available.
When selecting an off-site recycling scheme, one
should consider or investigate all of the items
listed in Exhibit 17. Some viable off-site recycling
arrangements include toll recyclers and waste
exchange/brokerage.
Rtcyckrs. Toll recyclers offer services to
generators by supplying solvent wash equipment
and solvent and waste recycling services. The
solvent wash equipment is maintained by these
companies and the solvent is replaced periodically.
The used solvent is recycled at an off-site facility.
Costs for these services range from 50 to 90
'percent of new solvent cost
Wmae Exchange mud Brokerage. This is not a
technology but an information service. A waste
exchange can match a generator of waste with a
facility that can use the waste as a raw material
Commercial waste brokerage services are also
available. A waste generator is matched with a
potential waste user who can utilize the waste as a
feedstock. Matching generators and users is based
on the knowledge of raw material inputs and
-------
43
One-plate
Still
Exhibit 16
\
CONTINUOUS STEAM STRIPPING
Separator
Filter
Pump
Source: DuPont
Evaporator
Steam.
Waste
Oil
Stripping
Column
Superheater
Cooler
Condenser
Steam ;
Condensate
Recovered
Solvent
.
Water
Separator
-------
.Exhibit 17
:
L
FACILITY CONSIDERATIONS
IN CHOOSING AN OFF-SITE RECYCLER
Types of solvent wastes managed.
Availability of laboratory facilities and suitable analytical procedures.
Ability to meet solvent purity specifications.
Avaflabflity of custom recycling services (e.g., vendor-owned recycling units that
can be operated on the generator's property).
Expertise on in-plant waste management strategies and process controls.
Availability of registered trucks to transport the solvent wastes.
Distance to the recycling facility and associated transportation costs.
Completeness of recordkeeping. ,
Adequacy of permits held by the facility.
Sufficiency of insurance for recycMng/treatment/disppsal operations.
Adequacy of disposal procedures for still bottoms and other solvent wastes.
Compliance record of the facility.
Reputation of the facility.
Financial stability. ,
Costs of using service. .
-------
45
Other Control Technologies
Carbon Adsorption
..*-.'
Because dragout losses are a major contributor to
iae overall solvent loss, causing high levels of
solvent vapor in the manufacturing area, vapor
capture systems should be considered. These
systems adsorb the solvent molecule -on an
activated carbon bed which is subsequently
extracted by steam. After water separation, the
solvent is reblended with additives for reuse.
The intake and .exhaust ports of the cleaner are
vented to hoods where vapors are drawn under
negative pressure through the activated carbon
bed. Proper design of the collection hood at the
cleaner discharge is vital since this is where
dragout and drying losses are most significant
Adsorption proceeds until the carbon bed
approaches saturation. At that time, steam is
injected onto the carbon surface to strip solvent
molecules for later condensation and water
separation. Exhibit 18 shows a point-of-use carbon
adsorption process schematic.
Three material streams are produced: pure
solvent, clean air, and wastewater. '
Solvent is rcblended/reconstituted-with additives
for reuse;
Air is returned to the plant or exhausted;
Wastewater is treated and released to the sewer
system. With circuit board cleaners, there could
be some alcohol in the waste water streams and
local legislation should be reviewed and
considered in equipment selection. Alcohol in
the wastewater increases the biological oxygen
demand (BOD) load to the local sewage
treatment plant
Systems can be sized to suit the scale of
application, and one. adsorption system can service
more than one cleaner. However, carbon
adsorption systems are expensive to purchase and
to operate unless their is a large quantity of
solvent to capture.
For maximum emission reductions, the bulk
storage tank, the stills, and the adsorption system
i should all be located in an enclosed, room so that
air can pass through the adsorption system to
capture and recycle any fugitive solvent losses.
MCF and Carbon Adsorption
I Steam desorption of MCF results in the loss of
stabilizers and the formation of hydrochloric acid.
This leads to corrosion problems and damage to
equipment In addition, the MCF has to be
restabilizcd after stripping for reuse.
New technologies to recover MCF vapors, by
carbon adsorption have been developed. These
technologies eliminate the problem of MCF
hydrolysis and associated corrosion present in
traditional carbon adsorption/steam desorption
systems. These new adsorption methods include
replacing water with nitrogen as the stripping
agent, employing a new condensation membrane
technology, hot gas desorption cycle, and polymeric
particle adsorption.
A carbon adsorption system using a hot gas
desorption cycle is shown in Exhibit 19. In this
process the solvent and the small quantity of water
are expelled from the activated carbon by hot air
in a closed circuit The solvent/water mixture then
passes through a condenser. The solvent is
separated from the wsiter in a subsequent gravity
separator. Solvent residues in the "processing
water" are then removed and the clean water is
discharged.
1 - :' .
Safety Note: When operating carbon adsorption
systems, use proper chemical procedures, and
include fire protection on beds.
Mr Stripping i
Air stripping, which is a process similar to
distillation, can reclaim CFCs. In air stripping a
contaminated stream is fed into a packed column
from the top and air is injected at the bottom. As
the two streams pass one another through the
'Column, they exchange volatile materials. The air
phase and the volatile:, are then carried from the
top for recovery usually by granular activated
carbon. The bottom products containing the
heavier phases are sent for recovery, perhaps by
distillation. Emissions from, air stripping are
probably subject to environmental regulation.
-------
Exhibit 18
POINT-OF-USE CARBON ADSORPTION
PROCESS SCHEMATIC
Recovered Solvent
Sourt*: Digital Equipment Corporation
-------
47
Exhibit!?
ROTARY CARBON ADSORPTION SYSTEM
Flowchart i
RA Rotary Adsorbers
CC Crude Gas Conditioner
AH Air Heater
HP Heating Pipe
AC Air Cooler
WS Water Separator
ST Solvent Tank ; j
PR Processing Water, Purification
Source: Bowe
FltMM
-------
TTwima/ Destruction
In a thermal destruction unit, the CFCs and
hydrocarbons are mixed and ignited and passed
through a hot. ceramic furnace to complete the
destruction. Incineration of the gases is
accomplished at approximately l^OOT. A thermal
destruction unit consists of two beds and the flame
is alternated between one bed and the oilier to
optir.se efficiency (see Exhibit 20).
Recent developments in catalytic chemistry appear
to make catalytic destruction of halogenated
hydrocarbons a viable control option. In addition
to significantly reducing the temperature required,
these new catalysts allow complete destruction and
have been shown to be resistant to deactivation.
Exhibit20
THERMAL DESTRUCTION FLOW DIAGRAM
TO ATMOSPHERE
1430*F
THERMAL
OXtOIZER
(1500 T@ 1.0 SEC.)
H>
1500*F
SCRUBBING
SYSTEM
95%
PRIMARY
HEAT
EXCHANGER
FROM PROCESS
CFC
SOURCES
ROOM AIR
NATURAL GAS
Source: Manch*Mr Corp.
-------
49
RECAP OF THE MANUAL
Previous sections of this manual have provided information on:
Stratospheric ozone depletion and restrictions on the use of CFC-113 and MGF.
Steps to characterize a process to determine solvent use and emissions.
' ' i ' ' .- ..
Conservation practices and strategies specific to batch cleaning, in-line cleaning,
and cold cleaning. ,
Rationale for conserving and recycling solvents in cleaning processes.
Reclamation and recycling systems and services.
A summary of problems and solutions for solvent emission is presented in Exhibit 21.
-------
Exhibit 21
EMISSIONS REDUCTIONS:
PROBLEMS AND SOLUTIONS CHECKLIST
Possible Problems
Possible Solutions
Improper degreaser placement
Failure to cover degreaser
Poor maintenance
Spraying above the vapor zone
Excessive solvent dragout
Product is too large for machine
Cleaning system should be placed to avoid cross
drafts from open doors, windows, fins, and air
conditioning vents. If possible, enclose the unit
Remove or reduce dedicated vents.
Degreasers should be covered when not in use. A
tight sliding cover is best A rolling cover is
acceptable.
Clean-out doors, piping, pumps, and filter housings
should be checked weekly for leaks.
Chiller package should be maintained regularly.
Spraying should always be conducted at least 6
indies below the vapor line. Sprays should be
directed downward.
Work should be oriented and rotated to allow
maximum solvent drainage.
Immersion and withdrawal rates should be less
than 10 fpm for open top units.
Conveyor speeds should be approximately 3-5 fpm
for in-line belt units.
Work should remain in vapor zone until
condensation stops.
The area of the basket or work load should not
exceed 50 percent of the area of the boil sump.
The mass (weight) of the workload processes
should not exceed the machine's rated capacity.
-------
51
Exhibit 21 (Continued)
-"!.- ,
EMISSIONS REDUCTIONS:
PROBLEMS AND SOLUTIONS CHECKLIST
Possible Problems
Possible Solutions
Degreasing of absorbent materials
Improper start-up and shut-down
procedure
Solvent degradation
Inadequate freeboard height
Inadequate condensing capacity
Possible repermitting and attendant
changes in regulatory requirements
Absorbent materials (such as cloth, wood, porous
plastics, etc) should not te cleaned in vapor
systems or used in the construction of baskets or
carriers.
i
Activate condenser prior to turning on heat
Do not turn on sprays until a stable vapor level
has been established.
After cleaning operations are complete, turn off
heaters and continue to operate the condensing
coils until the vapor zone has completely collapsed
and the boil sump cools well below the solvent
boiling point
Hot spots on heating coils should be repaired, as
they cause thermal breakdown of solvent
Electric heater watt density should not exceed 20
watts/sq. inches.
Desiccint system
malfunction.
should be checked for
Cooling coil design should be altered.
Freeboard height to degreaser width ratio for
CFC-113 and MCF cleaning systems should be 1.0
or mote.
Turn on water-cooled systems and check the
condenser discharge water temperature. Vapor
degreasers should be provided with chilled water at
40"F (4J°C), and discharge water temperatures
should be 50°F (10°C) for CFC systems and 70°F
(21°C) for MCF systems.
Contact and work with yoiiir local air quality
representative.
-------
52
-------
53
CASE STUDIES OF INDUSTRIAL PRACTICES
I * . - ' .' '
'.'"', ' 'I" - -
The following section presents industrial case studies of conservation and recycling.
The mention of any company or product in this document is for informational purposes onhr
and does not constitute a recommendation, of any such company or product either expressed
orimphed by EPA, IO>LP,ICOLP committee members, 0?^ companies that eStSe
ICOLP committee members. _r ,-f v "*c
Case Study #1: CFC Reduction/ Elimination in Electronics; Cleaning
Case Study #2: Using Industrial Hygiene Techniques to Monitor and Reduce
oolvent Losses
Case Study *J; Solvent Equipment Selection -A Case Study of Errors
Case Study #4: Emissions Monitoring and Reduction
Case Study #5: History of Equipment Upgrades.
Case Study #6: Solvent Conservation and Recycling.
-------
54
-------
55
CASE STUDY
CFC REDUCTION/
ELIMINATION IN
ELECTRONICS
CLEANING
Case Study #1 describes the steps taken by Digital
Equipment Corporation to reduce CFC emissions
and to select an alternative cleaning method.
Digital has-used CFC-113 to dean many different
parts and sub-assemblies in the assembly and
testing of disk drives (a storage device* for
computers).
The equipment is a 5-sump, open-top vapor
degreaserthat was emitting 124,000 Ibs of CFC-113
fugitive emissions each year before reduction steps
were taken.
Selecting a Technology to
Reduce Emissions
Digital commissioned a study to investigate several
technologies for reduction and/or elimination of
CFC-113. The following summarizes each of the
technologies and recommendations that came from
the study.
Incineration
Thermal oxidation is a choice of last resort for
CFC-113. Oxidized CFC-113 creates by-products
of hydrochloric acid and hydrofluoric acid which
react with the insulating materials used on
commercial oxidizers. The acid vapors must also
be scrubbed in a caustic scrubber. Thermal
oxidation has no solvent recovery. It is, however,
an effective means of reducing volatile organic
compounds (VOCs).
Water scrubbing
Water scrubbing extracts solvent from the process
air stream and, consequently, is most effective in
'removing solvents that require one scrubbing.
These solvents generally have high solubility in
water. When this method is used to remove CFC-
113, a solvent that has low solubility in water, the
water after one scrubbing is so saturated with
solvent that it loses its ability to remove any
additional CFC-113 torn the air stream. Two
other factors also malice this process questionable
for removing CFC-113: Not only must the water
coming out of the scrubber be air stripped before
it can be reused or drained, but the exhausted air
must also be treated to capture the solvent
Oil scrubbing
Under certain conditions oil scrubbing has been
demonstrated as an effective means of extracting
solvent from the process air stream. However,
there are no known installations for capture and
recovery of CFC-113. The process air enters a 7
diameter column approximately 30* tall, while a
low viscosity, high boiling point petroleum-based
oil is sprayed downward from the top of the
column over a 20* long mesh packed at intervals
against the air flow. The solvent dissolves into the
oil and collects at the base of the column. The
scrubbed air exits the top of the column into the
atmosphere. The oil/solvent mixture at the base of
the column is pumped to a holding tank. The
i mixture then moves to a retirculating evaporator
where the oil is heated to distill the solvent from
the mixture. The solvent vapors and oil are sent
to a cyclone separator. In the separator, the oil is
captured and sent to a holding tank where it is
pumped back up to the scrubber distributor. The
solvent vapor is vented out the top of the cyclone
separator, condensed!, and gravity fed to a
recovered solvent tank.
Refrigeration
Refrigeration is a means of recovering VOCs by
! condensation of the airborne solvent Extremely
low temperatures for first droplets are required to
; reduce the solvent vapor pressure to a point where
90 percent recovery by condensation can be
\ achieved. Refrigeration recovery is best suited for
applications where airflow is low and solvent
concentrations high. This technique is widely used
i for storage tank vents.
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56
Carbon Adtorption
Carbon adsorption, a good means of recovering
and reusing solvents, is accomplished by adsorbing
the solvent in a bed of carbon and later steam
stripping for reuse. This technique was chosen
because it is the best available technology known
at this time, has a relatively low cost, and is proven
in many actual installations.
The basic steps are:
Solvent laden air is drawn from an enclosure
built around the 5-sump, open-top degreaser to
capture fugitive emissions. Solvent vapors are
collected at the bottom and top of the enclosure
(designed to minimize any drafts across the
degreasers) and ducted to carbon adsorbers
through a paniculate filter to catch any
particles. Air is collected by lip vents at the
base of the cleaning chamber access door of the
shear stress machine. '
At the carbon adsorber, the solvent laden air is
drawn through the carbon beds by a process
blower at 800 to 1,200 cftn. Blowers pull the air
through one or two carbon adsorption beds,
each bed filled with 600 Ibs. of carbon leaving
the solvent deposited on the carbon (coconut).
Two or three carbon beds (depending on the
solvent loading and cftn required) are installed
in parallel One or two beds are adsorbing CFC
while one is de-sorbing and drying CFC for re-
use. The beds are switched by either the stack
analyzer (typically set at 5 ppm) or a timer as a
back-up to the analyzers.
Upon completion of this phase of the process,
steam is used to remove trapped solvent from.
the carbon pores by pushing steam in a reverse
flow through the beds. A water/solvent mixture
is created when the steam is passed through a
condenser. From this condenser, the water/
solvent mixture is sent to a separator tank
where the water and solvent are separated by
gravity with the water going out the top and the
solvent out the bottom.
The solvent then goes to a solvent holding tank.
The solvent is pumped to a still where it is
further refined and then transferred to another
holding tank where the technician pumps it on
demand to the still on the open top or the
solvent tank in the shear stress machines.
The carbon adsorbers are designed to
meet the following specifications:
10 and 16 Ibs per hour of. CFC-113
loading for recovery;
800 and 1,200 cfm blower for solvent
air stream;
Stainless steel recovery vessels;
Carbon granules designed specifically
for CFC-113 recovery (charred
coconut husk);
Stack analyzer for bed switching when
saturated with hour time as backup.
The project cost of the carbon adsorbers was:
For a 2 bed, 10 Ibs per hour, 800 cfm unit:
562,000
For a 3 bed, 16 Ibs,per hour, 1200 cfm unit:
573,000
Automated material handling unit: $45,000
« Facility fit-up and miscellaneous: $187,000
Total project cost, including start-up and operator
training was $380,000.
Currently there are two carbon adsorbers operating
at Digital. Based on actual usage numbers for
1990, solvent emissions are projected to be reduced
by 69 percent (see Exhibit 22).
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57
Exhibit 22
SOLVENT USAGE REDUCTION PROGRAM
140
THOUSANDS
co
£
120 -
too -
UJ
CO 80 H
UJ
i
60 -
40 -
20 -
0
I
1987
1988
Source: Digital Equipment Corp.
1989
YEIARS
i
1990
1991
F1MW-11
-------
58
A Three-Phase Plan
This study also resulted in a three phase plan to
recover and reuse solvents and eventually to
eliminate usr c-f CPC-113.
PHASE 1
o Education and training
« Equipment enhancements
Process engineering changes
Operating disciplines
Accountability (make one person
responsible for managing the
program)
Limiting new applications
This phase reduced the solvent emission
and usage by 20 to 30 percent, as shown in
Exhibit 22.
PHASE 2
« Install new vapor recovery system
(carbon bed adsorption), for point-of-
use only.
This phase is projected to reduce the tofc.1
emission and usage by 55 to 70 percent, as
shown in the Exhibit 22.
PHASES
Conversion to alternative methods of
cleaning.
This phase will reduce the emission/ usage
to zero.
Phases 1 and 2 have been completed. Phase 3 is
being implemented and is expected to eliminate
CFC usage by mid-1992.
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59
CASE STUDY #2i
USING INDUSTRIAL
HYGIENE TECHNIQUES
TO MONITOR AND
REDUCE SOLVENT
Case Study #2 shows how monitoring solvent
emissions can identify ways to reduce solvent
consumption and protect worker health.
A Problem with Excessive
Emissions
At Honeywell a MCF vapor degreaser was losing
large quantities of solvent and employees were
complaining about strong solvent odors. The
degreaser is an open top degreaser with no hoist
The maintenance departments showed through
inspection of the heat and cooling systems that all
systems were operating properly within the
designated temperatures and there were no
identifiable leaks.
Taking Action to Solve the
Problem
Ac investigation was completed by the Industrial
Hygiene staff to identify employee, solvent
exposures. During the investigation, air samples
were collected in operator breathing 'zones with
length-of-stain caloiimetric detection tubes.
Readings were found to vary greatly between SO
and 300 ppm MCF. The current threshold limit
value is 350 ppm. Further monitoring found a
correlation between air monitoring results and air
conditioner and elevator operations. Smoke
testing of air currents and vapor blanket
disturbances indicated that increased velocities
across the top of the vapor degreaser. caused by air
conditioning and elevator shaft drafts, broke down
the vapor blanket Detector tube readings in
stable conditions ware SO ppm compared to
\ turbulent conditions of 300 ppm solvent
Partitioning, the work area stopped air currents
from passing across the vapor degreaser. To allow
some air movement and reduce the chance of
; vapor buildup in the work area, the partitioning
did not extend to the ceiling. Follow-up personal
monitoring of the operator confirmed these levels.
Results
Worker exposures and solvent losses were reduced
greatly. An immediiite reduction in work area
concentration was achieved with solvent levels
dropping to between 25 and 50 ppm MCF.
Improvements from the program are presented in
the table below. The overall solvent losses were
reduced by 75 percent. This easy-to-perform
monitoring can be completed at a cost of less than
$100 per investigation and an initial equipment
investment of approximately $300. In this case
study, the value of the MCF saved in one month
exceeds the $300 investment in equipment, and
j contributed to employee satisfaction.
Conditions
Steady
Air Conditioning on
Elevator Door Open
Partitioning in Place
.
Detector Tube .
Reading I'ppml
50
125-200
175-300
25-50
I. ,
. "- ;
Approximate
Solvent
Losses rGalday)
03
3.2
4.0
0.2 .
/
- :.. . ' ' .- . """
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CASE STUDY #3:
SOLVENT EQUIPMENT
SELECTION-A
CASE STUDY OF
ERRORS
Case Study *3 fllnstrates errors that can be
avoided daring planning and implementation of a
CFC reduction program.
Wlh the growing concerns associated with CFC
sotyent usage. Northern Telecom, a large,
multinational supplier of telecommunications
dectronfcs, began an aggressive campaign to
eliminate the materials. While the conservation
ponton of this program was successful in reducing
CFC emissions by about 50 percent.. there are
lessons from the experiences that wfll help others
avoid investment mistakes.
Errors resulted in several areas:
Ineffective use of an automated hoist
Poor education of operators
Incorrect equipment selection
Improper equipment operations
Poor control over use and handling of
solvents.
Northern Tekcom was using CFC-113 in an open-
top batch cleaner for cleaning printed circuit board
assemblies. The open-top unit had the following
specifications:
At 50 percent utilization,, the unit cleaned
30,000 square feet of boards;
The unit consumed 80 gallons of solvent per
month;
Energy costs were insignificant;
Labor costs were
Total operating costs (labor + solvent) was
$45,000#r. ;
Shortly after the open-top unit was .installed, an
automatic hoist was added for better process
control and to conserve solvent. However, the
hoist system was removed within six months of
installation because operators complained of
inefficiencies associated with its use. Failure to
utilize the hoist represented management's
reluctance to support a conservation process that
would have reduced solvent use. Operators had
not been educated about the importance of solvent
observation.
After two years of operation, Northern, Telecom
introduced a new product line. As part of this
product line, the company purchased a new in-line
solvent cleaning machine. The batch cleaner was
replaced by an in-line cleaner and stilL The in-line
system was being used in other high volume
corporate facilities, and was therefore was assumed
to be appropriate.
The operating characteristics of the in-line unit
included:
. Capital costs $90,000 (with still);
Capacity of 200 gallons of solvent;
At idle the unit consumed 0.75 Ibs of solvent
per hour,
. Operating at 4 fpm, the unit consumed 143
Ibs/hr of solvent;
. Average production was near 36,000 square feet
of product per year,
Average solvent use was 3 to 4 barrels per
month. Solvent costs were $78,000 per year,
The unit required a pan-time operator (25
percent of the time), even though at the time of
purchase it was assumed to need no operator.
Labor costs were $6,250 per year,
o Annual utility costs were $25,000;
Total operating costs (labor, utilities, and
solvent): S109,250#r, or over S3.00/board.
-------
61
In replacing the batch cleaning system with an in-
line system and associated still. Northern Telecom
encountered a number of problems. Although the
new in-line system was more sophisticated, it was
much more expensive (based on per square Coot of
boards cleaned) and used a greater amount of
solvent than the batch machine.
The new cleaner was not the best machine for the
specific needs and functions and was not entirely
appropriate for the new product applications. A
financial analysis of the break-even point would
have identified the shortcomings of the new
machine and the likelihood that CFC legislation
would make the unit obsolete.
To conserve CFC-113, a reduced CFC-113 blend
was used in this machine. The machine was not
compatible with the blend and the ball valves used
in the machine failed.
Besides specific problems related to the equipment
choice, there were also errors in general handling
of solvents. Throughout this entire process, the
solvent was never treated as a chemical of concern.
Operator awareness was not stressed, and as a
consequence excessive solvent usage continued
unabated.
Excessive solvent consumption was not initially
noticed because of two errors in the procedures
implemented to track solvent usage. First,
operators were asked to report solvent use on their
respective machines, and who were initially
assumed to be accurate, consistently made mistakes
in reporting solvent use by over 50 percent
Because the measuring errors were random, several
months were lost The management group
responsible for tracking the efficiency of the
solvent cleaners from two solvent tracking reports
somehow mishandled the data presented it out of
context It was not until all reports were
channelled through one individual that confusion
and misunderstanding was replaced by reliable
reporting of data.
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62
CASE STUDY #4:
EMISSIONS MONITOR-
ING AND REDUCTION
Case Study #4 outlines the 50 percent reduction of
CFC-113 solvent consumption from a conveyor
degreaser. Motorola accomplished the reduction
with the following actions:
The temperature of-the vapor cooling coils was
reduced until water started condensing on the
coik This required a system with a dosed loop
cooling unit with a refrigeration system. Water
condensation initially caused the alcohol in the
solvent to separate into a second phase.
destroying the cleaning effectiveness and
creating a Ore hazard. To overcome this
problem, the desiccant must be dried daily.
Entrance and exit brushes were installed to
contain vapors and fans arid other, air currents
'near the degreasing machine were eliminated.
All system leaks were detected and eliminated
on 4, regular basis. Solvent usage is tightly
tracked and plotted. Any spikes in the usage
level triggers a thorough systems check of all
seals, fittings, covers, using a common
refrigerant vapor detector. Note that solvent
evaporates so quickly that leaks will not appear
as drips. Exhibit 23 depicts a spike caused by a
seal leak which was detected by close
monitoring of the solvent usage. UCL and LCL
are the acronyms for upper confidence limit and
, lower confidence limit respectively.
Internal baffles were installed to reduce the
disturbance to the vapor blanket caused by
external air currents.
Vapor leaks were sealed where possible.
Exhibit23
SOLVENT USAGE PROFILE FOR A
CONVEYOR DEGREASER
38 40 42
|1988 |
Source: Motorola
44 46 48 50 52 f 2
(MO
10 12 14 18
F1MO-1U
-------
CASE STUDY #5: HISTORY OF EQUIPMENT
UPGRADES wujrMcw i
Case Study #5 presents a history of six solvent users who {switched from old to
Mittceinvic TV* ««*A «>»«*.. .._.._ __ .*. j « .. '-. n . - *^
provided by the Hatogenated Solvents
ems to «
S2T' T^aSC SttMly Provkted * «« HaJogenated Solvents Indus
describes specific equipment .nd operating characteristics and the systems whtl/re^eTthem
1.
Type of product manufaaured:
Previous method of cleaning:
Approximate age of equipment:
Reason for expenditure:
New method of cleaning:
Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:
Hours operated per week:
Emission per noun
Solvent savings per yean
Cosmetic packaging
Crossrod in-line vapor degreaser using trichloroethylene
20 years, . .
Regulation of trichloroethylene as an oxidant
Crossrod in-line vapor degreaser using trfcbtoroetoytene,
refrigeration chiller, carbon adsorber, negative pressure
1,250 gall/mo.-
450gal/ino.
64 '! !
$400,000
120
IS Ib. tnichloroethylene/hr. ;
$44,160
Type of product manufaaured:
Previous method of cleaning:
Approximate age of equipment:
Reason for expenditure:
New method of cleaning:
Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:
Hours operated per week:
Emission per houn
Solvent savings per yean
Cosmetic packaging
Crossrod in-line vapor degreaser using methyl chloroform
15 years
Obtain better cleaning
Crossrod in-line vapor degreaser using methyl chloroform
encosed, superheat, no refrigeration, river water for
cooling
1,050 gal/mo.
105 gal/mo.
90
$270,000 (includes new boiler)
80
3.4 Ib. MCF/hr.
$49,900
3.
Type of product manufactured:
Previous method of cleaning:
Approximate age of old equipment:
Reason for expenditure:
New method of cleaning:
Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:
Hours operated per week:
Emission per houn
Solvent savings per yean
Small household appliances
Crossrod vapor degreaser using trichloroethylene
20 years j . *
Automate handling and reduce emission
Crossrod vapor degreaser using trichloroethylene, enclosed
cooling tower, primary cold trap, negative pressure, and
'carbon adsorber
£500 gal/mo.
250gaJ/mo. -|
90' ' ! - ' i - : -
$500,000
120 ;
6.0 Ib. trichloroethylene/hr. i
$124,200 !
-------
64
4. Type of product manufactured:
Previous method of cleaning:
Approximate age of old equipment:
Reason for expenditure:
New method of cleaning:
Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:
Hours operated per week:
Emission per hour
Solvent savings per yean
5. Type of product manufactured:
Previous method of cleaning:
Approximate age of equipment:
Reason for expenditure:
New method of cleaning:
Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:
Hours operated per week:
Emission per hour.
Solvent savings per yean
6. Type of product manufactured:
' Previous method of cleaning:
Approximate age of equipment:
Reason for expenditure:
New method of cleaning:
Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:
Hours operated per week:
Emission per noun
Solvent savings per year.
Screw machine parts -.',-..
Crossrod vapor degreaser using methylene chloride
15 years
Eliminate solvents or reduce emission
Crossrod vapor degreaser using methylcne chloride,
enclosed, auto hoist, refrigeration chiller, superheat, down
time chiller ,
750 gal/mo.
100 gal/mo. ,
87
5350,000
80
33 Ib. methylene chloride/hr.
$24.900
Screw machine parts
Crossrod vapor degreaser using methylene chloride
15 years
Eliminate solvents or reduce emissions
Crossrod vapor degreaser using methylene chloride,
enclosed, auto hoist, refrigeration chiller
750 gal/mo.
200 gal/mo.
73
$80,000
40
13.1 Ib. methylene chloride/hr.
$21,050
Screw machine parts ,
Open-top vapor degreaser using methylene chloride, two
dip
15 years
Eliminate solvents or reduce emissions
Open-top vapor degreaser using methylene chloride,
enclosed, auto hoist, refrigeration chiller :
350 gal/mo.
100 gal/mo.
72
$50,000
40
&5 Ib. methylene chloride/hr
$9,570
-------
CASE STUDY #6:
SOLVENT CONSERVA-
TION AND RECYCLING
Case Study #6 presents a solvent conservation and
recycling project undertaken at Royal Ordnance
Blackburn, United Kingdom. Royal Ordnance
Blackburn was Originally established to produce
artillery fuzes, and continues to dp so today
although these are now electronic based as distinct
from being purely mechanical Additional
expansion and diversification over the years into
electronic control and communication systems of
various lands has seen the work pattern change,
but essentially Royal Ordnance Blackburn still
manufactures large numbers of small precision
engineered components in brass, steel, 'and
aluminum.
Royal Ordnance Blackburn's usage of CFCs is of
three types:
De-fluxing of printed circuit boards;
Precision cleaning of assemblies/sub-assemblies;
and
Stain-free drying of components after
processing.
In order to meet the requirements of the Montreal
Protocol, a program of control and recycling was
introduced. This program included surveying the
usage of CFCs, and how individual plants operated.
This survey showed that in some instances CFCs
were being used (often in open containers) for
general cleaning purposes when other solvents
would have been more appropriate. Some working
practices were also identified as being wasteful of
solvent An in-house training program which
explained the problem and consequences of ozone
layer destruction was instituted. This program was
aimed at all levels of shop-floor staff. As a result
of this program, a reduction in usage of CFCs
coupled with improved methods of working were
achieved. .
A second phase was to examine recycling of
solvents for reuse in the factory. All departments
were required to dram their waste solvents
separately and return them to a central collection
point, correctly identified and labelled. A solvent
distillation plant was purchased and installed. The
plant was designed to meet all present and
foreseeable safety and legislative requirements and
was to be capable of re-distilling most solvents
used in the factory, e.g^ trichloroethylene, in
addition to CFCs. The plant, including some
necessary conversion 'work on the building housing
the plant cost some U.S. $79,500. The solvent
reclaimed over approximately six months indicates
that the plant will pay for itself in 12-15 months.
The plant is capable of distilling up to 500 liters
per hour, depending on the solvent and operating
parameters. It lias considerable spare capacity, and
is capable of meeting all future requirements. The
quality of solvent obtained from the distillation
process is of an acceptable quality for normal
usage.
-------
66
-------
References
Special
in batch v,ipor degreascis. Presented
AndelUJ- Solvent conservation in batch degreasers. Pan 2: CFC-1 13 vs. methyl chloroform solvents From
the proceedings of the 1989 International Conference on CFC Alternatives. . *
''" ; '
Anonymous. 1986 (June). Solvent vapor recovery and VC)G emission control Pollution Engineering.
Anonymous. 1984 (August 24). Activated carbon fiber aids in solvent recovery. Chemical Engineering.: 6344.
Anonymous. 1982 (November 19). Vacuum rotary dryer recovers solvent Chemical Processing: 36.
Anonymous. 1980 (March 10). Solvent recycling system sa^es costs and cleans air. Chemical Engineering: 91-
Qeinent, R.W., J. Rains, R. Simmons, and K. Suprenam. undated. Solvent cleaning. ASM Committee on
solvent Cleaning. . , . . - .
. : "'.'.' ' "' " ' ' '
.Dow Chemical Corporation. Product stewardship manual -
DuPont de Nemours & Co. 1982. Performance guide for
specially chlorinated solvents. 1988/1989 edition.
Itreon solvent systems.
*""* ' cta"""e
DuPont de Nemours & Co. 1987. Freon cleaning agents -
literature) Wilmington, DE.
recommended work piactices. FS-30B (product
Hatogenated Solvents Industry Alliance. 1989. Manual on vapor degreasing. ASTM Manual Series: MNL2,
-
recovery of solvent from air streams. Runcorn.U.K.
ICI Chlor-Chemicals. 1990 (January). Activated carbon
ICI Chtor-Chemicals. 1989. Genklene fact sheets. Runcorn, U.K.
Joshi, S.B. 1988 (August 15-18). Use of solvent test kits to....
utilization. Symposium proceedings of Process Technology '88
Sacramento, CA. Sponsored by Air Force Logistics Comma
Kenson, R.E. 1985 (August). Recovery and reuse of i
Progress: 161-165.
monitor solvent condit on and maximize solvent
!: The Key to Hazardous Waste Minimization.
nd.
solvents from VOC air emissions. Environmental
-------
68 f .
Kohl, JJ., M. Person, Rose and P. Wright. 1986 (May). Managing and recycling solvents in the furniture
industry. Industrial Extension Service, School of Engineering, North Carolina State University. Raleigh, N.C
Kohl, J.P., Moses, and B.Triplett. 1984. Managing and recycling solvents: North Carolina practices, facilities,
and regulations. North Carolina State University. Raleigh, N.C
Massouda, BflL 1988. Assessment of chlorinated solvent usage and control costs in metal cleaning and
electronics cleaning. US. Environmental Protection Agency, Office of Pesticides and Toxic Substances.
Washington, DC
Ramsey, R.B. 1990 (September 1990). Vapor degreaser emission control. Presented at the International
Machine Tool Show. Chicago, IL.
Tbofstensen, Peter. 1990 (September 13). Process-equipment modifications to reduce CFC emissions.
Presented at the ICOLP Solvent Conservation Workshop. Chicago. IL.
US. Environmental Protection Agency. 1986. Analysis of treatment and recycling technologies for solvents
and determination of best available demonstrated technologies.
US. Environmental Protection Agency. 1977 (November). Control of volatile organic emissions from solvent
metal cleaning. EPA-450/2-77-022. Office of Air Quality Planning and Standards, Research Triangle Park,
N.C , . , , ; . '-'' ' ' .
US. Environmental Protection Agency. 1989 (August). Waste minimization in metal parts cleaning. Office
of Solid Waste. Washington, DC
US. Environmental Protection Agency. 1989 (August). Alternative control technology document -
halogenated solvent cleaners. Office of Air Quality Planning and Standards. Research Triangle Park, NC
US. Environmental Protection Agency. 1990 (March). Manual of practices to reduce and eliminate CFC-113
use in the electronics industry. EPA 400/3-90-003. Office of Air and Radiation. Washington, D.C
-------
U« erf Solvent Recyclers and Equipment Manufacturers*
Alhvorth, Inc.
500 Medco Road
Birmingham, AL 35217
(205) 841-1707
Arivec Chemicals, Inc.
7962 Huey Road
P.O. Box 549
Douglasville. GA 30122
(404)942-1550
Baron-Blakeslee, Inc.
2001 North Janice Avenue
Melrose Park, IL 60160
(312) 450-3900
Chem Pak Corporation
P.O. Box 7151
Warwick. RI02887
(401)738-2200
Chemical Solvents. Inc.
3751 Jennings Road
Cleveland, OH 44109
(216)741-9313
Chemtron Corporation
35850 Schneider Court
Avon, OH 44011
(216)871-8048
CWM Resource Recovery; Inc.
P.O. Box 453
West Carrollton, OH 45449
(513)859-6101
Gibraltar Chemical Resources
P.O. Box 1640
Kilgore. TX 75662
(214)894-0270
AMocfeffonJ
Anachemia Solvents, Ltd
3549 Mavid Road
Mississauga. Ontario. CN L5C 1T7
(416)279-5122
i " 'i . '
Avganic Industries. Inc.
114 North Main Street
P.O. Box 208
Cottage Grove. WI53527
(608)257-1440
Berkley Products Company
P.O, Box E
Akron. PA 17501
(717)859-1104
Chemical Reclamation Services
P.O. Box 69
Avalon, TX 76623
(214) 299-5043
i '
Cliempro .
2203 Airport Way, South
Smite 400
Seattle. WA 98134
(206) 223-0500
Clayton Chemical Company
1 Mobile Street
, Saiuget, IL 62201
(618)2714)467
General Chemical
P.O. Box 608
Framingham, MA 01701
(617) 872-5000
Huikill Chemical Corporal ion
7013 Krick Road
Bedford, OH 44146
(216)232-9400
only, and does not constitute any endo^memT^33S5? il^Si** J*S°tio** *»**<*«
or service offered by such entiry; ; * Cxpress or "mP1'^ of any product
-------
Hydrocarbon Recycleis
5354 West 46th Street South
P.O. Box 9557
Tufca, OK 74157
446-74?'1
International Solvent Corporation
9800 190th Street
Surrey, Vancouver. CN VST 4W2
(604)888-4653
Liberty Solvents and Chemical
9429 Ravena Road
Twimburg, OH 44087
(216) 425-4484
Marisol, Inc
125 Factory Lane
Middlesex, NJ 08846
(201) 469-5100
Mllsolv Company
P.O. Box 444
Butler, WI53007
(414) 252-3550
Nortru,Inc
515 Lycaste
Detroit, MI 48214
(313) 824-5850
Omega Recovery Services
12504 East Whittier Blvd.
Whittier.CA 90602
(213) 698-0991
Prillaman Chemical Corporation
P.O. Box 4024
Martinsvflle, VA 24112
(713) 638-8829
Rho-Chem Corporation
425 Isis Avenue
Ingtewood,CA 90301
(213) 776-6233
Romic Chemical Corporation
2081 Bay Road
Pato Alto, CA 94303
(415) 324-1638
Industrial Solvents & Chemical
P.O. Box 158
Emigsville. PA 17318
(717) 938-4621
KDM Company .
4303 Profit Drive
San Antonio, TX 78219
(512)333-4011,
M & J Solvents Company
1577 Marietta Road, N.W.
P.O. Box 19703
Atlanta, GA 30325
(404) 355-8240
Michigan Recovery Systems
36345 Van Born Road
Romulus, MI 41874
(313)326-3100
North East Chemical Corporation
3645 Warrensville Center Road
Cleveland, OH 44122
(216) 961-8618
00 and Solvent Process Company .
P.O. Box 907
Azusa, CA 91702
(818)334-5117
Pride Solvents & Chemical Company
88 Lamar Street
Wist Babylon, NY 11704
(516) 643-4800
Reclaimed Energy Company, Inc.
P.O. Box 418111
Indianapolis, IN 46241
(317)241-9021
Rinchem Company
4115 West Turney Avenue
Phoeniuc, AZ 85019
(602)233-2000
Safety Kleen Corporation
777 Big Timber Road
Elgin, IL 60120
(312) 697-8460
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71
Sol-Pro. lot
P.O. Box 1781
Tacoma, WA 98401
(206)627-4822
Spartan Chemical Compa*"-
2538 28th Street, S.W.
Wyoming, MI 49509
(616)5344921
US. Chemical Company
29163 Calahan
Roseville, MI 48066
(313)778-1414
Southeastern Chemical & Solvent
170 South Lafayette Boulevard
Sumter, SC 29150
(803)773-7387
| TricU Recovery Services, Inc.
Bartow Municipal Airport
Route 3, P.O. Box 249
| Bartow, FL 33830-9504
(813)533-6111
Waste Research & Reclamation
Route No. 7
Eau Claire, WI54701
(715) 834-9624
Equipment Suppliers - Carbon Adsorption Equipment
Ameg
Handelsges mbH 7 Co. KG
28 Bremen 66
Postfach 66032
Knechtsand 4
Germany
Tel: 0421-580038
Telex: 245445
BOWE Reinigungstechnik GmbH
Haunstetter Str. 112
D-8900 Augsburg
Germany
Tel: (0821)57021
Ceilcote Company
140 Sheldon Road
Berea,-OH 44017
(216)243-0700
Detrex Corporation
Equipment Division
P.O. Box 5111
Southfield, MI 48086-5111
(313)358-5800
Otto Dflrr AG
Werk Bernhausen
Postfach 1260
7024 Filderstradt 1
.Germany
Tel: 0711-790281
Telex: 7255850
Baron-Blakeslee, Inc.
2001 North'Janice Avenue
Melrose Park, IL 60H50
(312)450-3900
BrechbuhlAG
Sihlquai244
CH-8031 Zurich
Switzerland
Tel: 01-448950
Telex: 54195 PLAZU CH
1DCI International '
1229 Country Oub Road
Hndianapolis, IN 46234
(317)271^001
I ,.,.-, !
Hoyt Manufacturing Oimpany
-i51 Forge Road
Westport, MA 02790
(617) 636«11
Omniatex
40013 Castel Maggiore
Via Andrea Costa 4
Eiologna
Iiafy '
Tel: 051-70034
Telex: 213418 OTEX-1
-------
Phillips Manufacturing Company
_ i . * ^**_~.l« f*trmmt /
7334 North Clark Street
Rotamll Maschinenbar GmbH
Postfach 12053
.5900Siegen
Eisenhuttenstrasse 26
0271 6711
Germany
Telex: 872352
Sutdilfe Croftshaw Limited
P.O. Box 2526
Columbus, OH 43216
Tel: (614) 258-9501
Vara International, Inc.
120119th Place
Veto Beach, FL 32690
(407) 567-1320
Rekuperator KG
Dr Ing Schack & Co.
Sternstrasse 9-11
Postfach 320960
D-4000 Dusseldorf 1
Gennany
Tel: 0211-49Q055
Telex: 8584894
Sutcliffe Croftshaw Limited
NeillsRoad
Bold
St. Helens
Merseyside WA9 4TH
England
Tel: 0744-810107
Vic Manufacturing Company
1620 Central Avenue, N.E.
Minneapolis, MN 55413
(612)781-6601
Equipment Supplier* - Vapor D*gna*ing Efju/pment
Baron-Blakeslee, Inc
2001 North Janice Avenue
Melrose Park, IL 60160
(312) 450-3900
Corpane Industries
10100 Bluegrass Parkway
Louisville, KY 40299
(502) 491-4433
Delta Industries
8137 Allport Avenue
Santa Fe Springs, CA 90670
(213) 945-1067
Hectrovert Corp.
4330 Beltway Place
Suite 350
Arlington, TX 76017
(817) 468-5171
Branson Ultrasonics Corporation
Eagle Road
Danbury, CT 06484
(203)769-0400
Crest Ultrasonics Corporation
Scotch Road - Mercer County Airport
P.O. Box 7266
Trenton, NJ 08628
(609) 883-4000
Detrex Corporation
Equipment Division
P.O. Box 5111
Southfield, MI 48086-5111
(313)358-5800
Finishing Equipment, Inc.
3640 Kennebec Drive
St. Paul, MN 55122
(612)452-1860
-------
73
Hoshikawa Co., Ltd.
Tokyo, Japan
Tel: 03-643-6601
Fax: 03443-6093
Kerry Ultrasonics, Ltd.
Hunting Gate, Wilbuiy Way, Hitchin
Herts SC4 OTQ England
Tel: 0462-50761-5
Fax 0462-420712
Phfllips Manufacturing Company
7334 North dark Street
Chicago, IL 60626
(312)338-62*30
ICI Chemical & Polymers Ltd.
P.O. Box 19
Runcorn
Cheschire, WA7 4LW
Tel: 0928514444
Fax: 0928580742
Ohtsuka Technical Industry Co., Ltd
3-32 3 Chome, Kigawahigashi
Yodogawa-Ku, Osaka, Japan
Tel: 06-304-7963
Unique Industries
111544 Sheldon Street
Stan Valley, CA 91352
(213) 875-3810
Equipment Suppliers - Monitoring Equipment
Foxboro Co..
151 Woodward Ave.
Box5449
S. Norwalk, CT 06856
Mine Safety Appliances
Box427
Pittsburgh, PA 15230
Sensidyne
12345 Starkey Rd.
Largo, FL 33543
Other Resources
Center for Emissions Control
1225 19th Street, N.W.
Suite 300
Washington, DC 20036
(202) 785-4374
Gastech
8445 Central Ave.
Newark, CA 94560
11F
3561 NW 74 SL
Miami. FL 33147
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74
-------
75
Glossary'
Carbon Adsorption - A recovery process that captures solvent vapors from air on activated carbon. The
solvent is recovered (by desorption) from the carbon by injecting steam into the carbon bed and condensing
the resultant solvent and water vapor.
CFC ' An abbreviation for chlorofluorocarbon. .
- ' . ' 'l
OriorofluorocBrbbn - An organic chemical composed of chlorine, fluorine and carbon atoms, usually
characterized by high stability contributing to a high ODP. ;
Condensate - Liquid solvent resulting from cooling solvent vapors. It is the dean solvent that condenses on
the cooling coils of a vapor degreaser or stflL
Desiceant Dryer - A means of removing water from a solvent by adsorption with desiccant such as a silica
gel or molecular sieve. ;
Desorption - The process of regenerating a carbon adsorption unit by treating the carbon with steam to
remove the adsorbed solvent.
Distillation - A process of purifying a solvent by boiling, condensing the vapor, and collecting the condensate.
Dragout - Solvent that is carried out of a vapor degreasing operation as a liquid trapped in or on the parts
being processed, and a micro-layer of solvent on pan surfaces.
Freeboard Distance from the top of the vapor level to the top of the degreasing tank.
Freeboard Ratio -The ratio of freeboard height to width of jhe machine opening. It should be between .75
and 1.0 for reduced emissions.
' ' i - - ' ." j . ' ' :
Greenhouse Effect - A thermodynamic effect whereby energy absorbed at the isarth's surface, which is
normally able to radiate back out to space in the form of long-wave infrared radiation, is retained by gases in
the atmosphere, causing a rise in temperature. The gases in question are partially natural, but manmade
pollution is thought to increasingly contribute to the effect The same CFCs that cause ozone depletion are
known to be "greenhouse gases,* with a single CFC molecule having the same estimated effect as lO.oOO carbon
dioxide molecules. . , '
Halogenated Solvents - Liquid substances that contain carbon, halogen or carbon hydrogen, and halogen (such
as fluorine or chlorine) atoms. In this text, the term refers 10 the commercial solvents, methylene chloride,
perchloroethylene, 1,1,1-trichloroethane (MCF), trichloroethylene, and trichldrotriiluoroethane (CFC-113).
' , ' -' .{. ' ' i " .
~ Batons Fire-extinguishing agents with high ODPs.
HCFC An abbreviation for hydrochlorofluorocarbpn.
HFC An abbreviation for hydrofiuorocarbbn.
ODP - An abbreviation for ozone depletion potential.
Ozone A gas formed when oxygen is ionized by, for example,
electric field. It has the property of blocking the passage
Whereas it is a desirable gas in the stratosphere, it is toxic to
organic compound).
:, the action of ultiaviolet light or a strong
of dangerous wavelengths of ultraviolet light
living organisms at ground level (see volatile
-------
76
Oaooe depletion - Accelerated chemical destruction of the stratospheric ozone layer by the presence of
substances produced, for the most part, by. human activities. The most depleting species for the ozone layer
are the chlorine and bromine free radicals generated from relatively stable chlorinated, fluorinated, and
brominated. products by ultraviolet radiation.
Oxooe depletion potential - A relative index indicating the extent to which a chemical prodn-: may cause
ozone depletion. The reference level of 1 is the potential of CFC-11 and CFC-12 to cause ozone depletion.
If a product has an ozone depletion potential of 0:5, a given weight of the product in the atmosphere would,
in time, deplete half the ozone that the same weight of CFC-11 would deplete. The ozone depletion potentials
are calculated from mathematical models which take into account factors such as the stability of the product,
the rate of diffusion, the quantity of depleting atoms per molecule, and the effect of ultraviolet light and other
radiation on the molecules.
Oaooe layer - A layer in the stratosphere, at an altitude of approximately 10-50 km, where a relatively strong
concentration of ozone shields the earth from excessive ultraviolet radiation.
Piston Effect - Displacement of solvent vapors due to entry and exit of basket or part that is too large.
Refriterated Freeboard Device - A low-temperature heat exchange coil located in the degreaser freeboard
zone, immediately above the water-cooled condensers. The freeboard chiller lowers the partial pressure of the
solvent in the freeboard zone which results in a reduction in the solvent diffusion rate.
Shock Load - A large part or toad of pans which cause the solvent vapor level to drop substantially below
the normal operating leveL
Staun Distillation - The practice of injecting steam directly into the still after normal distillation has ceased
to recover more solvent from the residue.
Still A unit employed to purify solvent by distillation.
Vapor Line - The line or level of the solvent vapor-air interface in the vapor degreasing unit
Volatile organic compound (VOQ - These are constituents that will evaporate at their temperature of use
and which, by a photochemical reaction, will cause atmospheric oxygen to be converted into potential smog-
promoting troposphsric ozone under favorable climatic conditions.
Water Separator - A device designed to remove water from the solvent by flotation.. .
Work Capacity - The toad a degreaser is designed to process efficiently while maintaining a steady vapor level
-------
77
APPENDIX A
INDUSTRY COOPERATIVE
FOR OZONE LAYER PROTECTION
Hie Industry Cooperative for. Ozone Layer
Protection (ICOLP) was formed by a group of
industries to protect the ozone layer. The primary
role of ICOLP is to coordinate the exchange of
non-proprietary information on alternative
technologies, substances, and processes to
eliminate ozone-depleting solvents. By working
closely with solvent users, suppliers, and other
interested organizations worldwide, ICOLP seeks
the widest and most effective dissemination of
information harnessed through its member
companies and other sources.
ICOLP corporate members include:
AT&T
Boeing Company
British Aerospace
Compaq Computer Corporation
Digital Equipment Corporation
Ford Motor Company
General Electric
Hitachi Limited
Honeywell
IBM
Matsushita Electric Industrial
Company
Mitsubshi Electric Corporation
Motorola
Northern Telecom
Sundstrand
Texas Instruments
Toshiba Corporation
In addition, ICOLP has a number of industry
association and government organization affiliates.
Industry association affiliates include American
Electronics Association (AEA), Electronic
Industries Association, Japan Electrical
Manufacturers Association and Halogenated
Solvents Industry Alliance (U.S.). Government
organization affiliates include the City of Irvine,
California, the State Institute of Applied Chemistry
(U.S.S.R.), the US. Air Force, and the US.
Environmental Protection Agency (EPA). The
American Electronics Association, the Electronic
Industries Association, the City of Irvine,
California, the Japan IBectrical Manufacturers
Association, the Swedish National Environmental
Protection Agency, the U.S. Air Force, the U.S.
EPA, and the U.&S.R. State Institute or Applied
Chemistry have signed formal Memorandums of
Understanding with ICOLP. ICOLP will work
with the U.S. EPA to disseminate information on
technically feasible, cost effective. ' and
environmentally sound alternatives for ozone
depleting solvents.
i . ! . ' ,
ICOL? is also working with the National Academy
. of Engineering to hold a series of workshops to
identify promising research directions and to make
most efficient use of reasarch funding;
i , . . ''/-",
The goals of ICOLP are to:
Encourage the prompt adoption of -safe,
1 environmentally acceptable, non-proprietary
alternative substances, processes, and
; technologies to replace current ozone-depleting
solvents;
Act as an international clearinghouse for
information on alternatives;
It. - '
Work with existing private, national, and
.: international trade groups, organizations, and
i government bodies to develop the most efficient
-------
78 _ ___.
means of creating, gathering, and distributing
information on alternatives.
One example of ICOLP's activities is the
development and support of an alternative
technologies electronic database OZONET.'1
OZONET is accessible worldwide and has relevant
information on the alternatives to ozone-depleting
solvents. OZONET not only contains technical
publications, conference papers, and reports on the
most recent developments of alternatives to the
coma* oses of ozone-depleting solvents, but it also
contains:
* Information on the health, safely and
environmental effects of alternative chemicals
and processes;
Information supplied by companies developing
alternative chemicals and technologies;
Names, addresses, and telephone numbers for
technical experts, government contacts,
institutions and associations, and other key
contributors to the selection of alternatives;
* Dates and places of forthcoming conferences,
seminars, and workshops;
Legislation that has been enacted or is in place
internationally, nationally, and locally.
Information about ICOLP can be obtained from:
Mr. Steven B. Heltem
Executive Director
ICOLP
1440 New York Avenue, N.W.
Suite 300
Washington, D.C 20005
Tel: (202) 737-1419
F»c (202)639-8685
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