United States Environmental Protection Agency Air and Energy Engineering Research Laboratory Research Triangle Park NC 27711 Research and Development EPA/600/S2-91/056 Dec. 1991 EPA Project Summary Manual for Non-CFC Aerosol Packaging: Conversion from CFC to Hydrocarbon Propellants K.M. Adams, K.E. Hummel, T.P. Nelson, and S.L. Wevill Because stratospheric ozone pro- vides protection from biologically dam- aging ultraviolet-B radiation, and because chlorofluorocarbons (CFCs) have been strongly implicated in the thinning of the Earth's stratospheric ozone layer, there is an urgent need to eliminate production and use of the. CFCs. In the U.S., CFCs were banned for use as propellants from nearly all aerosol products as early as 1978. In place of the CFC propellants, liquefied hydrocarbons such as propane, n-bu- tane, and isobutane were found to be acceptable substitutes for the majority of aerosol products. This report pro- vides technical assistance to aerosol product marketers and fillers in other nations now faced with eliminating CFCs under the terms of the Montreal Proto- col. The report addresses the Issues of hydrocarbon propellant supply, prod- uct reformulation, equipment conver- sion, and safety concerns for both the manufacturing plants and the aerosol products themselves. This Project Summary was devel- oped by EPA's Air and Energy Engi- neering Research Laboratory, Research Triangle Park, NC, to announce key find- ings of the research project that Is fully documented in a separate report of the same title (see Project Report ordering information at back). Introduction Recent concern about depletion of the stratospheric ozone layer has focused on synthetic chemicals known as chlorofluo- rocarbons (CFCs). Scientists have con- cluded that destruction of the ozone layer by CFCs will allow too much harmful ultra- violet radiation to reach the Earth's sur-* face, with potentially catastrophic results. The most serious consequences include a higher incidence of skin cancer and cata- racts, suppression of the human immune system, damage to plant and animal life, and global warming. In response to these concerns, coun- tries around the world have agreed to phase out the production and use of CFCs by the year 2000. The Montreal Protocol, drafted under the auspices of the United Nations Environment Programme (UNEP), has been ratified as of October 1990 by 68 countries and the European Economic Community (EEC). Work is now underway to find substitutes and alternatives to re- place CFCs, as well as to decrease CFC emissions in areas for which substitutes are currently unavailable. Many alternatives exist for replacing the CFC-propelled aerosol package. This manual does not discuss the strengths and weaknesses of the many potential options. A brief list of the alternatives, how- ever, follows: • Hydrocarbon propellants; Other liquefied gas propellants such as dimethyl ether (DME); Compressed gas propellants such as carbon dioxide, nitrous oxide, and nitrogen; Hydrochlorofluorocarbons (HCFCs) such as HCFC-22, HCFC-123, and HCFC-142b; Printed on Recycled Paper ------- • Hydrofluorocarbons (MFCs) such as HFC-152a and HFC-134a; and • Non-aerosol packaging such as me- chanical finger pumps, trigger spray- ers, and other alternative packaging. This manual provides manufacturers of aerosol products with the technical infor- mation that will enable them to convert from CFC propellants to hydrocarbon pro- pellants. Hydrocarbon propellants are pri- marily mixtures (or pure components) of butane and propane, along with pentane, and to a much lesser extent, ethane. For the reasons listed below, if manu- facturers choose to continue to use aero- sol dispensers instead of non-aerosol alternatives, hydrocarbon propellants are the most feasible near-term alternative to CFC aerosol propellants: • Hydrocarbons can be treated and blended to obtain the physical and chemical properties that make them suitable aerosol propellants; • Most hydrocarbons are essentially nontoxic, making them suitable for use in a variety of personal care and household products; • Hydrocarbon propellants are less ex- pensive than CFCs, enabling manu- facturers to produce aerosols at a tower unit cost; • Hydrocarbons are compatible with properly selected container materi- als and formulations, thus preserving shelf life and product stability; and • Since the banning of CFC aerosol propellants, hydrocarbons have be- come the dominant aerosol propel- lant in many developed and developing countries and useful ex- perience is available that can mini- mize the conversion cost for other countries. Hydrocarbons also have two limitations or disadvantages: • Hydrocarbon propellants are flam- mable; therefore, precautions must be taken by producers, distributors, and end-users to ensure that the aerosol products are handled safely. • Hydrocarbon propellants belong in a class of compounds known as volatile organic compounds (VOCs), which are natural and synthetic compounds that contrib- ute to the formation of what is known as photochemical "smog." In some urban areas where smog formation is a health and envi- ronmental problem, regulations have been proposed to reduce the amounts of VOCs in con- sumer products. Properties and Availability of Hydrocarbon Propellants A replacement aerosol propellant must have properties that allow the aerosol pack- age to function: 1) the aerosol propellant must provide the pressure to expel the product from the container; 2) the propel- lant may serve as a solvent to aid in keep- ing the active ingredients in solution; and 3) the propellant must vaporize after leav- ing the container, producing a spray or foam. Other important properties of aero- sol propellants are toxicity, stability, den- sity and flammability. Table 1 compares the properties of the most common CFC propellants (CFC-11 and CFC-12) and the hydrocarbon propellants (isobutane, n-bu- tane, and propane). Either liquefied gases or compressed gases can provide pressure to expel prod- uct from the container. Hydrocarbon and CFC aerosol propellants are both liquefied gases. Throughout the life of the aerosol product, they generally provide a more uniform internal pressure. The solubility of the propellant is impor- tant since it determines whether the over- all contents are uniformly blended ("homogeneous"), or whether the contents exist in separate phases ("heterogeneous"). The hydrocarbon compounds are all non- polar, which renders them insoluble with many polar solvents (including water). How- ever, in some cases co-solvents such as ethanol can be used to provide single- phase blends of hydrocarbons, alcohol, and water. The toxicity of propellants may be com- pared by using the threshold limit value (TLV, a trademark of the American Confer- ence of Governmental Industrial Hygien- ists—ACGIH). The TLV is the maximum level of exposure for a person working 8 hours a day, 40 hours a week throughout a normal working career without adverse health effects. The occupational exposure guidelines for CFC-11, CFC-12, and hy- drocarbon propellants are roughly compa- rable. The corrosion properties of propellants may be compared by testing their hydro- lytic stability. These tests measure the rate of hydrolysis (decomposition) in the pres- ence of a steel test coupon in water. CFCs are generally less stable than the hydro- carbons. However, contaminants in "field- grade" hydrocarbons (water, and sulfur compounds) may have a major effect on corrosion. No discussion of the properties of hy- drocarbons would be complete without con- sidering flammability. The flammability of an aerosol spray is a combined function of the composition of the product inside the container and of the design of the valve. Frequently, other major ingredients of the formula (e.g., alcohols or petroleum distil- lates) are also flammable. Hydrocarbon propellants are derived from liquefied petroleum gases (LPGs) which come from the ground as constitu- ents of wet natural gas or crude oil or as a by-product of petroleum refinjng. LPG usu- ally refers to a mixture of propane and butane, although other hydrocarbons may also be present (ethane at the light end, and pentanes at the heavy end). The amount of LPG used for aerosol propellant is very small (less than 0.1% in the U.S. in 1981). Aerosol grade hydrocarbon propel- lants are prepared by first distilling the LPG to separate the various species. The distillation of hydrocarbon propellant is nor- mally carried out at a specially designed plant that serves the regional aerosol in- dustry. These plants are generally quite sophisticated and would be too large for any single aerosol filler. Some aerosol products may use so- called "natural blend" LPG instead of dis- tilled hydrocarbons. The primary advantage of natural blend LPG is that it is less ex- pensive because there is less processing of the hydrocarbon. The natural blend pro- pellant is suitable in products where odor is not as important (i.e., where the concen- trate itself is quite odorous as in some degreasers or spray paints) or where the spray characteristics are not critical (such as wet sprays in some residual insecti- cides). A disadvantage of natural blend hydrocarbon propellant is that the quality varies, resulting in inconsistent pressure. Because the natural blend is produced by a coarse distillation, the amount of pro- pane, butane, and pentanes may differ from one lot-to the next, and this will affect the spray pattern. Natural blend propel- lants are likely to contain larger quantities of impurities (such as water, sulfurous com- pounds, olefins, or reactive particulates). The presence of water can be tolerated in water-based products, but not in products intended to be anhydrous. Some types of aerosol products re- quire a purer hydrocarbon propellant than other types. The most demanding aerosol products are aerosol perfumes and fra- grances. Other products which require a highly refined hydrocarbon propellant in- clude personal care products, food prod- ucts, medicinal or pharmaceutical products, some household products, certain paints and coating sprays, and certain automo- tive and industrial sprays. Before the propane and butanes are suitable for these aerosol propellant appli- cations, they must be purified further to ------- Table 1. Physical Properties of CFC and Hydrocarbon Propellants Name CFC-11 CFC-12 Propane Isobutane n-Butane Formula CCI3F CCIf, C3H$ C4H10 CtHw Molecular Weight 137.4 120.9 44.1 58.1 58. 1 Vapor Pressure @21°C (kPa) 89 586 855 317 221 Specific Gravity 1.476 1.311 0.5077 0.5631 0.5844 Solubility in Water (Kauri- Butanol) 60 18 15.2 17.5 19.5 Toxicity (TLV) 9 1000 1000 1000 ' 800 (est.) _ 600 Stability (g/L per year) (w/steel 30PC, 101.3 kPa) 10 0.8 — — — Flammability (explosive range) Nonflammable Nonflammable Flammable (2.18 - 9.5 vol%) Flammable (1.86- 8.5 vol%) Flammable (1.86 - 8.5 vol%) remove odorous and reactive compounds such as unsaturated hydrocarbons (for ex- ample, 1-butylene or propylene), as well as sulfur compounds and water. The pro- cesses used include: dehydration (for re- moving moisture); acid gas removal (for removing sulfur compounds); and sulfuric acid treatment or desiccant treatment (for removing unsaturated compounds). Con- tacts with industry experts and limited pub- lished data suggest that the most common type of hydrocarbon propellant purification is the solid adsorbent process. The solid adsorbent process can use such materials as silica gel, activated aluminas, or mo- lecular sieve adsorbents for water or sulfur compounds (dehydration or acid gas re- moval). Unsaturated compounds can be removed using activated carbon or mo- lecular sieves. The nonregenerable sys- tem is simpler and less expensive than a regenerable system, but the adsorbent(s) must be replaced periodically. The disad- vantage of a non-regenerable adsorbent system is that, once the adsorbent be- comes saturated, the impurities will no longer be removed, and contaminated pro- pellant will enter the system. An alternative to on-site purification is to use a central purification facility in con- junction with a distillation system. The cen- tral purification facility can operate with multiple beds that are alternated between purification and regeneration. Such a com- bined facility would comprise the basic elements of a regional hydrocarbon pro- pellant supply. Countries can import purified hydrocar- bon propellant or LPG by overland or ocean shipment in bulk containers. Containers for shipping LPG include tank trucks, rail tank cars, and containerized pressure vessels (International Organization of Standardiza- tion containers) for ocean shipment. Safety in Using Hydrocarbon Propellants Hydrocarbon gases are used primarily as fuels. Because of their flammability, they must be handled with great care. In the U.S., the National Fire Protection As- sociation (NFPA) has issued standards for manufacturing and storing aerosol prod- ucts (NFPA Code SOB), and for storing and handling LPG (NFPA Code 58). In addition to these codes, which relate di- rectly to the safety of aerosol products, many other NFPA codes are relevant. Im- portant safety measures include: Locating manufacturing buildings and flammable propellant storage tanks at a safe distance [7.6 m (25 ft) or more] from the property fenceline and from other areas of the plant that could become sources of ignition or shrapnel. Providing for a blast wall between flammable propellant charging rooms and other areas. Providing a well-ventilated gas house that gives positive ventilation (at both normal and emergency rates). Routing all discharge vents from vacuum pumps, propellant pumps, and building ventilation systems no less than 3 m (10 ft) above the roof to ensure adequate dispersion. Complying with the 1990 U.S. Na- tional Electrical Code (NEC) for haz- ardous atmospheres, which requires that equipment be isolated so that these potential ignition sources are enclosed in "explosion proof" hous- ings. The NEC Code specifies that approved fixtures be used on electric . motors, switches, lamps, and other electrical equipment. The minimum ratings for the gas house and pump room where flammable hydrocarbon propellants are used are Class I, Di- vision 1, Group D. Installing blowout walls or ceiling ("de- flagration venting") to allow a con- trolled release of pressure if an . explosion occurs. If venting is not possible or if personnel will be present when filling is underway, a specially engineered "explosion suppression" system is required. This type of sys- tem often employs pressurized halon, which is an ozone-depleting sub- stance, and its production will be phased out under the Montreal Pro- tocol. Providing automatic sensing systems to measure flammable gas concen- trations in the gas house, sound alarms, and activate the emergency ventilation system and interlocks to cut off the propellant supply from the tank farm. Again, this is only a partial list of the Code requirements. Other important areas cover such topics as fire sprinkler systems, standpipes, fire hoses, and fire extinguish-. ers. A fully enclosed gas house with two- speed ventilation and an explosion sup- pression system may not be necessary in warm climates, where an "open-air filling" area may be possible. The open-air filling technique has several advantages, such as reduced capital expenditures for install- ing or retrofitting an aerosol-filling plant. In addition to the general safety consid- erations for hydrocarbon storage and build- ing construction, other engineering safety measures apply to the hydrocarbon con- tainer valves and accessories, piping, and safety relief devices. ------- Labeling Requirements and Flammabillty Testing Manufacturers normally place warnings on labels of aerosol products to ensure that the products are used safely and for thoir intended purposes. Among the most important labeling statements are the words FLAMMABLE and EXTREMELY FLAM- MABLE. These warnings do not generally discourage purchases of useful products except on baby products, foods, and some Pharmaceuticals. In the U.S., two tests are used to deter- mine when FLAMMABLE or EXTREMELY FLAMMABLE labels are required: 1) the Modified Flash Point Test, and 2) the Flame Projection/Flashback Test. Equipment Conversion of Hydrocarbon Filling Operations Automated Filling Lines The large aerosol filling operation uses an automated production line that can pro- duce 14,000 to 28,000 units per shift, which equals approximately 35 to 70 units per minute. The equipment that must be modi- fied to convert from CFG aerosols includes the propellant supply, the gassing area, and possibly the main production area, depending on the location of the gassing area. Automated filling lines typically use bulk storage of the hydrocarbon propellant. One of the most important guidelines is ensur- ing that the distance between the tanks and charging pumps and the production and gassing area meets the specifications in NFPA 30B. For tanks under 7.6 m3 (268 ft3), at least 8 m (25 ft) from the nearest production facility is recommended. For tanks over 7.6 m3, at least 15 m (50 ft) is recommended. If existing fixed storage tanks are reused, they must be thoroughly cleaned (sandblasted) and hydrostatically tested at 2 times their maximum working pressure to ensure they can safely store the hydrocarbon propellant. In addition to the storage area, modifi- cations may be needed for the gassing and production areas. The gassing room should be constructed outside the main production area. The modifications required include increased ventilation, combustible gas detectors, isolation of electrical equip- ment in "explosion proof" housings, and possibly an explosion suppression system. The walls and roof of the gas house should be made blast proof, and blowout panels should be provided to allow a controlled release of pressure. If a facility is not able to make the modifications suggested above, then an open-air gassing room may be an alterna- tive. The main feature of the open-air gas house is the use of natural ventilation to keep any escaped hydrocarbon vapors below flammable or explosive limits. The gassing apparatus is located outside of the, main production facility, with a solid roof, wire mesh walls on three sides, and a solid wall between the gassing area and the main production facility. The costs for converting an automated aerosol filling line are difficult to estimate without site-specific details. One example is the Mexico Case Study, which estimated the cost to convert an automated filling line (producing 8 million cans per year) from CFCs to LPG to be $566,000 for capital investment (machinery and filling lines) and $793,000 for auxiliary equipment (gas de- tectors, fire extinguishing systems, and alarms), resulting in a conversion cost of $1.36 million U.S. dollars. However, the estimated propellant savings from using less expensive hydrocarbons in place of CFCs would be $1.69 million U.S. per year. Therefore, the cost savings from con- verting to hydrocarbons would more than offset the initial capital investment. Manual Filling Lines Small- to medium-sized aerosol-filling operations typically use a manual produc- tion line capable of producing 6,000 to 8,000 units per shift with two persons (lim- ited to filling, gassing, crimping only), which would equate to approximately 15 units per minute. On the basis of one 8-hour shift per day and a 5-day work week, such a plant could conceivably produce nearly 2 million units per year. Other operations, such as labeling containers with paper la- bels or packing, would either slow the rate or require additional labor. Atypical manual aerosol filling line uses air-operated and manually actuated equip- ment. Each container must be transferred manually from one step to the next. Cold filling is nor appropriate with hydrocarbon propellants and should be replaced by pres- sure filling. A single-station pressure filling machine may cost up to $30,000. Required equipment modifications would typically be limited to the propellant supply and the gassing area. The hydro- carbon storage used for small manual fill- ing lines are typically several 53-kg (117-lb) cylinders manifolded together or a 385-kg (849-lb) container. Cylinders not in use should be stored in the open air or in well- ventilated areas. No more than six cylin- ders should be stored together with a minimum distance of 3 m (10 ft) between the storage and a boundary, building, or fixed ignition source (such as pumps, elec- trical motors, or vehicles). All cylinders should be stored upright, with protective valve caps in place, and securely chained. In addition to the propellant supply, equipment modifications for manual lines must be made to the gassing area. Many small filling operations are located in crowded urban areas, and the use of an open-air gassing area would not be pos- sible. One way to significantly reduce the hazards associated with hydrocarbon pro- pellants would be to locate the gassing and crimping operations within a labora- tory fume hood. These types of hoods have been successfully used for labora- tory-scale, manual filling operations that closely correspond to cottage-size produc- tion facilities. The exhaust from the fume hood should be connected to a flue or pipe duct that uses an explosion-proof fan motor. The end of the duct or piping should exit di- rectly through the roof of a one-story build- ing or to an adjacent outside wall if the filling room is located in a multi-story build- ing. The location of any ignition sources that may be near the exhaust duct should be considered. The fume hood, fan-motor, and any equipment used within the fume hood (such as lighting) should be Class I, Division 1, Group D explosion-proof equip- ment. The costs for converting a'manual aero- sol filling line are also difficult to estimate without site-specific details. The estimated cost to convert a hypothetical manual fill- ing line (producing 500,000 cans per year) from CFCs to LPG is at least $12,000 U.S. dollars. This includes purchase of explo- sion-proof motors, starters, and solenoid valves; installation of explosion-proof fume hoods for gassing equipment and test baths; and construction of a covered, fenced hydrocarbon storage area. This ini- tial capital investment would be more than recovered by the material cost savings of using hydrocarbon propellants instead of CFC propellants. Aerosol Product Storage Since hydrocarbon propellants are flam- mable (containing butane, propane, or a mixture of- these two, or less frequently, pentane or ethane), producers, distribu- tors, and end users must take extra care to handle them safely. Aerosol products can be classified into three levels according to their perceived flammability. hazard. The classification considers the percentage of flammable base material and flammable propellant. Materials that mix with water, such as ethanol, isopropanol, propylene glycol, and acetone, would dissolve in the water from sprinklers and fire hoses during ------- afire and be rendered nonflammable. Wa- ter immiscibje materials, on the other hand, such as toluene and aliphatic petroleum distillates would not dissolve and could spread as a burning top layer as water was directed at a fire. Level 1 aerosol products are those whose base products contain up to 25% by weight of materials with flash points of 260°C (500°F) or less. Level 1 aerosol products do not require special fire pro- tection measures. These "water-based" aerosol products may be stored as a Class III commodity as defined in NFPA Standard 231 for Rack Storage of Materi- als; i.e., equivalent to paper, cardboard, and wood products. Level 2 products are those whose base product contains either 1) more than 25% by weight of water miscible materials with flash points of 260°C (500°F) or less, or 2) more than 25% but less than 55% of water immiscible materials with flash points of 260°C (500°F) or less. Level 3 products are those whose base product contains more than 55% of water miscible materials with flash points of 260°C (500°F) or less, or the flammable propellant equals or ex- ceeds 80% of the net container weight. Level 2 and Level 3 aerosol products may be stored in a general purpose ware- house that either has no sprinklers or is not protected in accordance with NFPA 306, but the quantity is limited to 1135 kg (2,500 Ib). Storage of greater amounts of Level 2 and Level 3 aerosol products in general purpose warehouses requires com- pliance with the protection guidelines for automatic sprinklers and palletized, solid pile, or rack storage arrangements as listed in NFPA 30B. Aerosol 'storage in sales display areas and backstock storage areas is also ad- dressed in NFPA 306. Product Reformulation The characteristics of hydrocarbon pro- pellants as they relate to formulations and performance are discussed. Dispersion, one major attribute of aerosol propellants, is the efficiency with which a propellant can produce a fine spray or acceptable foam. The dispersive effect is not linear but is modified by vapor pressure and solubility factors, ft normally can be used as a general guideline to determine equiva- lencies when changing from one propel- lant to another. After a concentrate has been tenta- tively developed, the correct type and amount of propellant must be added, and an aerosol valve must be used that will develop the desired spray pattern or foam puff. One of the most important character- istics that the formulator looks for is par- ticle size distribution. There are several techniques to decrease the droplet size if it is too coarse. One approach is to use a vapor-tap valve. Approximately 40-50% of the world's 8 billion aerosol products use vapor-tap valves. Such valves have an orifice ex- tending through the side or bottom wall of the valve body and into the head space area. The orifice may be enlarged to de- crease particle size. However, this has several negative effects. To devise a good aerosol product, a formulator must minimize the risks of flam- mability and possible explosivity. It is a tribute to the excellence of the aerosol packaging form that extremely flammable products can be safely dispensed, if the user follows label directions, and if the formulator is able to make allowances for reasonably foreseeable consumer misuse. Most U.S. aerosols are formulated to a pressure as low as is consistent with good operational performance across the antici- pated temperature range of their use. For example, hair sprays are expected to work well between 13°C and 37°C, and reason- ably well just outside these limits. The formulator's job is not complete when an acceptable product and packag- ing system have been developed. Test packing is always needed to establish data on weight loss rates, can and valve com- patibility, etc. Several options are discussed to correct corrosion problems, such as ad- dition of corrosion inhibitors, increasing the pH, or minimizing the presence of chloride ion. •&U.S. GOVERNMENT PRINTING OFFICE: 1992 - 648-080/40119 ------- ------- ------- K.M. Adams, K.E. Hummel, T.P. Nelson, and S.L Wevill are with Radian Corp., Austin, TX 78720-1088 N. Dean Smith is the EPA Project Officer, (see below). The complete report, entitled "Manual for Non-CFC Aerosol Packaging: Conversion from CFC to Hydrocarbon Propellants," (Order No. PB92-101344/AS; Cost: $35.00, subject to change) will be available only from: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: Air and Energy Engineering Research Laboratory U.S. Environmental Protection Agency Research Triangle Park NC 27711 United States Environmental Protection Agency Center for Environmental Research Information Cincinnati, OH 45268 BULK RATE POSTAGE & FEES PAID EPA PERMIT NO. G-35 Official Business Penalty for Private Use $300 EPA/6QO/S2-91/056 ------- |