PROCEEDINGS OF THE
U.S. ENVIRONMENTAL PROTECTION AGENCY
WORKSHOP ON
INTEGRATING CASE STUDIES CARRIED OUT
UNDER THE MONTREAL PROTOCOL
January 15-17, 1990
Washington, D.C.
Division of Global Change
Office of Air and Radiation
United States Environmental Protection Agency
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TABLE OF CONTENTS
Meeting Summary
Meeting Agenda
List of Attendees - Attachments 1, 2, and 3
PRESENTATIONS
1. "Proposal For a Unified Approach", Dr. Stephen O. Andersen, Chief, Technology and
Economics Branch, Office of Air and Radiation, U.S. Environmental Protection Agency.
2. "Global Environmental Problems - Policy in Mexico", Mr. Sergio Reyes-Lujdn, Undersecretary
for Ecology, SEDUE (Secretaria de Ecologla y Desarrollo Urbano.)
3. "Status of Case Study: Egypt", Dr. Ahmed Amin Ibrahim, Consultant for Egyptian Environment
Affairs Agency.
4. "Status of Case Study: Brazil", Mr. Alberto Carrizo, White-Westinghouse Climax, Brazil.
5. "Status of Case Study: China", Mr. Zhang Chongxian, Senior Engineer, National Environmental
Protection Agency - China.
6. "Overview of UNEP Technical Assessment", Mr. G. Victor Buxton, Environment Canada.
7. "Technology Transfer Projects by the Industry Cooperative for Ozone Layer Protection", Mr.
A.D. FitzGerald, Director, Environmental Affairs, Northern Telecom, Canada.
8. "Switch from CFCs to Hydrocarbon Propellants", Mr. Montfort Johnsen, President, Montfort A.
Johnsen and Assoc., United States.
9. "Adapting Aerosol Technologies to Developing Country Needs", Mr. Jorge Corona,
CANACINTRA (C^mara Nacional de la Industria de la Transformaci6n), Mexico.
10. "Electronics Cleaning in Developing Countries", Mr. Brian Ellis, General Director, Protonique
S.A., Switzerland.
11. "Replacement of CFC-113 Solvent", Mr. Bryan Baxter, British Aerospace Precision Products
Group, United Kingdom.
12. "Assessment of Alternative Substitutes and Technologies in Refrigeration", Dr. Lambert
Kuijpers, Philips Research Laboratories, Netherlands.
13. "Important Considerations in Evaluating Substitutes to CFC Blowing Agents in Foam Plastic
Products", Ms. Jean M. Lupinacci, Office of Air and Radiation, U.S. Environmental Protection
Agency.
14. "CFCs and HCFCs as Feedstocks", Dr. Nobuo Ishikawa, Director F & F Research Center,
Japan.
15. "Halons: Advantages and Disadvantages", Halons Work Group.
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ATTACHMENT 4 - Terms of Reference for the Case Studies
ATTACHMENT 5 - Survey Questionnaire for the Case Studies
APPENDICES
SOURCE MATERIALS AND DOCUMENTS DISTRIBUTED AT THE WORKSHOP
1. "Replacement of CFC-113 in Industry", Swiss Federal Office of Environment, Forests and
Landscape.
2. "CFC Alliance Special Bulletin", Alliance for Responsible CFC Policy, United States.
3. "The Destruction of Halons in the Nordic Countries", Jan Bergstrom, Raine Harju, and Eva
Hyden, Nordic Council of Ministers' Steering Committee for the Halon Project.
4. "CFCs in India - Phase 1 Work Plan", Avani Vaish, Ministry of Environment and Forests, India.
5. "Protonique News", Protonique, S.A., Switzerland.
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EPA WORKSHOP SUMMARY
The U.S. Environmental Protection Agency (EPA) sponsored a workshop on
"Integrating Case Studies Carried Out Under the Montreal Protocol" in
Washington, D.C., on January 15 to 17, 1990. The workshop was attended by
representatives of government and private organizations from Australia,
Brazil, Canada, China, European Economic Community (EEC), Egypt, Federal
Republic of Germany, India, Japan, Malaysia, Mexico, Norway, Singapore,
Sweden, United Kingdom, United States, Venezuela, the United Nations
Development Programme (UNDP), and the World Bank. In addition, a group of
experts on various use sectors of CFCs were also present. The purpose of the
meeting was to:
• develop a methodology and framework to encourage uniformity
between case studies being conducted in various countries;
• obtain first hand information from representatives of various
countries on the status of case studies being conducted;
• assemble a group of representatives and experts from various
countries to share ideas, provide information, and discuss
arrangements for conducting case studies in each country; and to
• identify commercially available, cost-effective, reliable
technology that could be used by developing countries to reduce
and/or eliminate their particular uses of CFCs, halons, and other
ozone depleting chemicals.
Exhibit 1 summarizes the status of the case studies being conducted in
various countries.
The Mexican, Egyptian, and Brazilian case studies jointly sponsored by
the U.S. and these host countries are well underway. Mr. Sergio Reyes Lujan,
Undersecretary for Ecology, SEDUE (Secretaria de Ecologia y Desarrollo Urbano)
discussed the progress of the Mexican case study. Mr. Reyes Lujan discussed
SEDUE's pioneering initiatives in efforts to protect the ozone layer by
reaching nine voluntary agreements with various industry groups to reduce
their consumption of CFCs and halons. It is expected that a first draft of
the Mexican Case Study will be available by February 15, 1990 and the cost
estimates for this study will be prepared by March 1990. The draft report on
the case study will be available for the April 4-6,1990 UNEP meeting.
Dr. Ahmed Ibrahim, consultant to the Egyptian Environmental Affairs
Agency, presented information on the status of the Egyptian case study. Dr.
Ibrahim noted that Egypt does not produce any CFCs and that the majority of
the CFCs use in Egypt results from the use in refrigeration and aerosol
applications. A number of Egyptian aerosol manufacturers have already
switched to alternatives such as liquified petroleum gas (LPG) which mainly
consists of propane and pentane. The use of LPG has been demonstrated as a
cost effective and technically viable alternative to CFC use in aerosols. Dr.
Ibrahim stated that the first draft of the Egyptian case study will be
completed by March 15, 1990 and the draft including some costs estimates will
be completed by the April, 4-6, 1990 UNEP meeting.
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Mr. Alberto Carrizo, representing the Brazilian case study project team
discussed the progress on the Brazilian case study. The Brazilian case study
project team includes representatives from IBAMA (Institute Brazileiro do Meio
Ambiente e dos Recursos Naturais Renovaveis -- the Brazilian environmental
agency), Foreign Affairs, Health, and Industry & Trade Ministries, and members
of various industry groups. The project team expects to have a first draft of
the study by the April 4-6, 1990 UNEP meeting.
The case study on India is being conducted in collaboration with the
United Kingdom. Mr. Avani Vaish, Ministry of Environment & Forest, noted that
India currently has a production capacity of 7,500 metric tons that is
expected to increase to about 20,0000 metric tons by 1995. He noted that the
majority of CFC use in India results from the use in refrigeration
applications. Mr. Vaish stated that preliminary estimates of costs are likely
to be available by the February 1990 meeting of the Protocol Parties. It is
expected that the cost estimates provided during the February meeting will be
refined and that improved estimates will be available for the April UNEP
meeting.
The case study on China is being sponsored by the United Nations
Development Program and Finland. Mr. Zhang Chongxian, National Environmental
Protection Agency, stated that China has an indigenous CFC production capacity
of approximately 30,000 metric tons and that the majority of CFC use in China
is in refrigeration and foam blowing applications. Mr. Chongxian stated that
preliminary results may be available by the June meeting of the Protocol
Nations and that the final estimates would be available by November 1990.
Venezuela is conducting its own case study and the government
representatives present at the workshop stated that they expect that
preliminary cost data will be available by the April 1990 meeting.
Sweden, possibly in cooperation with Norway is planning to sponsor a
case study on Kenya. An agreement formalizing the case study is likely to be
signed in the near future. It is expected that a preliminary report will be
available for the June 1990 meeting of the Protocol Nations.
Canada has decided to sponsor a case study on Malaysia. An agreement is
currently being worked out and Canada expects that preliminary information on
costs will be available for the June 1990 meeting of the Protocol Nations.
The Australian, EEC, Federal Republic of Germany, and Japanese
representatives expressed their willingness to sponsor case studies. The
following countries were suggested as possible candidates for additional case
studies: Algeria, Argentina, Chile, Czechoslovakia, Hungary, Indonesia,
Libya, Pakistan, Philippines, Poland, Saudi Arabia, Tanzania, Thailand, and
Yugoslavia. It was suggested that sponsoring and case-study countries should
contact each other.
The workshop participants formed six work groups to discuss and prepare
guidance material for the case studies. The working groups consisted of:
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• a group that developed the "terms of reference" for the case
studies (Attachment 4);
• a group for each of the end use sectors: aerosols, foam, halons,
refrigeration, solvents that developed the survey questionnaire
materials that could be used to gather relevant information on
each end use sector for the case studies (Attachment 5).
The materials developed by each of the work groups were distributed
among the workshop participants for final review. The workshop participants
by consensus agreed on the "Terms of Reference" and the survey questionnaire
materials prepared for the case studies. It was agreed that these materials
were guidelines and local conditions in each country might necessitate some
variation.
Technical Presentations
The technical presentations by the industry experts are included
elswhere in this volume. A brief summary of each presentation follows.
Mr. Montfort Johnsen, Technical Consultant, U.S., presented information
on the use of hydrocarbons as substitutes for CFCs in aerosol applications.
Mr. Johnsen stated that hydrocarbon propellants cost less than CFC based
propellants. He also stated that because the hydrocarbons are flammable,
special precautionary measures such as properly designed gas house have to be
used in the aerosol filling process.
Mr. Jorge Corona, representative of CANACINTRA (the Mexican Technical
and Economic Chamber of Industries) discussed the characteristics of
hydrocarbon propellants and explained how the Mexican aerosols industry has
adapted technology to local circumstances to successfully switch from CFCs to
hydrocarbons. He offered Mexican assistance to other developing countries in
adapting Mexican designs to their environment.
Mr. Bryan Baxter, British Aerospace Dynamics Ltd., U.K., discussed the
technical feasibility of using isopropanol as a possible replacement for CFC-
113 based cleaning for precision cleaning applications. He noted that the
flammability aspects of isopropanol are completely suppressed by blending the
isopropanol with perfluorohydrocarbons. In addition, he stated that British
Aerospace is designing special equipment that would eliminate the loss of
solvent vapor for this cleaning application.
Mr. Brian Ellis, Protonique, S.A., Switzerland, presented a comparative
assessment of various alternative technologies that could be used to replace
CFC-113 use in the electronics industry. These technologies include the use
of aqueous based processes with and without saponifiers, the use of low
solid/"no clean" flux, controlled atmosphere soldering, and the use of
hydrochlorofluorocarbon (HCFCs) and hydrocarbon (HC) based solvents.
Dr. Lambert Kuijpers, Philips Research Laboratories, The Netherlands,
presented information on alternative refrigerants being considered for various
refrigeration applications. Dr. Kuijpers stated that the currently available
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substitute refrigerants include ammonia, HCFC-22, hydrocarbons, HCFC-142b and
HFC-152a. Medium term alternatives include HFC-134a, HCFC-123, and azeotropic
mixtures. Finally, long term alternatives include HCFC-124, HFCs 125, 134,
32, and 143a. Dr. Kuijpers summarized the current state of technology for
these refrigerants and presented information on the research efforts under way
to commercialize the use of these new refrigerants.
Ms. Jean Lupinacci, U.S. EPA presented information on alternatives to
CFG blow foams. Ms. Lupinacci stated that countries with large CFG
consumption in flexible and packaging foams have the largest opportunity to
reduce their use of CFCs using alternatives such as water blown foams,
increase foam density, use of HCFC-22 as a blowing agent, and through product
substitutes. In the case of polyurethane insulation foam applications the
foam industry faces greater challenges to reduce their use of CFCs. In these
end uses the use of HCFC-123, HCFC-141b, and the use of water blow foams
represent promising alternatives.
Dr. Nobuo Ishikawa, F&F Research, Japan, presented a summary of chemical
processes that can transform CFCs, HCFCs, and methyl chloroform to other
useful chemicals. For example, methyl chloroform can be converted to HCFC-
141b and HCFC-142b. The HCFC-142b can then be converted to vinylidene
fluoride that is used to produce polymers and copolymers that are used in a
number of application (e.g., electrical applications such as wire insulation
and fiber optics, and as piezoelectronic materials). Similarly, HCFC-22 can
be converted to HCFC-225, HFC-134a, and a variety of polymers and copolymers.
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EXHIBIT 1. STATUS OF NATIONAL CASE STUDIES
CASE STUDY COUNTRY
SPONSORING COUNTRY
STATUS
Mexico
U.S.
First draft - February
12, 1990; Draft with
cost estimates March
1990; Report to UNEP
April, 1990.
Egypt
U.S.
First draft March 15,
1990; Draft with cost
estimates March 30,
1990; Report to UNEP
April, 1990.
Brazil
U.S.
Draft with cost
estimates April 1990;
Report to UNEP April,
1990.
India
U.K.
Preliminary cost
estimates February 1990;
Better estimates April
1990.
China
UNDP/Finland
Preliminary report April
1990; Final November,
1990.
Venezuela
None
Preliminary cost
estimates April 1990.
Kenya
Sweden & Norway
Not yet begun;
Preliminary report June
1990.
Malaysia
Canada
Not yet begun;
Preliminary report June
1990.
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EPA WORKSHOP:
Integrating Case Studies Carried
Out Under the Montreal Protocol
January 15-17, 1989
J.W. Marriott at National Place
1331 Pennsylvania Ave.
Washington, D.C. 20004
(202) 393-2000
Final Agenda
JANUARY 15
8:00-9:00am
9:00-9:30am
9:30-10:00am
10:OOam-12:00pm
Workshop Check-in and Coffee
Welcome and Introductions
— Eileen Claussen, Director, Office of
Atmospheric and Indoor Air Programs, EPA
Proposal for a Unified Approach
— Stephen Andersen, Chief, Economics
and Technology Branch, EPA
Status of Ongoing Case Studies
— Alberto Carrizo, Gerente Divisao
Qualidade de Produto, Climax, White-
Westinghouse, Brazil
— Ahmed Amin Abrahim, Consultant to
Egyptian Environmental Affairs Agency
(EEAA), Egypt
— Sergio Reyes-Lujan, SEDUE
Undersecretary for Ecology, Mexico
— Zhang Chongxian, Division Chief,
Office for Foreign Affairs, China
12:00-2:00pm
Lunch
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January 15
2:00-5:00pm Open Discussion
Characterizing CFC and Halon Use
Applications (refrigeration, solvents,
foam, etc.)
Source (chemical imports, imported
products containing or made with
CFCs or halons)
Company/facility
Estimating Future Demand
Historic growth rates or specific
estimation for end-use sectors
Special Circumstances of Developing Countries
Access to new technology
Industrial and development policy
Infrastructure and training
Technical expertise and research
facilities
6:00pm Presentation & Dinner
"Technology Transfer Projects by the
Industry Cooperative for Ozone Layer
Protection," Art FitzGerald
Dinner sponsored by the National
Institute for Emerging Technology (NIET)
Location: Hogates Restaurant
9th St. & Maine Ave. S.W.
Washington, D.C.
484-6300
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January 16
9:00am-12:00pm
12:00-2:00pm
2:00-5:30pm
7:00pm
Overview of UNEP Technical Assessment
— G. Victor Buxton, Chief, Chemical
Controls, Environment Canada
Best Existing Technology Presentations by
Technical Experts
— See Attachment A
Open Discussion
— Matching Best Technology to Existing
and Anticipated Uses
— Utilizing Technical Experts for
National Case Studies
Lunch
Preparation of guidance for case studies
Dinner
Location: Eileen Claussen's Home
4733 Fulton St. N.W.
Washington, D.C. 20007
Suggested Transportation - Taxi
January 17
9:00am —
Final drafting and editing of case study
outlines; end-use survey forms; demand
estimation methods; text and data files
Next steps (organization, operation &
cooperation)
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Technical Experts
FOAMS:
AEROSOLS:
SOLVENTS:
Jean Lupinacci, EPA, USA
Jorge Corona, Astral Internacional, Mexico
Montfort Johnsen, Consultant, USA
Bryan Baxter, British Aerospace, UK
Brian Ellis, Protonique S.A., Switzerland
Hans Lagerhorn, Brandtekniska Ingenjosbyron, Sweden
Gary Taylor, Taylor/Wagner Associates, Canada
REFRIGERATION & AC:
Lambert Kuijpers, Phillips, Netherlands
CHEMICAL ALTERNATIVES TO CFC & FACTORY RETROFITS
Nobuo Ishikawa, F & F Research Center, Japan
HALONS:
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ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
Australia
Canada
Canada
Canada
Canada
David Roberts
International Development Assistance
Bureau
GPO Box 887
Canberra ACT 2601
G. Victor Buxton
Environment Canada
351 St. Josephs Blvd.
Ottawa, Ontario
Canada KlA OH3
Ann Corwln-Cossette
Canadian Embassy
501 Pennsylvania Avenue, NW
Washington, DC 20001
Rebecca Mllo
Environment Canada
22nd Floor
Terrasses de la Chaudlere
Ottawa, Ontario
Canada KlA OH3
Julie Vandershot
Environment Canada
10 Wellington St.
Hull, Quebec
Canada KlA OH3
062-764658
819-953-1675
202-682-1740
819-953-9000
819-953-8999
062-487521
819-997-0547
202-682-7792
819-953-5975
819-953-5975
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ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
Canada
EEC
FRG
Japan
Norway
Sweden
Robert Weir
Canadian Development Agency
200 Promenade du Portage
Hull, Quebec
Canada K1A OG4
Heinz Hilbrecht
Energy/Environment/Transport
Commission of the European Community
2100 M St., NW 7th Floor
Washington, DC 20037
Jurgen Lottmann
Kreditantstalt fur Wiederaufbau
Palmengartenstrabe 5-9
D-6000 Frankfurt am Main
Yasu-hiro Shimizu
Environmental Attache, Embassy of Japan
2520 Massachusetts Ave, NW
Washington, DC 20008
Eli Vike
State Pollution Control Authority
P.O. Box 8100 DEP N-0032
Oslo 1. Norway
Ingrid Kokeritz
Swedish Environmental Board
Smidasvajen #5
17125 Solna Sweden
819-997-6731
202-862-9578
069-7431-3142
202-939-6725
47-2-659810
468-799-1565
819-953-4676
202-429-1766
069-7431-2944
202-939-6788
47-2-658890
468-799-1253
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ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
Sweden
USA
USA
USA
USA
Tom Hedlund
Swedish Environmental Board
Smidesvagen #5
Box 1302
S-171 25 SOLNA, Sweden
Eileen Claussen
Environmental Protection Agency
Office and Air and Radiation
401 M St. SW
Washington, DC 20460
Stephen Seidel
Environmental Protection Agency
Office of Air and Radiation
401 M St., SW
Washington, DC 20460
Stephen 0. Andersen
Environmental Protection Agency
Office of Air and Radiation
401 M St. SW
Washington, DC 20460
Jean Lupinacci
Environmental Protection Agency
Office of Air and Radiation
401 M St. SW
Washington, DC 20460
358-8799-1137
202-382-7407
202-382-2787
202-475-9403
202-475-8468
(Telex #)
11131 Environ S
202-382-6344
202-382-6344
202-382-6344
202-382-6344
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ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
USA
USA
Denise Mauzerall
Environmental Protection Agency
Office of Air and Radiation
401 M St, SW
Washington, DC 20460
William Rhodes
Environmental Protection Agency
AEERL
MD 62B
Research Triangle Park
North Carolina 27711
202-245-3554
919-541-2853
202-382-6344
919-541-7885
INTERNATIONAL ORGANIZATIONS:
UNDP
The World Bank
Erik Helland-Hausen
UNDP/BPPE/TAD
One UN Plaza
New York, NY 10017
Peter Bohm
1818 H St. NW
Room S-5125
Washington, DC 20433
212-906-5057
202-473-3426
212-906-5365
202-477-0565
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ATTACHMENT 2: DEVELOPING COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
Brazil
Brazil
Brazil
Brazil
Monica Moraes
Brazilian Environmental Agency
SAIN - QL 4
IBAMA
Brasilia - D.F. 70.000
Brazil
Regina Helena Costa
Brazilian Environmental Agency
SAIN - QL 4
IBAMA
Brasilia - D.F. 70.000
Brazil
Santiago Mourao
Brazilian Embassy
3006 Massachusetts Ave, NW
Washington, DC 20008
Alberto Carrizo
White Westinghouse, representing the
Brazilian Industry
Av. Jose Pereira Lopes, 250 - 13560
Sao Carlos - SP
Brazil
061-274-6850
061-321-2324
202-745-2766
162-711235
In Care of:
Karla Amorin
5561-224-5206
In Care of:
Karla Amorin
5561-224-5206
202-745-2827
162-725768
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ATTACHMENT 2: DEVELOPING COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
Brazil
China
Egypt
India
Paulo Vieira
DuPont do Brazil, representing the
Brazilian Industry
Al. Itapecuru, 506 Alphaville
CEP 06400 - C.P.26
Baruerl - SP
Brazil
Zhang Chongxian
Senior Engineer, National Environmental
Protection Agency of China
No. 115, Xizhimennei
Nanxiaoj ie
Beijing, China
Ahmed Ibrahim
Consultant, Egyptian Environment
Affairs Agency
80 Ahmed El-Sayat St.
Dokki, Egypt
Avani Vaish
Director, Ministry of Environment
& Forest
Paryavaran Bhavan C.G.O. Complex
Lodi Road
New Delhi 110003
55-11-421-8005
861-6011193
202-701655
362840
55-11-4214051
861-653681
202-342-0768
(Telex #)
3166185 DOE IN
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ATTACHMENT 2: DEVELOPING COUNTRY REPRESENTATIVES
COUNTRY
NAME
TELEPHONE
FAX NO.
Malaysia
Mexico
Singapore
Venezuela
Venezuela
Tan Meng Leng
Dept of Environment
12th Floor Wisma Some Darby
50662 Kuala Lumpur
Sergio Reyes-LujAn
Undersecretary for Ecology, SEDUE
Rio Elba No. 20 PISO 16
Col. Cuaahtemoc
06500 MEXICO, D.F.
Lim Choon Slew
Institute of Standards & Industrial
Research
1 Science Park Drive
Singapore 0511
Carmelina de Lombard
Ministry of Environment
COVENIN
Avenida Andres Bello
Torre Fonde Comun, Piso 11
Caracas, Venezuela 51116-1050A
Milagros Diaz
Ministry of Environment
COVENIN
Avenida Andres Bello
Torre Fonde Comun, Piso 12
Caracas, Venezuela 51116-1050A
603-293-8955
603-293-6006
905-553-9538
905-271-3205
65-772-9568
65-778-3798
58 2-408-1497
In Care of:
Jean Preston
582-285-0336
58 2-575-2298
In Care of:
Jean Preston
582-285-0336
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ATTACHMENT 3. TECHNOLOGY EXPERT PARTICIPANTS
TECHNOLOGY
COUNTRY
NAME
TELEPHONE
AEROSOLS
Mexico
AEROSOLS
USA
FOAMS
USA
HALONS
Canada
Jorge Corona
Director General
Astral Internacional
Mar Negro No. 99
Col. Popotla
11410 MEXICO, D.F.
Montfort Johnsen
President
Montfort A. Johnsen & Associates
26 Sheral Drive
Danville, IL 61832-1354
Jean Lupinacci
Technology & Economics Branch
Global Change Division, U.S. EPA
401 M St, NW
Washington, DC 20460
Gary Taylor
Consultant
Taylor/Wagner Incorporated
177 Maxome Ave
Wi1lowdale, Ontar io-Canada
M2M 3L1
905-399-9130
217-442-1400
202-475-8468
416-222-9715
HALONS
Sweden
Hans Lagerhorn
Skandia Insurance Co.
S - 103 50 Stockholm
468-7881436
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ATTACHMENT 3. TECHNOLOGY EXPERT PARTICIPANTS
TECHNOLOGY
COUNTRY
NAME
TELEPHONE
HALONS
USA
REFRIGERATION &
AIR CONDITIONING
Netherlands
CFG ALTERNATIVES
Japan
SOLVENTS
Canada
Tom Morehouse
Project Manager
Air Force Engineering & Service Center
HQ USAF/LEEL
Pentagon
Washington, DC 20330-5124
Lambert Kuijpers
Project Leader
Phillips Research Laboratories
Building WAp.6.20
PO Box 80000
5600 JA Eindhoven
Nobuo Ishikawa
Director
F & F Research Center
2-9-3, Akasaka
Minato-ku, Tokyo 107
A.D. FitzGerald
Director, Environmental Affairs
Northern Telecom Limited
3 Robert Speck Parkway
Mississauga, Ontario
Canada L42 3C8
904-283-6194
3140-742860
03-5828896
416-566-3048
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ATTACHMENT 3. TECHNOLOGY EXPERT PARTICIPANTS
TECHNOLOGY
COUNTRY
NAME
TELEPHONE
SOLVENTS
Japan
SOLVENTS
Switzerland
SOLVENTS
USA
SOLVENTS
UK
Shigeo Matsui
Environmental Protection Group
Toshiba Corporation
1, Komukai Toshiba-Cho
Saiwai-Ku, Kawasaki, 210
Brian Ellis
General Director
Protonique, S.A.
PO Box 78
CH-1032 Romanel
Sudhakar Kesavan
Vice President
ICF Incorporated
409 12th St. SW
Washington, DC 20024
Bryan Baxter
Chief Materials Scientist
British Aerospace
Six Hills Way
Stevenage
Herts, United Kingdom SGI 2DA
044-549-2293
412-1382334
703-934-3052
438-753222
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PRESENTATIONS
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PROPOSAL FOR A UNIFIED APPROACH
Stephen O. Andersen
Chief, Technology and Economics Branch
Office of Air and Radiation
U.S. Environmental Protection Agency
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Brazil, Egypt and Mexico Case Studies
Managed by national environment agency
Participation by other important agencies
Strong cooperation with national industry
Developing and developed country experts
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National Experts
Excellent technical skills
Experience in adapting technology to
local conditions
Better able to improvise and fabricate
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Developing Countries as
Sources of Technology
On-site fabrication of hydrocarbon
aerosol factories
Open-air aerosol filling stations
Ammonia refrigeration
CFC-12/HCFC-22 swing plants
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Advantages of Cooperation
on Case Studies
Assure comparable methods and
presentation
Investigate all special needs
Discover innovative technical solutions
Identify model institutions
Share best technical experts
Organize for technology transfer
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Comparable Existing and Future Use
Same scope and outline
Same chemical coverage: CFC, Halon,
MC, carbon tetrachloride
Same basic tables and figures
Same units of measure
Same demand estimation
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GLOBAL ENVIRONMENTAL PROBLEMS
POLICY IN MEXICO
Mr. Sergio Reyes-Lujan
Undersecretary for Ecology
Secretaria de Ecologia y Desarrollo Urbano
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(MICA NO. 1)
GLOBAL ENVIRONMENTAL PROBLEMS
POLICY IN MEXICO
PRESENTED BY:
MR. SERGIO REYES LUJAN
UNDERSECRETARY FOR ECOLOGY
1
SECRETARIAT FOR URBAN DEVELOPMENT AND ECOLOGY (SEDUE)
Washington, D.C.
January 15, 1990
1
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I
(MICA NO. 2)
OUTLINE
I. INTRODUCTION
II. IMPLEMENTED MEASURES TO REDUCE THE USE OF OZONE DEPLETING
SUBSTANCES
A. VOLUNTARY AGREEMENTS WITH THE MEXICAN INDUSTRY
B. STATUS OF JOINT SEDUE/ INDUSTRY/EPA CASE STUDY
III. ACHIEVED AND PROJECTED RESULTS
A. FOAMS
B. AEROSOLS
C. HALONS
IV. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS
V. MEASURES TO BE IMPLEMENTED TO ADDRESS GLOBAL WARMING
VI. CONCLUSIONS
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I. INTRODUCTION
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Protocol's meetings. Mexico was the first country in ratifying
the Protoco1.
II. IMPLEMENTED MEASURES TO REDUCE OZONE-DEPLETING SUBSTANCE USE
A. VOLUNTARY AGREEMENTS WITH THE MEXICAN INDUSTRY TO
REDUCE CFC AND HALON USE
(MICA NO. 4)
As a result of the commitment associated with the
ratification of the Montreal Protocol, the Mexican Government
proceeded to implement measures that will yield significant near-
term reductions in the consumption of ozone depleting substances.
The Secretariat for Urban Development and Ecology negotiated and
signed nine agreements with industry which control the
consumption of CFCs and halons. The CFC producers and halon
distributors, and representatives of industries that use CFCs in
Mexico voluntarily agreed to the same reduction measures and,
therefore, the SEDUE/Industry agreements control ozone-depleting
substances in upstream and downstream markets.
(MICA NO. 5)
In the area of polyurethane foams, the two CFC producers in
Mexico have committed to eliminate all of the distribution of
CFCs for flexible polyurethane foam manufacturing by 1990.
Flexible foam manufacturers that use the CFCs have agreed to
undertake this reduction. These industry groups have also
indicated their commitment to keep users updated with the latest
information on the development of CFC substitutes for rigid
-------
poly.tr ethane foams so that these substitutes are adopted in the
f uture. The signatories of these a>yreement s a. 1 so p r omi = eri to
facilitate technology transfer.
Only 1(3% of all aerosol cans manufactured in .19S3 in rleNico
contained CFCs. Based on 1988 CFG consumption in aerosols, the
suppliers of CFCs as well as aerosol manufacturers represented by
CANACINTRA (the National Chamber of Industries — the major
Mexican association of manufacturing industries), the Mexican
Aerosol Institute, and the Chamber of the Perfume and Cosmetics
Industry, agreed to reduce CFC use by 50% in 1989 and to
eliminate the remaining 50% by 1990. Mexico considers that the
relatively small use of CFCs in medicinal, electronic, and
aircraft maintenance aerosols is essential and therefore has been
exempted from reductions due to the lack of adequate substitutes
for these uses. The signatories will also recommend the
labelling of ozone-safe aerosols.
Mexico imports halons through three major companies. These
ha Ion distributors have agreed to provide users with information
on conservation measures and recycling technologies and committed
efforts to maintain users updated on important events regarding
the development of alternative fire extinguishing agents.
Finally, the National Board of In-Bond Industries, a group
of export-oriented industries neighboring the U.S. border —also
known as Maquiladoras— has also signed an agreement with 3EDUE
that covers a broad scope of environmental initiatives. Among
them, the Board has committed to promote the control of
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contaminant emissions to meet official standards. Specifically,
the National Board of In-Bond Industries will promote the
reduction of ozone-depleting substance use to the maximum extent
feasible.
B. STATUS OF JOINT SEDUE/INDUSTRY/EPA CASE STUDY
(MICA NO. 6)
1. Background
The United States and Mexico have a long history of
successful environmental cooperation as proven by the various
consultations conducted since the initial international efforts
to protect the stratospheric ozone layer. Recent SEDUE
initiatives and the December visit to Mexico of the EPA expert
team headed by Dr. Stephen Andersen of the Global Change Division
consolidated our cooperative efforts and resulted in an agreement
to conduct a joint study in which SEDUE, the Mexican industry,
and the EPA are participating.
The case study will provide, first, an analysis of
current and projected future demand of CFCs and halons given
Mexican industry trends. The study will also provide a review of
the use of methyl chloroform and carbon tetrachloride in Mexico
in light of the current international concern regarding the ozone
<
depletion potential of these compounds not currently regulated by
the Montreal Protocol. Second, the case study will describe the
industries that use CFCs and halons and the technology used in
these industries, and, third, the analysis will evaluate the
costs of reducing CFC and halon use to comply with the Montreal
-------
Protocol. Hence, the study will present the net cost*
aridcSSSSsfaEEB^sr the f inane ing needs of our- country to comply with
the Protoco 1.
The case study currently underway will be an extreme 1y
helpful source of information for- current and potential parties
to the Montreal Protocol not only because of the economic
assessment but also because it will list alternative technologies
appropriate to developing country circumstances.
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manufacturing technology of the user industries to assess the
extent of the modifications required to adopt alternative
technologies. Finally, the project team will estimate and
evaluate the costs associated with the alternate technologies in
each end use and will generate aggregate cost estimates.
III. ACHIEVED AND PROJECTED RESULTS
As stated earlier, SEDUE successfully negotiated nine
industry agreements to reduce the production and emissions of
ozone depleting substances in Mexico. Beginning discussions in
1987, these voluntary agreements were signed on November 9, 1989
and include: two agreements with companies that produce CFCs and
distribute haIons, and seven agreements with industries that
represent users of these substances.
These efforts lead to the following current and projected
results:
(MICA NO. 3)
1. The consumption of C-FC-11 and CFC-12 as foam blowing
agents and aerosol propellants dropped by 13.1% in 1939
with respect to 1987 levels. By 1991, we expect to
achieve a 31.7 percent reduction with respect to 1937
consumpti on.
(MICA 9>
2. This reduction is primarily due to the sharp decrease
planned in the consumption of CFC-12 as blowing agent.
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This past year an annual deer-ease- of 75% was achieved
in this area arid further reduction are expected, as
shown in the transparency.
(MICA 10)
3. Industry reports that the consumption of CFC-11 as
blowing agent is likely to grow by 10 percent given
current trends in the foam industry. However, growth
in this area will be more than offset by the impressive
decrease in the consumption of CFC-11 and CFC-12 as
aerosol propel 1ants.
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CMICA 14)
7. In the ha Ion area, approximately 50 % of ha Ion
emissions are avoidable. This emissions will be
controlled through a number of conservation measures
which include limiting releases during testing and
demonstration procedures. By the year 2000, we expect
that ha Ion emissions will represent only 56% of 1989
emi ssions.
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IV. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS
(MICA 17)
Although Mexico is a developing country it can be a source
of some new and adapted technologies to protect the ozone layer.
Mexico has highly skilled and inventive engineers who have
adapted and developed technology to local conditions, such as
climate, and to be flexible as market changes occur.
For example, as Mr. Jorge Corona will explain, our aerosol
industry has simplified the technology to fill aerosols and,
overall the Mexican design approach is cost-effective and safe.
The know-how for- adapting or designing new technology is
available in Mexico. These technologies may be applicable to
other developing countries interested in protecting the ozone
layer.
11
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V. MEASURES TO BE IMPLEMENTED TO ADDRESS GLOBAL WARMING
(MICA NO. IS)
The combustion of fossil fuels is One of the largest sources
of pollutant emissions that contribute to the problems of global
warming and ozone depletion. -Mexico is aware of this problem and
will promote through institutions and organizations involved in
this area the- implementation of a program to preserve and improve
the efficiency of fossil fuel utilization.
The program will also control the emissions of methane from
landfills and will promote research in the use and development of
alternative fuels.
The rational use of water- through the legal reevaluation of
the technical and economic components of water supply management
are very important for- Mexico, as well as the implementation of
efficient techniques for water use.
The use and consumption of energy in Mexico requires the
guidance of a program to increase the efficiency of energy
production and use, foster- the development of alternative energy
systems to those based on fossil fuels, or addresses a
restructuring of oil prices. There is also a need to accelerate
the replacement of old machinery with new energy efficient
i
techno logy.
Other measures to address air pollution that should be
encouraged include tree planting, reforestation, and new
agricultural technologies for the production of rice, meat, arid
mi Ik.
12
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(MICA NO. 19)
VI. CONCLUSIONS
THE: PROTECTION OF THE OZONE LAYER
POSSIBILITY OJF "FAIR" SHARES OF
COMPOUND USE. ""ALTHOUGH MOST OF THE
ATMOSPHERE IS DUE TO EMISSIONS
RULES OUT THE
OZONE DEPLETING
CHLORINE IN THE
FROM DEVELOPED
COUNTRIES. DEVELOPING COUNTRIES MUST ALSO STOP THEIR
PRODUCTION AND CONSUMPTION OF THESE SUBSTANCES.
IT IS NECESSARY TO TIGHTEN THE IMPLEMENTED MEASURES TO
REDUCE OZONE DEPLETING COMPOUND EMISSIONS AND TO TAKE
ALL NECESSARY ACTIONS TO ACHIEVE THE REDUCTIONS NEEDED.
THE CASE STUDY UNDERWAY IN MEXICO WILL EVALUATE THE
PRESENT AND FUTURE DEMAND OF OZONE DEPLETING SUBSTANCES
AND THE ECONOMIC: NEEDS ASSOCIATED WITH THE
IMPLEMENTATION OF THE MONTREAL PROTOCOL. THE STUDY WILL
ALSO PROVIDE USEFUL INFORMATION ON NEW TECHNOLOGIES AND
APPROACHES USED IN MEXICO.
4. MEXICO'S TECHNICAL KNOW-HOW
DEVELOPING COUNTRIES.
MAY BE USEFUL TO OTHER
MEXICO IS CONSIDERING TO ALLOW MANUFACTURING OF CFCs
FOR MEDICAL AND OTHER USES FOR WHICH NO SUBSTITUTES ARE
CURRENTLY AVAILABLE.
fr. THE MEXICAN GOVERNMENT PLACES HIGH PRIORITY
ENERGY CONSERVATION PROGRAM FOR MEXICO.
IN AN
7. TO ATTAIN SUSTAINABLE DEVELOPMENT THERE IS A NEED TO
REDUCE POLLUTANT EMISSIONS FROM MAJOR CITIES AND
PROMOTE COST EFFECTIVE AND EFFICIENT ENERGY SOURCES AND
TECHNOLOGIES.
13
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THE VIENNA CONVENTION AND THE MONTREAL PROTOCOL
REPRESENT A PATTERN THAT CAN BE USED FOR A WORLDWIDE
CONVENTION ON GLOBAL CLIMATE CHANGE.
14
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s eouE
GLOBAL ENUIRONMENTAL PROBLEMS
POLICV IN MEXICO
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I C ¥ IN Mt£XICO
I . INTRODUCTION
II. IMPLEMENTED MEASURES TO REDUCE THE USE OF OZONE DEPLETING
SUBSTANCES
MOMKKHKMT8 MITH TUBE MKXICAM XMOU&TMV
0V
III. ACMIKVED AND PROJECTED RESULTS
A . VOMM8
»- AKMOSOX.8
C. MAE-OM8
IU. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS
V. MEASURES TO BE IMPLEMENTED TO ADRESS GLOBAL UARNIMG
UI . CONCLUSIONS
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INTRODUCTION
THE MONTREAL PROTOCOL IS THE FIRST GLOBAL AGREEMENT TO ADDRESS A CRITICAL
ENUIRONHENTAL PROBLEM OF OUR TINE
MEXICO HAS ACTIUELV PARTICIPATED IN THE INTERNATIONAL EFFORTS TO PROTECT
THE OZONE LAYER
MEXICO UAS THE FIRST COUNTRY TO RATIFY THE MONTREAL PROTOCOL DUE TO CLOSE
COLLABORATION BETUEEN THE GOUERNHfMT AND INDUSTRY
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SEDUE/INDUSTRV/EPA' S CASE STUDV
ANALYZES THE PRESENT AND POTENTIAL CONSUMPTION IN MEXICO
OF CFC&, HALONS AND OTHER OZONE DEPLETING SUBSTANCES
ANALYZES THE SPECIFIC APPLICATIONS AND USES OF THESE
SUBSTANCES IN THE MEXICAN INDUSTRY
THE OPTIONS TO REDUCE THE CONSUMPTION OF THESE
SUBSTANCES AND THEIR IMPLEMENTATION COST
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SEDUjE/INDUSTRV/EPA STUDV GROUP
DIRECTION
SEDUE
GENERAL COORDINATION
MINISTRY OF FOREIGN AFFAIRS
INDUSTRIAL COORDINATION NATIONAL CHAMBER OF INDUSTRIES
DATA MANAGEMENT
SEDUE
TECHNICAL ADUISER
EPA
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EPA' s STUDV GROUP
<1> COLLECTION OF EXISTING DATA ON CONSUMPTION AND DRAFT
DESCRIPTION OF THE INDUSTRIES THAT USE OZONE DEPLETING
SUBSTANCES
(2) DATA COLLECTION ON THE PRODUCTION TECHNOLOGY EMPLOYED
IN SPECIFIC INDUSTRIES USING SUCH SUBSTANCES
C3> ASSESSMENT AND COSTING OF ALTERNATIVE TECHNOLOGIES
ADEQUATE TO THE DOMESTIC CHARACTERISTICS OF EACH INDUSTRY
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THE SEDUE/INDUSTRY AGREEMENTS CONTROL OZONE DEPLETING SUBSTANCES
UPSTREAM AND DOWNSTREAM
Nine Sedue/lndustry
CFC Produces and • *\> ^X1 , End Use Industries
Halon Distrlsbutors ' \^
Voluntary Agreements
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VOLUNTARY AGREEMENTS WITH THE MEXICAN INDUSTRY TO REDUCE CFC AND HALON USE
EndUse
Polyurethane
Foams
Aerosol
Products
Agreement Signatories
DuPont
Quimobasics
Mexican Polyurethane Institute
Dupont ' - *
Quimobasicos
National Chamber of Industries
Mexican Aerosol Institute
Chamber of Perfume and
Cosmetics Industry
Nature of Organization
CFC Producer
CFC Producer
Industry Association
CFC Producer
CFC Producer
Main Association of all
Manufacturing Industries
Industry Association
Industry Association
Measures
• Reduce CFC distribution and use by 100%
by 1990 in flexible foams
• Update information on development of CFC
substitutes for adoption in rigid foam systems
. Facilitate technology transfer
In 10% of all aerosols units still containing
CFCS in 1988:
. Cut CFC use by 50% in 1989
. Cut remaining 50% by 1990
• Medicinals, electronic cleaners, and aircraft
insecticides and deororants are exempt
. Recommend labelling of ozone-safe aerosols
Halons
Miscellaneous
DuPont
CAISA
ICI
National Board of In Bond
(Maquiladora) Industries
Halon Importer/Distributor
Halon Importer/Distributor
Halon Importer/Distributor
Association of Export
Industries Neighboring
the US. Border
• Provide users with information on halon
conservation measures
. Update users on development of alternatives
Promote the reduction of ozone depleting
substance use and emissions
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MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
REDUCTION IN THE USE OF GFC'S AS BLOWING AGENTS AND PROPELLANTS
CFC-ll AND CFC 12
4OOO
YEAR 1987 1988 1989 1990 1991
HISTORICAL AND PROJECTED CONSUMPTION
%Dt.CRtASE IN USE DURING
PERIOD
% DECREASE
PERIOD
1987-1988 8.6
19871989 13.1
1987 199O 26.3
1987-1991 31.7
i CONSUMPTION
•*OU«QJ::CFC PRODUCERS
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MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
REDUCTION IN USE OF CFC-12 AS BLOWING AGENT
CFC-12 AS BLOWING AGENT
70O
CO
I
o
-------
f\
seoue
MEXICAN PROGRAM TO COMPLY WITH MONTREAL PROTOCOL
USE OF CFC-I i AS BLOWING AGENT
CFC-II AS BLOWING AGENT
2000
mm
HI!
ANNUAL % CHANGI.
YEAR % CHANGE
1988 - 0.8
1989 +20.9
1990 4 10.0
1991 +10.0
fx-;.: DOME STIC CONSUMPTION
S&: AND EXPORTS
YL~R 1987 1988 . 1989 1990 1991
HISTORICAL AND PROJECTED CONSUMPTION
SOURCE :CKC PRODUCERS
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Exhibit 2
1986 PRODUCTION OF HALONS AND CFCs
Weighted By ODP
CFCs
Halons
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HALONS: ADVANTAGES AND DISADVANTAGES
Halons Work Group
I. Advantages of Halons
• Low Toxicity for Humans
• Non-Damaging to Electronics
• Low Space and Weight Requirements
• Highly Effective Fire Suppressant
• Low Installed Cost
• System Efficiency
II. Disadvantages of Halons
High Ozone Depletion Potential (OOP)
Upper Bound is 30 OOP
Average Estimate is 10.6 ODP
• Greenhouse Warming Potential
• High (and increasing) Relative Costs
$150 - $200 per square meter for Halon Systems
$10 - $15 per square meter for Water Sprinkler Systems
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III. Halon Production Levels and Relative ODFs
• In 1986, Halons accounted for only 2.5% of total CFG production by
weight. CFC-11, -12, -113, -114, and -115 accounted for 97.5% of
production by weight.
• In the same year, however, Halons accounted for 12.9% of total
production when compound contributions are weighted by ODP. CFCs
accounted for 87.1%.
• The breakdown of Halon production for that year was as follows:
Halon 1211 - 56%
Halon 1301 - 40%
Halon 2402 - 4%
• Quantities of Halon banked around the world are estimated as:
11,200,000 tonnes of Halon 1211
7,000,000 tonnes of Halon 1301
650,000 tonnes of Halon 2402
• Stockpiling is now in progress because:
DuPont will cease production in 1999.
Companies plan to inventory enough Halon for systems
operation until 2050.
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HALONS:
ADVANTAGES AND DISADVANTAGES
Halons Work Group
-------
O
O
rx
22
CHs-CCUF
153
137
H7
\oi
203
32
s-/
ODP
o.oZ
o. t
0.05-
CLP
o.
o.f>2
o.of
o-/
0.35"
o. o2
O.I
o.l
0.37
CT
hCF
CHsCCb
'77
'7V
I.I
/. o
0. /
Chlori
ne
-------
- 113-
\\I3'
2«
N
ff* '" . f
' j
/
S-.
Y
tW'-th
P/ T^^
O I ] ' •;
Co
-------
v\
ffyZ
ft-
32
(A
u.. o
CHF.-CHF2
o
i i
12-0
\02
u
1 70
-27
-25"
-17
f
Co.
(°.o3)t
-------
HALOGENOCARBONS WIDELY- USED IN INDUSTRY
^•1
Code
CFC-11*
CFC-12*
CFC-113*
CFC-114*
CFC-115^J
HCFC-22
halon" 1301* 1
halon 1211* j
1
halon 2402* J
CT2)
MCF31 '
| Formula
CC13F
CC12F2
CC12F-CC1F2
CC1F2-CC1F2
CC1F2-CF3
CHC1F2
CF3Br
CF2CI3r
CF2BrCF2Br
ecu
CH3-CC13
b. P. °C
24
-30
48
4
-39
-41
-58
-4
47
.77
74
Life/y
60
120
90
200
400
15
50
6.3
OOP11
1.0*
1.0*
0.8*
1.0*
0. 6*
0.05
10.0*
3.0-
6. 0*
I . '
0. 13
GWP:' •
1.0
3. 1
1. 4
3.9
7.5
0.35
0.25
0.024
Main us
Foaming
Cooling
Cleanin
. Blending
i
Blend ir=
Cooling
Fire ex4"
"ire e .< *
Fire e/
CFCs
Cleaning
* Production is reguraied by the Montreal Protocol.' .
'Ret: Synthesis Report!. UNEP/Ozl. Pro.WG. II (1)/4, Nov. 4.1989.
2)Carbon tetrachloride; 31 Methylchloroform or 1.1.1-Trichloroethan*
-------
_£
*
CHClf
P
l&^t.'c
61:
V
f 1
-------
hCF
I!
&H3-CG&
J
-wee.
-------
Characteristics of Pentafluoropropanol(5FP)
i .. .
Molecular Weight
Boiling Point [*C]
Specific gravity
Surface tension [dyne/cm]
Heat of vapourization [cal/g]
Solubility of II2O [%]
Flash Point [*C]
Ozone Depletion Potential
Green House Effect Potential
•>
Mu tagenicity
Fish bioaccumulation
Japanese TSCA
TSCA
E INECS
Acute oral t, QJL i c. i t v T. DRO |"m c / \f c ]
Inhalation toxicity LC50 [p p m]
di>i^<
150
^f^
1.509
^19^
63 A
(T3.4_^
none
0
<0.1
•^ — »« • -
none
none
2-3364
4 22-05-9
2070127
2,250
7,000(211)
^CFC^JJL>
187.5
4 7
1.561
1 8
3 4 . 4
0.01
none
0.8
0.3-0.8
none
none
2-95
76-13-1
2009361
4 3,000
87,000(611)
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CFCs AND HCFCs AS FEEDSTOCKS
Dr. Nubuo Ishikawa
Director, F & F Research Center
Japan
-------
CFC's & HCFC's
as Feedstocks
Nobuo ISHIKAWA
(Japan)
1/16/90, Washington, DC
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TABLE 1 (Continued)
SUMMARY OF TECHNICAL OPTIONS AVAILABLE FOR CFC REDUCTIONS
The actual amount of water substitution possible will vary geographically by 15-50 percent according to the choice of ran materials, initial
energy efficiency value of the insulation and energy efficiency standards. The following table illustrates the average reductions expected
worldwide:
Region CFC Consumption X Reduction Total
(Tonnes) (Tonnes)
M. America 9.400 15-30 1,410-2,820
W. Europe ' 9,900 50 4,950
Japan 4,700 15 705
Other 13,200 15-30 1.980-3,960
Total 37.200 9.045-12.435
The actual amount of water substitution will vary geographically by 15-50 percent according to the type of facers, polyurethane or
polyisocyanurate foam chemistry, energy efficiency, and combustibility requirements.
Region CFC Consumption ' X Reduction Total
(Tonnes) (Tonnes)
N. America 21.700 15 3,255
W. Europe/ 29,300 25-50 7,325-14,650
Other
total 51,000 10,580-17,905
c In polyurethane rigid packaging, rigid integral skin, and other miscellaneous polyurethane applications, it is technically possible to reduce
CFCs by 80 to 100 percent by 1993. For flexible integral skin foams, the level of CFC reductions worldwide is expected to be around 50 percent.
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TABLE 1
SUMMARY Of TECHNICAL OPTIONS AVAILABLE FOR CFC REDUCTIONS
Type of Foam
*
Tonnes of
CFC Used
(1986)
Possible Global
Near Term Options Reductions by 1993
Possible Global
Longer-Term Options Reductions After 1993
Polyurethanes:
Flexible Slabstock
Flexible Moulded
Rigid Insulation:
Appliance
laminate
Spray, Slabstock,
and Poured-in-
place
45,600
13,700
37,200
51,000
44,200
New polyol technology
Increased Foam
density/increase water
"AB" technology
CFC recovery
Methytene chloride
Product Substitutes
(Fibrefill. latex foam)
Mew polyol technology
Increased water/
increased densities
Increased water
substitution
Increased water
substitution
Product substitutes
(EPS, perlite,
fiberboard)
Increased water
substitution
Product substitutes
BO-100X
80-100X
SOX*'
(15-SOX)
2S&
(15-SOX)
15-50X
HCFC-Ulb
MCFC-141b
HCFC-123
HCFC-HIb
HCFC-123
Product
substitutes
Vacuum panel
insulation
HCFC-141b
HCFC-123
Product
substitutes
HCFC-141b
HCFC-123
Product
substitutes
0 20%
0 20%
Remaining CFC use
Remaining CFC use
Remaining CfC use
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TABLE 1 (Continued)
SUMMARY OF TECHNICAL OPTIONS AVAILABLE FOR CFC REDUCTIONS
Type of Foam
Integral Skin and
Hi see I laneous
Tonnes of
CFC Used
(1986)
17,700
Near Terra Options
Increased water
total water blowing
Possible Global
Reductions by 1993
50- 100XC/
Longer -Term Options
HCFC-Klb
HCFC-123
Possible Global
Reductions After
0-20%
1995
Sub-total Polyurethane
Phenolic
Extruded Polystyrene
Sheet
(209,400)
6,900
20,000
Extruded Polystyrene
Boards lock
Polyolefin
17,600
13,000
HCFC-22
Hydrocarbons
Methylene chloride
Air toading
Product Substitutes
Capture/recycle
Product substitutes
HCFC-22
Hydrocarbons
Blends of these two
alone and with other
atmospheric gases
Product substitutes
HCFC-22
HCFC-142b
Hydrocarbons
Blends of the above
Product Substitutes
HCFC-22
HCFC-H2b
Hydrocarbons
(butane)
Product Substitutes
SOX
100X
100X
100%
HCFC-Ulb
HCFC-123
HCFC-Ulb
HCFC-123
HCFC-124
HFC-125
HFC-134a
Modified
resins/
atmospheric
gases
HCFC-124
HFC-1348
HCFC-Klb
HCFC-123
HCFC-124
HFC-134a
Remaining CFC use
N/A
N/A
N/A
Total
266,900
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Longer term options for reducing CFC use in Foam Plastic Products
Longer term options Foam products for which option is appropriate
1 Insulation Cushioning Packaging Other
HCFC-141b ooo
HCFC-123 ooo
HCFC-124 o
HCFC-125 o
HCFC-134a o
Product substitutes o o o o
Vacuum panels o
Modified resins and o
atmos. gases
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GLOBAL PHASE OUT SCHEDULE FOR CFCS IN FOAM PLASTIC
Near Term (by 1993):
The foam plastics industry can reduce approximately 60
percent of 1986 CFC consumption with available substitutes:
increased and total water blowing (carbon dioxide blowing
agent), new polyol technologies, hydrocarbons, HCFC-22,
HCFC-142b, and others.
Polyurethane flexible foams, polyurethane packaging and
miscellaneous foams, extruded polystyrene packaging foams,
extruded polystyrene insulation, and polyolefin foams have
announced CFC phase out by 1993.
Long Term (after 1993):
The foam plastics industry, principally polyurethane and
phenolic insulation foams, will depend upon the development
and acceptable use of HCFCs to achieve a complete phase out
of CFCs.
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"C Reductions in Foam Plastics Can Vary Significantly from
mntry to Country Depending Upon:
;e patterns- in Each country
Countries with large CFC consumption in flexible and
packaging foams have opportunity for largest and
quickest reductions:
Water blown foams
Increased foam density
New polyol technology
HCFC-22
Product substitutes
Countries with large CFC consumption in polyurethar.e
insulation foams for appliances, buildings and pipes
face greatest challenge for substitutes:
Increased water blowing for immediate reduction:
in CFC consumption.
HCFC-141b and HCFC-123 most promising longer te:
substitute.
Energy efficiency is important criteria in
substitute selection.
-------
Near term options for reducing CFC use in Foam Plastic Products
Near term options Foam products for which option is appropriate
Insulation Cushioning Packaging Other
*
New polyol technology o
Increased foam density o
Increased water blowing o o o o
Total water blowing o
"AB" technology o
CFC recovery o
Methylene chloride o o
Product substitutes o o o o
Air loading o
HCFC-22 o o
Hydrocarbons o o o
Hydrocarbon/HCFC-22 blends o
HCFC-142b o o
-------
Global CFC Use in Foam Plastics
(by type of product)
Cushioning
22%
Packaging
12%
Insulation
58%
Source UNEP Foam Technical Options
-------
Figure 1
Types and Major Uses of CFC-Blown Foam
Polyurethane
Polyurethane
Phenolic
Polystyrene
Polypropylene
Polyethylene
Furniture Cushion*
Bidding
Carpet Underlies
Moulded
Seat Cushions
Moulded Furniture
Polyurethane
Poured
Packaging
Bunstock
Poured
Bulldlna 1 mutation
Refrigeration and
Building Insulation
Wall and Roof
Insulation
Polystyrene
Boardstock
Building Insulation
Building Insulation
Sheet
Stock Food Trays
Carry-Out Containers
Egg Cartons
Cushioning
Packaging
Protective
Packaging
Floatation Devices
Source: ICF Incorporated, 1989
-------
1986 Global CFC Use - by Application
(in metric tons)
Solvents
177,600
Other
77,700
Aerosols
299,700
Refrigeration
267,000
Foam Plastics
267,000
CFCUse86
-------
Global CFC Use in Foam Plastics
(in metric tons)
Polystyrene
37,600
(14%)
Polyolefin - 13,000
Phenolic - 6,900
(3%)
Polyurethane
209,400
(78%)
Source: UNEP Foam Technical Options
-------
IMPORTANT CONSIDERATIONS IN
EVALUATING SUBSTITUTES TO CFC
BLOWING AGENTS IN
FOAM PLASTIC PRODUCTS
Ms. Jean Lupinacci
Office of Air and Radiation
U.S. Environmental Protection Agency
-------
Important Considerations in Evaluating Substitutes
to CFC Blowing Agents in Foam Plastic Products
Prepared by:
Jean M. Lupinacci
Chairperson,
UNEP Foams Technical Options Committee
EPA WORKSHOP
Integrating Case Studies Carried
Out Under the Montreal Protocol
January 16, 1990
-------
REFRIGERATION APPLICATION AREAS
Refrigeration/Retail/Transport/Storage/AC-Chilling/Automotive
Refrigerators Retail/Trans. Storage AC-Chill. Automotive
Containment
Recycling
Reduced Charge
HCFC-22
Drop-ins (R-500)
Substitutes Existing
(ammonia, HC)
New Substitutes
+
++
o
+
o
+
o
++
0
+
-/•
+,
++ very interesting from reliability/environment point of view
+ interesting
o not applicable/marginal
not interesting
-------
Examples;
Recycling will be interesting from a point of view of cost-effectiveness, environmental
acceptability, etc.
However, recycling of refrigerant from disposed refrigerators may not be cost-effective,
but may be of high public interest (environmental consciousness).
Application of HCFC-22 in equipment can reduce the dependence on CFC-12 in a lot of
equipment (in case it uses CFC-12) at short notice.
Most of the developing countries have high CFC consumption shares in the retail/storage
sector. Mostly due to recharging of leaking systems and component failures/repair. High
reductions of consumption can be achieved by education of engineers and the creation
of good practice methods.
Reduction of charge may be applicable in smaller systems where piping is also used as
construction material. 10/20% reduction may be possible.
Ammonia technology should receive considerable attention and can provide substantial
saving in CFC-consumption.
New substitutes have to be applied in refrigerators, e.g., there is no reliable solution so
far (near future).
-------
ASSESSMENT OF
ALTERNATIVE SUBSTITUTES AND TECHNOLOGIES
IN REFRIGERATION
Dr. Lambert Kuijpers
Philips Research Laboratories
Netherlands
-------
UNEP - TECHNOLOGY ASSESSMENT
25% Refrigeration
25% Foams
25% Aerosols
Solvents
Miscellaneous
Global Values
Refrigeration varies over countries: 5-50 percent
Low percentage of refrigeration in developed countries which have:
• Low amount of CFC-solvents
• No automotive air conditioning
• Aerosols
1986/87 Values
FRG
Refrigeration <10%
10% Refrigerators
70% Retail/Storage, Transport
USA
Refrigeration =35%
4% Refrigerators
30% Storage, 20% large
units
PRO
Refrigeration 45%
10% Refrigerators
90% retail, storage, chilling
Automotive
40% Automotive
-------
The first application of this technique will be a batch pcb defluxing
machine which is currently being assembled this year. A diagram of the
principle of the system is shown in the figure. Simplified versions of the
technique can be used for dewatering as well as precision small parts
cleaning.
Because of the high cost of the p.f.h. and also because it has a high
global warming potential, the prototype cleaner is designed to be hermetically
sealed with zero solvent loss and its commercial viability will depend in
large measure on the success of this aspect of the design. The alcohol is the
"working solvent" for the system and can be made up automatically as flux or
other soil rich solvent is discarded to waste or recovery.
-------
SEALED LID
PUMP
REFRIGERATED
CONDENSER
VAPOUR BLANKET
COOLING COILS
SPRAY HEADS
CFC FREE DEFLUXING SYSTEM
-------
REPLACEMENT OF CFC-113 SOLVENT
Mr. Bryan Baxter
British Aerospace Precision Products Group
United Kingdom
-------
REPLACEMENT OF CFC-113 SOLVENT
Presented at the EPA Workshop: Integrating Case Studies
Carried Out Under the Montreal Protocol
January 15-17, 1990
B.H. Baxter, British Aerospace Dynamics Ltd.
It is an easy oversimplification to assume that the only industrial use
of CFC-113 is as the major solvent in the defluxing of soldered electronic
circuits and components. The risk of such an oversimplification is that it
can lead to the conclusion that the introduction of aqueous cleaning, no-clean
flux options and controlled atmosphere soldering techniques can virtually
eliminate the need for CFC-113. Unfortunately, whilst these factors apply to
certain uses of the solvent, particularly in the large volume commercial
electronics manufacturing industry, they fail to cover adequately many other
uses of 113.
In particular dewatering and drying accounts for a large part of CFC-113
production. In some industries, especially optics and small component
manufacture, up to 60 percent of 113 consumption is for this purpose. In
comparison with alternate techniques such as oven or air-knife drying, it
offers energy efficient "one shot" drying and produces spot free cool
components of particular value in the optics and medical prosthesis
industries.
The precision engineering industry also uses large amounts of 113,
especially in clean areas where its low odor, zero flammability and low
toxicity are essential and its chemical compatibility with reactive metals
such as beryllium is difficult to match using alternate solvents.
The defense electronics industry is also radically different from large
scale commercial manufacturing; a wide range of technologies often needs to be
processed in the same area, sometimes in relatively small batches. Unlike the
commercial sectors where circuits can be designed to meet cleaning techniques,
the defense equipment manufacturer is often called upon to produce components
for long-running contracts using long "frozen" drawings and plannings.
One alternative to CFC-113 which is effective as a defluxing agent, a
cleaner and a dewaterer, is 2-propanol or isopropanol. However, this solvent
suffers the considerable disadvantage of high flammability. At British
Aerospace we are developing a process jointly with two other companies in
which this flammability is completely suppressed by the use of a perfluoro
hydrocarbon. This solvent, although immiscible with the alcohol, vaporizes
with it form a vapor mixture which is completely non-flammable.
-------
HCC.CC&HCFC solvents
ARAFIUX\
HC +
derivs.
Hydrocarbon/surfactant + water Saponifier + water
Practical substitute methods for CFC solvent cleaning in electronics
© Protonique SA, 1989
-------
ELECTRONICS CLEANING IN DEVELOPING
COUNTRIES
Mr. Brian Ellis
General Director, Protonique, S.A.
Switzerland
-------
Some ideas concerning electronics cleaning in developing countries:
Assumptions: at present prices, a wave soldering machine + in-line CFC-113 machine for medium-large production of
medium professional quality (e.g. computer, telecomms etc.) costs $120,000 in capital and an index of 1 to run.
Following figures are very approximate average estimations, based on average European figures for capital costs of
middle-of-the-range equipment, solvent costs, salaries, social charges, rent, energy and other overheads.
Indices: lowest figure best, highest figure worst.
Process Capital Running Overall Ease Space Reliability Comments
type costs k$ costs costs of use index index
Index Index Index
CFC-113 solvent (reference)
OK for most professional usage
No-clean conventional rosin flux 20-50 .2-.3
No-clean low-solids flux 30-80 .5-.8
No-clean Inert-gas soldering >300 1-2
Water-sol, flux + water cleaning 150 .5-.7
Rosin flux + saponifier cleaning 150 .6-.8
Rosin flux -i- HC/surf. + water 350 2-3
Rosin flux + HC deriv. (alcohol) 400 .5-1
Rosin flux + HCFC, HCC, CC 120 .9-1
.1-.25 0.5 .6
.4-.8 3 .6
1.5-3 3 1.5-2
.7-1.1 1-1.2 1
.75-1.2 1-1.3 1
>2 2 2
>2 1.8 1.8
.95-1 1.1 1
^^•^••l^M^^^HMBHRHHBB^^^VMBMM^^HMBBHBH^BB^B^HMH^^^H^^V
3-5 Not OK for truly professional use
2-4 OK for some professional usage2
2-5? OK for some professional usage3'4
.8-2 OK for most professional usage1 '8
.9-2.5 OK for most professional usage1 >7>8
<1 ? OK for most professional usage3'4'5'6'7
1 -1.2? OK for most professional usage3'4'5'7
1.1 OK for most professional usage1 *6'7
1 Established method: technology & equipment easily available
2 Recent method: technology and equipment available
3 New method: technology still partially under development
4 Massive nitrogen installations required
5 Important fire and explosion precautions required
6 Major potential or real environmental problems
7 Potential operator health & safety problems
8 Overall quality is very process-dependent
© Protonique SA, 1990
-------
CONVENTIONAL TECHNOLOGY
• PROPELLANT •
FILLING
» STATION
REST OF AEROSOL PRODUCTION LINE
* - Leak detectors, alarms, & devices for shutting down gas supply
lines.
-------
COMPARATIVE CHARACTERISTICS OF ALTERNATIVE PROPELLANTS
(BASED ON CFCs AS STANDARD)
Cost
(Raw Material)
Hydrocarbon
CO2
N2
DME/HCFC-22 +
HCFCs +
Environmental Simplicity/
OOP GWP Flammability Toxicity Reliability
0 - + + + = =
0 + = (-)
0 0 = - (-)
? +/- = (-)/=
+ ?
-------
TECHNOLOGY ADAPTED TO MILD CLIMATE AREAS
PROPELLANT
FILLING LINE
(OPEN)
EXPLOSION-PROOF WALL
REST OF AEROSOL PRODUCTION LINE
-------
HYDROCARBON PROPELLANT CHARACTERISTICS
Propane/lsobutane (Different Blends)
DRY
Deordorlzed (Usually by Removing Sulphur Compounds, Aromatic and Non-Saturated
Hydrocarbons)
-------
EXAMPLE OF INFORMATION REQUIRED
FOR ADAPTING TECHNOLOGY TO LOCAL CIRCUMSTANCES
Present Plant Design
Pneumatic or Electric Instruments
Location (Distance to Inhabited and/or Industrial Areas)
Climate (Maximum and MinimiuM Temps; Humidity)
Prevalent Wind Direction
Present Layout
Propellant Storage Tanks (Design, Location)
Availability of Hydrocarbons
-------
ALTERNATE TECHNOLOGIES FOR CFCs USES IN AEROSOLS
1. Substitute Propellants
Hydrocarbons
CO2; N2; Other Compressed Gases
DME; DME/FCFC-22
HCFCs (142a; 152a)
2. Alternative Delivery Systems
. Pumps
. Pistons
. Mechanical Pressure Dispensers
Non-aerosol Alternatives (e.g., roll-on,
sticks, brushes...)
. Airless Sprayers (paints)
-------
DIFFERENCES IN PLANT DESIGN REQUIREMENTS
For Non-Flammable Propellents
For Flammable Propellants
No special explosion-proof equipment needed
. Special explosion-proof equipment
installations and instrumentation needed
. Sophisticated leak detection required
. Plant shut-up equipment
. Alarms
Escape routes
. Location (far from existing industries
and urban areas)
-------
CFCs AS PROPELLANTS
Advantages
. Stability
Inertness
. Compatibility
Non-reactive
Non-toxic
. Non-flammable
. Odorless
Proper Pressure Ranges
Disadvantages
Deplete Stratospheric Ozone Layer
High Global Warming Potential
Price
-------
I. INTRODUCTION
II. BEST COST-EFFECTIVE ALTERNATIVE TECHNOLOGIES FOR CFC USE IN AEROSOLS
A. Available Alternatives
B. Selection Criteria for Alternative Propellants
III. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS
A. Switch From CFCs to Hydrocarbons in Mexico
B. Cost Effective Open-Air Hydrocarbon Filling Platforms
IV. EXAMPLE OF INFORMATION REQUIRED BY TECHNICAL EXPERTS FOR ADAPTING
TECHNOLOGY TO LOCAL CIRCUMSTANCES
-------
(i.e., additional space and ventilation are available) the total
investment required to adapt plants to safely handle these
flammable propellants may be recovered in one or two years due to
raw material savings.
Selection criteria for Alternate Propellants
The selection criteria for alternative propellants include raw
material costs, ozone depletion potential (OOP), global warming
potential (GWP), flammability, toxicity, and simplicity/reliability
of use. Using CFCs as the basis for comparison, hydrocarbon
propellants, carbon dioxide, nitrogen, mixtures of DME/HCFC-22, and
HCFCs are ranked based on these criteria, as shown in slide 5.
Hydrocarbon propellants and the compressed gases are less expensive
than CFCs; however, hydrocarbons are flammable, and the technology
needed to effectively use compressed gases is more complex. The
newer options, DME/HCFC-22 mixtures and HCFCs, are more expensive
than CFCs have low ODPs and GWPs, may be flammable, and the current
filling technology may be adequate to use them effectively. Except
for HCFC-22, which has been used in the refrigeration industry for
a number of years, the toxicity of the HCFCs is under review.
Most of the modifications needed to switch from CFCs to
hydrocarbons are related to safety, that is, dealing with the
flammable products. This requires considerable additional
investment, depending on the plant circumstances.
III. Adapting Technology to Developing Country Needs
Switch from CFCs to Hydrocarbons in Mexico
Currently, only 12 percent of all aerosols produced in Mexico
contain CFCs. The Mexican aerosol industry has committed to
phaseout the use of CFCs by 1991 by signing a voluntary agreement
with the Mexican environmental agency, SEDUE. The agreement does
not apply to medicinal aerosols, electronic cleaners, and aircraft
aerosols, for which no substitutes are currently available. The
Mexican aerosol industry has reduced its CFC consumption and
switched to hydrocarbons by adapting conventional technology to
local circumstances.
When switching from non-flammable propellants to flammable
propellants (i.e., hydrocarbons), various plants design
requirements must be met. The plant needs special explosion-proof
equipment and instrumentation, sophisticated leak detection
systems, plant shut-up equipment, alarms, escape routes, and
finally, the plant must be located far from populated areas.
Cost Effective Open Air Filling Platforms
An example of how all of these new plant design requirements
can be adapted to local circumstances is the use of open air
filling platforms. In developed countries where winter conditions
are harsh leading to potential gas line freezing and clogging, it
-------
is common practice to construct filling areas (gas houses) in a
closed room with concrete walls. For safety reasons the room is
isolated from the rest of the aerosol filling line (see slide No.
7). The room is equipped with leak detectors, alarms, and devices
for shutting down gas supply lines in case excessive concentrations
of hydrocarbons accumulate. The cost associated with such gas
house construction design is high. Mexico, as many other
developing countries has relatively mild and uniform weather year-
round. Filling lines are positioned outside the plant building
with an explosion proof wall separating the filling line from the
rest of the aerosol production line (see slide No. 8) . The design
approach is inherently cheaper and with adequate ventilation
(either natural or from explosion-proof fans) the open air filling
platform is also safe. This design approach has been used in
Mexico for many years with no reported incidents to date.
This is only one example where developing country engineers
have used ingenuity and common sense to adapt conventional
technology to local circumstances.
IV. Example of Information Required by Technical Experts for
Adapting Technology to Local circumstances
Mexican technical experts welcome the opportunity to assist
other developing countries in eliminating the use of CFCs and
adapting aerosol plants to safely use hydrocarbon propellants. An
example of the information that these experts would require to
evaluate the specific circumstances of an aerosol plant include:
• present plant design,
• use of pneumatic or electric instruments,
• plant location (distance to populated and/or industrial
areas),
• climate (minimum and maximum temperatures, humidity)
• wind direction,
• present layout,
• design and location of propellant storage tanks, and
• availability of hydrocarbons.
-------
ADAPTING AEROSOL TECHNOLOGIES TO
DEVELOPING COUNTRY NEEDS
Mr. Jorge Corona
C&mara National de la Industria de la Transformacidn
Mexico
-------
ADAPTING AEROSOL TECHNOLOGY TO DEVELOPING COUNTRY NEEDS
Mr. Jorge Corona de la Vega, CANACINTRA, Mexico
I. Introduction
In the past Mexico followed the worldwide trend of developing
an aerosol industry based on CFCs as prope11ants. CFCs are still
the most suitable chemicals for propellant applications, due to a
number of technical advantages and no technical disadvantages.
However, CFCs have great environmental disadvantages, namely their
Ozone Depletion Potential.
When news came that CFCs had the potential of affecting world
ecosystems by depleting the stratospheric ozone layer, it became
clear that the efforts made to develop an aerosol industry in
Mexico were in serious jeopardy, and that something had to be done
immediately. Looking for a suitable substitute proved to be a
difficult task.
II. Best Cost-Effective Alternative Technologies for CFCs in
Aerosols
The alternative technologies that may be used to substitute
CFCs in aerosols can be classified into two groups: substitute
propellants and alternative delivery systems. A number of
materials may be used to replace CFC propellants including
hydrocarbons, compressed gases (e.g., carbon dioxide and nitrogen),
dimethylether (DME) and mixtures of DME with HCFC-22, and HCFCs
(e.g., HCFC-142b, HCFC-152a). The alternative delivery systems
replace the traditional metal container with pumps, pistons,
mechanical pressure dispensers, non-aerosol alternatives (e.g.,
roll-on, sticks, brushes, etc. for deodorants and personal
products) and airless sprayers (for paints.)
Not all these alternatives match the numerous advantages that
made CFCs the preferred propellants for aerosol applications
worldwide. CFCs are stable, inert, compatible, non-reactive, non-
toxic, non-flammable, odorless, and possess the pressure ranges
ideal for aerosol applications. Nevertheless, the globally
recognized disadvantages of CFCs are their high ozone depletion,
global warming potential, and high price.
Although some of the above technologies are adequate as
substitutes for CFCs in certain applications, the aerosol industry
in Mexico has opted to use of the most cost-effective technology:
hydrocarbon propellants. Hydrocarbon propellants include different
blends of propane and isobutane. For the effective use of
hydrocarbons as replacement for CFCs, the supply of these gases
must be free of moisture, sulphur compounds, aromatic, and
unsaturated hydrocarbons. In Mexico, hydrocarbons are five times
less expensive than CFCs, and in cases where plants are flexible
-------
There are continued pressures to completely phaseout CFCs from
the U.S. aerosol industry; however, some products such as the
Metered Dose Inhalant (MDI) products do not lend themselves to
substitution. If toxicological studies are positive, HFCs may be
feasible alternatives.
In addition to a total phaseout of CFCs, the U.S. aerosol
industry faces a number of environmental pressures associated with
other materials used in the industry. These include potential
restrictions on Volatile Organic Compounds in states such as
California and New Jersey, and the potential addition of methyl
chloroform to the list of regulated compounds under the Montreal
Protocol.
t >
L »
i _
-------
GLOBAL WARMING POTENTIAL (GWP) AND OZONE DEPLETION POTENTIAL (OOP) OF GASES
JANUARY-1990
NUMBERING
SYSTEM
(CC-10)
CFG- 11
CFC-12
CFG- 13
CFC-113
CFC-114
CFG- 115
HCFC-21
HCFC-22
HCFC-31
HCFC-123
HCFC-124
HFC- 125
HCFC-132b
HCFC-133a
HCFC-141b
HCFC-142b
HFC-134a
HFC-143a
HFC-152a
HFC- 161
(HCC-110)
(HCC-20)
—
—
—
—
—
GWP,
COMPARED
CHEMICAL IDENTIFICATION TO CFG- 11
CCli, Carbon Tetrachloride
CC13F
CC12F2
CC1F3
CC12F.CC1F2
CC1F2.CC1F2
CC1F2.CF3
CHC12F
CHC1F2
CH2C1F
CHC1F.CC1F2
CHF2.CC1F2
CHF2.CF3
CH2C1.CC1F2
CH2C1.CF3
CH3.CC12F
CH3.CC1F2
CH2F«CF3
CH3 • CF3
CH3 . CHF2
CH3.CH2F
CH3.CC13 1,1,1-Trichloroethane
CHC13 Chloroform*
C02
CH* Methane
CH3>CH3 Ethane
CH3.O.CH3 Dimethyl Ether*
N20 Nitrous Oxide
0.36
1.00
2.99
9.6
1.42
4.19
8.24
0.30
0.29
0.30
0.019
0.093
0.42
0.06
0.07
0.085
0.06
0.22
1.00
0.019
0.01
0.022
0.00
0.000097
0.0024
0.0065
0.00
0.0017
GWP,
COMPARED
TO CFC-12
0.12
0.34
1.00
3.20
0.48
1.42
2.80
0.10
0.10
0.10
0.0065
0.032
0.14
0.02
0.024
0.029
0.02
0.075
0.34
0.0065
0.03
0.0074
0.00
0.000033
0.00083
0.0022
0.00
0.00058
GWP,
COMPARED
TO C02
3,600
10,200
30,000
96,000
14,500
43,000
84,000
3,100
3,000
3,100
190
950
4,300
600
700
870
600
2,250
10,200
190
100
200
-
1
25
67
-
18
OOP,
COMPARED
TO CFC-11
1.11
1.00
1.00
0.45
0.80
1.00
0.60
0.04
0.05
0.05
0.02
0.02
—
0.05
0.05
0.10
0.06
0.00
0.00
0.00
0.00
0.11
__
0.00
0.00
0.00
0.00
—
Ret
ire.
-------
SWITCH FROM CFCs TO
HYDROCARBON PROPELLANTS
Mr. Montfort Johnsen
Montfort Johnsen and Assoc., Ltd.
United States
i L
-------
SWITCH FROM CFCs TO HYDROCARBON PROPELLANTS
AN INDUSTRY PERSPECTIVE
Mr. Montfort Johnsen, Technical Consultant.
The aerosol industry worldwide produced approximately 8.3
billion units in 1989 of which 3 billion where produced in the U.S.
The use of CFCs in the U.S. was banned in 1978 and today only few
products exempt form this regulation, continue to use CFCs. The
U.S. aerosol industry has adapted to the use of hydrocarbon
propellants as the predominant replacement for CFCs. When
countries evaluate this substitution option, a number of technical
and economic factors must be considered:
• Hydrocarbons propellants are much less expensive than
CFCs. In the U.S., hydrocarbons cost approximately
$0.11/lb or $0.24/kg, whereas CFCs cost more than $l/lb
or $2.2/kg.
• Hydrocarbon propellants (primarily propane, isobutane,
and butane) are flammable; therefore, gas houses must
be adapted to safely handle these materials, and
employees must be trained to ensure that potential
hazards are mitigated.
• In some cases the risks to a neighboring urban community
may be too high, and thus, total relocation of the
manufacturing plant should be considered.
• CFCs are compatible with many active ingredients and
substances due to their good solvency power. Compared
to CFCs, hydrocarbons have inferior solvency power and
are incompatible with certain materials. In the U.S.,
the switch to hydrocarbons required extensive
reformulation and product re-development which included
the use of co-solvents to aid hydrocarbon solubility.
• The availability of hydrocarbons for aerosol use must be
carefully evaluated. Aerosol propellants must meet high
purity standards. In addition, different gas mixtures
yield different pressures needed for product formulation
flexibility. Some countries have supplies of natural
gas, but lack the infrastructure to purify and separate
the various hydrocarbons.
• For safety reasons, some countries require that
hydrocarbons be stenched with sulphur derivatives so that
leaks are detected during transportation. The technology
to purify these gases may be costly.
-------
Other Solvents
A proposed CFC-113 substitute, methyl chloroform (1,1,1-trichloroethane),
will likely become a controlled substance under the Montreal Protocol. HCFCs
and chlorinated solvents are under review for environmental safety as well. If they
do contribute significantly to ozone layer depletion or to global warming, restricted
use will result. Northern will, therefore, not knowingly recommend substances that
could become restricted materials.
Purchasing Practices
Northern Telecom will cease buying, by the end of 1991, products
containing CFCs or Halons. Vendors will be encouraged, through
correspondence from Northern Telecom Purchasing, purchase orders and such, to
stop using CFCs to manufacture products. This will help vendors develop their
own programs to end the use of CFCs and Halons.
-------
DIGITAL. CORP PR
CONTACT LIST
Stephen Anderson, Chief
Technology & Economics Branch
Environmental Protection Agency
M/CANR-445 Room 745
401 M Street, S.W. , West Tower
Washington, DC 20460
(202) 475-9403
FAX (202) 382-6344
David R. Chlttick
Vice- President, Environment & Safety Engineering
AT&T
One Oak Way
Room2WA15l
Berkeley Heights. NJ 07922
(201)771-3600
FAX (201)771-3782
Margaret Kerr
Vice-President, Environmental/Healtn/Safety
Northern Telecom, Ltd.
3 Robert Speck Parkway
Misjlssauga, Ontario
Canada L4Z 3C8
(416)566-3021
FAX (416) 566-3348
-------
e ,00
V •* ' NORTHERN TELECOM'S POSITION
on
CFC AND HALON ELIMINATION
Northern Telecom's goal is to cease buying CFCs and Halons by or befoi_
the end of 1991.
CFC-113
CFC-113 will not be purchased after 1991. For circuit board cleaning, tF
focus will be on selecting low solids, no-clean fluxes and on choosing new
technologies that do not require cleaning. Alternative solvents and other cleanir
processes would be considered only if no clean options prove impractical.
With the industry wide drive to eliminate CFCs, our circuit board cleaners w "
have low resale values. The cleaners will be scrapped after removal from service
Miscellaneous uses of CFC-113 will be replaced with environmentally sa'
alternatives.
Halons
Corporate Standards 9001.14 and 9001.15 detail Halon needs and us-
We believe that the need for Halon hand held extinguishers and Halon 1301 tot
flood systems is minimal.
Halon hand held fire extinguishers will be replaced with recommend)
'alternate extinguishers. Halon 1301 total flood systems will be decommissionec
where appropriate before the end of 1991.
Refrigerants
Conservation programs are emphasized for cooling, refrigeration and ai
conditioning installations. Corporate Standard 14017.00 details equipment, le^i-
testing, service, system operation and preventive maintenance procedure
Cooling and air conditioning equipment will be converted when new alternate
chemicals are available.
Miscellaneous uses of CFCs
We believe that all purchased products containing CFCs can be replace;
with environmentally safe substitutes before the end of 1991.
-------
-DIGITAL CORP PR
- 4 -
The Cooperative expects other companies that use CFC solvents to
join in their effort. The first meeting of the new organization will
be held in November.
m
-------
-DIGITAL. CORP PR
BASIC Q & A
Q. When was ICOLP founded?
A. In October 1989. Its formation was announced at the
International Conference on CFC and Halon Alternatives held
in Washington, DC.
Q. What makes ICOLP a "unique" association?
A. ICOLP is a repository and "clearinghouse" for technical and
research information. It is not an advocacy group and does
not lobby government. Among its chief aims is to
distribute information on CFC alternatives to smaller firms
and to engage in technology transfer internationally.
Q. What is the biggest challenge facing ICOLP?
A. Adapting manufacturing processes to CFC alternatives is an
extremely complex and costly undertaking. To meet this
challenge, companies belonging to the ICOLP cooperative are
willing to pool their resources and share research.
Q. What are members1 responsibilities?
A. ICOLP members are expected to:
0 Commit to a CFC elimination plan as soon as
safe, affordable alternatives are available
0 Cooperate in identifying, testing and
publishing non-proprietary information on
alternatives
0 Demonstrate new alternatives to companies
internationally whenever and wherever possible.
Q. What kind of projects will ICOLP engage in?
A. 0 The cooperative testing of alternatives
0 Demonstrations of new technologies and
processes that reduce usage of CFC solvents
0 Technology and trade missions, including
sponsoring and participating in international
conferences on CFCs
-------
- 2 -
- work with existing industry, technical and government
organizations to develop the most efficient means of gathering
and distributing information on alternatives worldwide,
particularly to developing countries. The new Cooperative
plans to work closely with existing information-sharing
programs such as the one being conducted by the American
Electronics Association.
The announcement was made here at the International Conference on
CFC and Halon Alternatives by representatives of the new group: David
Chittick, environment and safety vice president for AT&T, and Margaret
Kerr, vice president of environment, health and safety for Northern
Telecom. The International Conference is co-sponsored by the U.S.
Environmental Protection Agency, the Alliance for Responsible CFC
Policy, Environment Canada and the National Institute for Emerging
Technology.
CFCs solvents are man-made chemicals commonly used in
manufacturing as a component degreaser or as a cleaner for electronic
circuit boards and precision mechanical parts. These nan-made
compounds are suspected of depleting the protective osone,layer that
shields the earth from the sun's harmful ultraviolet radiation as well
as contributing to global climate change.
(more)
-------
-DIGITAL CORP PR
CFC use is now regulated under an international treaty called th<
Montreal Protocol, which has been ratified by 45 countries. Under the,
Protocol, CPC use is scheduled for a 50 percent reduction by 1998. Ir,'
response to new scientific data about ozone layer depletion, President '
Bush, major United states companies and many other countries have
called for the complete phaseout of the use of CPCs by the year 2000
or sooner providing safe substitutes are available. But even a
complete phaseout will not return the ozone layer to natural levels.
The work of the cooperative will be valuable because it will not
be easy or inexpensive to eliminate the use of CPC solvents around tht '
world before the year 2000. No single technology or substance can '
replace CPCs. These solvents are used in a wide variety of cleaning
processes that are dependent upon the type of manufacturing, the
t
materials to be cleaned and the contaminants to be removed.
Cooperation among these companies will also help to ensure that new
alternatives to CPC solvents are safe to use in the work place.
Furthermore, customer requirements, such as military specifications,
sometimes encourage or require use of CPC solvents. The Cooperative
will work to overcome these types of problems.
Developing countries have special needs for information on new
technologies to replace existing CPC solvent uses. The Cooperative i«.
committed to working with solvent-using manufacturers worldwide to
speed the protection of the ozone layer.
- more -
-------
-D:OIT>\:_ CORP PR
ICOLP FOUNDING MEMBERS
AT&T
NORTHERN TELECOM
GENERAL ELECTRIC
DIGITAL EQUIPMENT CORPORATION
FORD MOTOR COMPANY
HONEYWELL
MOTOROLA
TEXAS INSTRUMENTS
THE BOEING COMPANY
-------
Industry Cooperative •
News Release Ozone Layer Protect^
For further Mormttion:
Lydia Whitefield, AT&T
(201) 771-3260
Art Fitzgerald, Northern Telecom, Ltd.
(416) 566-3048
For release Tuesday, October 10, 1989 — 1:00 p.m. (EOT)
Washington, D.C. — AT&T, The Boeing Company, Digital Equipment
Corporation, Ford Motor Company, General Electric, Honeywell,
Motorola, Northern Telecom and Texas Instruments today announced the
•
formation of a new organization to work with the Environmental
Protection Agency in a world-wide effort to reduce and eliminate
chlorofluorocarbons (CFCs) used as solvents.
Members of the new organization, known as the industry
Cooperative for Ozone Layer Protection, will join forces to:
.
- encourage the prompt adoption of safe, environmentally
acceptable alternative substances and technologies to replac
current CFC solvent uses,
- act as a clearinghouse for information on new alternatives t
CFC solvents,
(more)
-------
TABLE OF CONTENTS
1COLP Mission Statement p. 1
ICOLP Founding Members p. 2
Basic Q&A p. 3
Contact List p. 4
-------
CITA.U CORP
MISSION STATEMENT
The Industry Cooperative for Ozone Layer Protection's (ICOLP)
primary role is to coordinate the exchange of non-proprietary
information on alternative technologies, substances and processes
for existing industrial CFC solvents. By working closely with
CFC solvent users, suppliers and other interested organizations
in all countries, ICOLP seeks the widest and most effective
dissemination of information harnessed through its member
companies and other sources. To achieve these objectives, ICOLP
has been founded on the following principles:
0 To encourage the prompt adoption of
safe, environmentally acceptable,
non-proprietary alternative substances,
processes and technologies to replace
current industrial CPC solvents.
0 To act as an international clearinghouse for
information on alternatives.
0 To work with existing private, national and
international trade groups, organizations
and government bodies to develop the most
efficient means of creating, gathering and
distributing information on alternatives.
-------
TECHNOLOGY TRANSFER PROJECTS
BY THE INDUSTRY COOPERATIVE
FOR OZONE LAYER PROTECTION
Mr. A.D. FitzGerald
Director, Environmental Affairs
Northern Telecom, Canada
-------
-DIGITAL. CORP PR
Industry Cooperative f
Ozone Layer Protect'
BACKGROUND INFORMATION
-------
20
16
10
(kllotoiuiM)
• Production »Imports
1070 ItTt 1074 1076 1076 t*OO «•! ««4 1066 1066
§«*•* Corpu*
K1
700
eoo
eoo
400
aoo
too
100
^
••—»
1t70
1174 1tT6 1t7i
1Mt 1M4 ItM 1M6
-------
Relative Contributions to Greenhouse Effect
Parcant
contribution
totha
total
global
warming
100-
80
60-
40-
Greenhouse gases
•I Other
H Carbon dloxkto
• NMrotMOxWa
• HCFC* and MFCs
O CFCs
2000
2030
Source: Presentation by AFEAS based
on WMO Report of 1985
-------
IT IS TECHNICALLY FEASIBLE TO REDUCE CONSUMPTION OF THE 5
CONTROLLED CFCs BY APPROXIMATELY 75% BY 1995 AND
VIRTUALLY PHASE OUT CFCs, BY THE YEAR 2000
IT IS POSSIBLE TO REDUCE HALON (1211,1301, 2402) BY
50 - 60% ALMOST IMMEDIATELY THROUGH CONSERVATION
MEASURES. A TOTAL PHASEOUT COULD BE ACHIEVED WITH
INCREASED FIRE DAMAGE RISK. HALON IS CURRENTLY USED IN
AREAS WHERE OTHER FIRE PROTECTION TECHNIQUES OR
CHEMICALS WILL SUFFICE.
IT IS TECHNICALLY FEASIBLE TO PHASE OUT METHYL CHLOROFQRM
AND EMISSIONS OF CARBON TETRACHLORIDE ALMOST
IMMEDIATELY SINCE SUBSTITUTES ALREADY EXIST FOR THE
MAJORITY OF THEIR USES
WE WILL NEED TO CONTINUE TO USE CARBON TETRACHLORIDE AS
A FEEDSTOCK FOR PRODUCTION OF HCFCs AND HFCs (IT IS
TECHNICALLY FEASIBLE TO REDUCE OR ELIMINATE EMISSIONS)
-------
• USE OF HCFCs IN ACCORDANCE WITH EXPECTED MARKET
DISPLACEMENT (BY DU PONT) AT THE YEAR 2000 WILL ALLOW
FOR AN ACCELERATED PHASEDOWN SCHEDULE AND WILL NOT ADD
SIGNIFICANTLY TO GLOBAL WARMING OUT TO 2030
• THE SUBSTITUTION OF CFCs BY HCFCs WILL HAVE THE NET
RESULT OF SIGNIFICANTLY REDUCING THE CLX CONC. IN THE
ATMOSPHERE UNTIL SUCH TIME AS CFC EMISSIONS HAVE BEEN
ELIMINATED
•THE PERMISSIBLE USE OF HCFCs IN THE NEAR AND MEDIUM TERM
IS CRITICAL TO THE ACHIEVEMENT OF THE EARLY PHASEOUT OF
CFCs SET OUT IN THIS REPORT
-------
11.0
£
1965
Total Clx Concentrations
1985 Through 2100
2085
(1) Montreal Protocol &
Defacto Carbon Tetrachloride
Freeze 1
(2) CFC Phase-out
(3) Methyl Chloroform Freeze
(4) Carbon Tetrachloride &
Methyl Chloroform Phase-out
(5) 20% HCFC Substitution
Average OOP of 0.02
Assumptions:
200Q Phase-out of Fully Halogsnstsd CFCs (Excspt Curve 1)
HCFCs Capture 50% of What CFC Market Would Have Been Without Regulation (Except Curve 1); Assumed Annual
Average Growth Rates for Fully Halogenated CFCs, Baseline HCFC-22 (non-substitute) and Methyl Chloroform
are Approximately 3% for the Period 1986 to 2050. After 2050 Use Is Assumed to be Constant.
Average OOP of Subatltutea la 0.05 (Except Curve 5)
100% Global Participation
Notes:
While possibilities exist for an increase in carbon tetrachlorlde use, such growth Is unlikely given the awareness
of carbon tetrachlorlde's potential contribution to stratospheric ozone depletion.
-------
n
[(PROGRAMME FOR ALTERNATIVE FLUOROCARBON TOXICITY
TESTING)
14 COMPANIES PARTICIPATING
CHEMICALS ARE HFC-134a AND HCFC-123
COMPLETION EXPECTED LATE 1*2 - EARLY 1993
8 COMPANIES
HCFC-141b
RESULTS 1992-1993
7 COMPANIES
HCF-124AND125
COMPLETION PATE NOT KNOWN
| (ALTERNATIVE FLUOROCARBON ENVIRONMENTAL ACCEPT-
ABILITY STUDIES)
• 14 COMPANIES
INVESTIGATING ODPs, GWPt, AND OTHER PROPERTIES
RESULTS EXPECTED BY LATE 1989
-------
• CATALYTIC INCINERATION
• PYROLYSIS
• ACTIVE METALS SCRUBBING
WET AIR OXIDATION
> SUPER CRITICAL WATER OXIDATION
CORONA DISCHARGE
ZEOLITE CATALYTIC REDUCTION
(JAPAN-CFC-113)
• WE NEED A WORKING GROUP OF RELEVANT EXPERTS TO
RECOMMEND CRITERIA ON A "PER TECHNIQUE" BASIS
WE NEED TO HAVE PREPARED A UNEP DOCUMENT "GUIDELINES FOR
THE CRADLE-TOGRAVE MANAGEMENT OF SUBSTANCES WHICH
DESTROY THE OZONE LAYER"
-------
ESTIMATED USAGE OF HALONS
BY APPLICATION
Electronics
Miscellaneous 3%
Records storage 5%
Cultural heritage 5%
Flammable liquids 10%
Transportation 12%
HALON 1301
Transporation 25%
Industrial and
institutions/ 30%
Electronics 35%
Residential 10%
HALON 1211
Sou ret i H»*Mt
ny D. Leah, Environment Canada
a, Canada (819) 953-1670
-------
•VERY LITTLE RECOVERY OF CFCs CURRENTLY
• DRAMATIC INCREASE EXPECTED SHORTLY DUE TO:
•• PUBLIC DEMAND
•• REDUCED CFC SUPPLY
•• INCREASING CFC COST
•• TECHNOLOGY NOW AVAILABLE
•PROBLEMS ARE INFRASTRUCTURE RELATED
• IMPORTANT TO CREATE RECYCLE INFRASTRUCTURE NOW
BECAUSE WE WILL NEED IT FOR HCFCs AND PERHAPS
OTHER CHEMICALS
-------
• NO EQUIVALENT PERFORMING SUBSTITUTE FOR HALONS IN
CERTAIN APPLICATIONS
• HALONS CURRENTLY USED WHERE DRY CHEMICALS OR OTHER
TECHNIQUES WILL SUFFICE
• 50-60% REDUCTIONS ARE ACHIEVABLE BY CONSERVATION AND
BANK MANAGEMENT ALONE
• MAJORITY OF HALON COMMITTEE IN FAVOUR OF A PHASEOUT
1992
1995
1997
2000
2005
CAP AT 1986 LEVELS
75% OF 1986
50% OF 19t6
25% OF 1!
0%
• QUESTION OF PHASEOUT OR NOT RELATES TO ACCEPTABLE RISK
• SOME COMMITTEE MEMBERS PREFER TO AWAIT SUBSTITUTES
BEFORE DECIDING ON A PHASEOUT
-------
Projected Halon Consumption
250-
200-
Halon
Consumption
(Adjusted
kilotonnes*)
150-
Control Regime
•• Protocol
•I 50% Reduction
CZJ Phase-out
100H
50-
1980
1985
1990
1995
2000
2005
Year
Sum of kilotonnes of each Halon multiplied by its
resoective ozone depletion potential (OOP).
-------
" "1 ~-
25% OF WORLD CONSUMPTION (POLYURETHANES, POLYSTYRENE,
POLYOLEFINS, AND PHENOLIC PLASTICS USED FOR BUILDING AND
APPLIANCE INSULATION, CUSHIONING FOAMS, PACKAGING,
FLOTATION, SHOE SOLES ETC.)
CFCs ARE USED TO: COOL EXOTHERMIC REACTION, GIVE "R" VALUE
TO INSULATING PRODUCTS, CONTROL DENSITY IN FLEXIBLE FOAMS
•TECHNICAL OPTIONS VARY WITH EACH FOAM TYPE
•TECHNICALLY FEASIBLE TO REDUCE GLOBAL CONSUMPTION OF
CFCs 11,12,113 AND 114 BY 60-70% BEFORE 1993
• 30% OF THESE REDUCTIONS RELY ON HCFCs
• TOTAL PHASEOUT IS FEASIBLE BY 1995
-------
• MAJOR USE OF CFC-113
• NO UNIVERSAL SINGLE SUBSTITUTE
• A SERIES OF ALTERNATIVES AND COMBINATIONS EXIST Ft
SUBSTITUTION
• 50% REDUCTIONS ARE ACHIEVABLE THROUGH
CONSERVATION ALONE
•CONSERVATION AND RECOVERY CAN REDUCE CFC-113
CONSUMPTION SUBSTANTIALLY IN NEAR TERM
• AQUEOUS, CHLORINATED AND TERPENE-BASEDCLEANE :
ARE ALSO ALTERNATIVES
• VERY SMALL USE
• WHITE SPIRITS, HCFCs 225ca AND 225cb ARE PROMISINC
ALTERNATIVES
IT IS TECHNICALLY FEASIBLE TO PHASEOUT ALL CFC-113 SOLVE*
USE BY THE YEAR 2000
-------
Kilotonnes
Technically Feasible Phasedown
for the Various Refrigeration Uses
250
200-
150-
100-
50-
0- —
Assumptions: (1) Gradually increasing use of recycle
material to 60% by 1999
(2) Complete substitution (new equipment)
* by acceptable alternatives by 1999
* USA/EPA scenario
1986 1988 1990 1992 1994 1996 1998 2000 2002 2004
Year
Refrigeration Categories
Hi Industrial I I Transport I 1 Heat Pumps
•I Chilling CD Cold Storage • Retail
Domestic
Automotive
* USA/EPA scenario for reductions resulting from recycling, retrofitting
blends (still under carcogenicity tests) and use of HFC-134a.
Source: Technical Options Report
-------
REFRIGERATION, AIR CONOfTIONINQ AND
HEAT PUMPS
•25% OF WORLD CONSUMPTION, 5-8% BEING FOOD PRESERVATION,
1% DOMESTIC REFRIGERATORS
MUST DISTINGUISH BETWEEN NEW AND EXISTING DESIGNS
CURRENTLY AVAILABLE SUBSTITUTES INCLUDE: NH«, HCFC-22,
HYDROCARBONS, HCFC-142b AND HFC-152a
MEDIUM TERM (WITHIN 3-4 YEARS): HFC-134a, HCFC-123, AND
AZEOTROPIC MIXTURES
* LONG TERM (BEYOND 4-5 YEARS: HCFC-124, HFCs 125, 134,
32 AND 143a
• 15-20 YEARS NEEDED FOR FULL PHASEOUT UNLESS CURRENT
BLENDS PROVE FEASIBLE AS A DROP-IN (EG. HCFC-22/124/HFC-152g)
-------
•APPROX. 27% OF GLOBAL CONSUMPTION (300Kt)
• SUBSTITUTES INCLUDE HYDROCARBONS, COMPRESSED
GASES, HCFC-22 AND VARIOUS BLENDS
• NEW HCFCs ARE ALSO POSSIBLE SUBSTITUTES
• "VIRTUAL" PHASEOUT IS POSSIBLE NOW
• MEDICAL USES (10-12 Kt - 3-4 Kt BEING INHALANT DRUGS)
MAY REQUIRE ANOTHER 5 YEARS
•12/88 (12% EO 88% CFC-12) IS MAJOR USER OF CFC-12 FOR
STERILISATION IN HOSPITALS
• 10/90 (10% EO/90% COa) IS A POSSIBLE SUBSTITUTE BUT
REQUIRES RETROFITTING (HIGHER OPERATING
PRESSURES)
• OTHER TECHNIQUES EXIST: STEAM, FORMALDEHYDE, GAMMA
IRRADIATION, BUT ALL HAVE LIMITATIONS
• MAIN PROBLEM IS HEAT SENSITIVE DEVICES (12/88 IS
UNIVERSAL, STEAM USEFUL ABOVE 121 °C,
FORMADEHYDE - 85 °C)
• PHASEOUT IS TECHNICALLY FEASIBLE BY 1995 (MAY TAKE
LONGER IN THE DEVELOPING COUNTRIES)
FAST FOOD FREEZING (SUBSTITUTE WITH CRYOGENICS)
OTHER MINOR USES INCLUDE: TOBACCO PUFFING,
FUMIGATION, LEAK DETECTION, CANCER TREATMENT
AND STANDARD LABORATORY PROCEDURES
-------
Technically Feasible Phasedown Projections
for Major CFC Use Categories
Projected
Consumption
as a
Percentage
of 1986
Consumption
120-.
100
CFC Use Categories
•• Aerosol
Hi Solvent
I I Foam
Refrigeration
20-
1986
2005
-------
Organization
Technology
Chairman and Five
Technical Option Committees
Refrigeration
Air Conditioning
Heat Pump
Electronic
Dry Cleaning
Solvents
Aeroeol
Steritants
Misc. Ueee
110 Direct Participants
Even greater number involved in Peer Review
-------
IT IS TECHNICALLY FEASIBLE TO PHASE DOWN THE CONTROLLED
CFCs70-75%BY1995
IT IS TECHNICALLY FEASIBLE TO PHASE DOWN THE CONTROLLED
CFCs BY 95 - 98% BY THE YEAR 2000 (A 98% REDUCTION WOULD
DEPEND ON THE USE OF BLENDS AS "DROP-INS" FOR
EXISTING EQUIPMENT)
•REMAINING CFCs WILL BE NEEDED FOR SERVICING OF EXISTING
EQUIPMENT (LARGE INDUSTRIAL REFRIGERATION UNITS, CHILLERS,
AUTOMOTIVE AIR CONDITIONING) AND A SMALL AMOUNT FOR
MEDICAL USES (INHALANT DRUGS)
-------
PUHPOM* Or.iftM«ft< ftQY RfeVJEW
RESPOND TO MONTREAL PROTOCOL ARTICLE (6)
-DEFINE TECHNICALLY FEASIBLE REDUCTION SCHEDULES
REVIEW RELEVANT TECHNICAL CONSIDERATIONS
SUBSTITUTES, FORMULAE, ODPs, GWPs
STATUS OF TOXICITY TESTING
STATUS OF COMMERCIALISATION
RECOVERY AND RECYCLE
DESTRUCTION TECHNIQUES
REPORT ON METHYL CHLOROFORM, CARBON TETRACHLORIDE
PROVIDE TECHNOLOGY TRANSFER AND DEFINE COMPLIANCE
TECHNIQUES VIA THE 5 SECTOR-SPECIFIC TECHNICAL
OPTIONS REPORTS
-------
1986 World Usage of Controlled CFCs
(a) by Region
Africa 1%
Western
Europe 32%
Eastern Europe 11%
North America 35%
Latin America
& Caribbean 3%
Asia and Pacific 18%
Source: UNEP
(b) by Use
Foams 25%
Aerosols 27%
Refrigeration 25%
Others 7%
Solvents 16%
Source: Sector data or
best estimates
-------
OVERVIEW OF
UNITED NATIONS ENVIRONMENT
PROGRAMME
TECHNICAL ASSESSMENT
Mr. G. Victor Buxton
Environment Canada
-------
REPORT OF THE TECHNOLOGY
REVIEW PANEL
i ««
aiPtiiiiiH
s, 1
-------
STATUS OF CASE STUDY: CHINA
Mr. Zhang Chongxian
Senior Engineer
National Environmental Protection Agency
China
-------
STATUS OF CASE STUDY: CHINA .
Zhang Chongxian
National Environmental Protection Agency - China
Ladies and Gentlemen:
First of all I would like to take this chance to express my sincere
thanks to our host -- USEPA -- for their hospitality and all the arrangements
providing us with the chance to exchange experiences and discuss the
background information relating to the progress of the country specific
studies on ozone depleting substances.
China has indicated its willingness to cooperate with the international
community to protect the ozone layer. To this effect China regularly
participates in international meetings on the problems of the ozone layer and
ozone depleting substances and signed the Vienna Convention in September of
1989.
Before the London Conference, about a year ago, almost no one who was
involved in the production and use of ozone depleting substances in China knew
of the destructive effect of ozone depleting substances on the ozone layer and
the harmful consequences of the increased exposure to UV-B radiation.
However, after the London Conference, NEPA used the opportunity of the World
Environmental Day to launch a great number of educational activities on this
concern. As a result of the work the Chinese government appointed NEPA as the
coordinating agency for all monitoring and regulating activities relating to
the issue of ozone depleting substances.
-------
-2-
NEPA also represents China in international efforts on the ozone
depleting problems based on discussions in such meetings. NEPA advises
various Ministries of government of China on the scope of the problem,
measures adopted by the international community to address the problem, the
relevance to China's practice and so on with the aim of internal consensus on
the work of protecting the ozone layer and agreeable necessary steps to be
taken in China.
With limited resources available, NEPA has done some work and achieved
certain progress. In this aspect I have to address our gratitude to USEPA
missions headed by Dr. Eileen Claussen and Dr. Hoffman. They visited China
respectively within the year and half. Their activities in China tremendously
helped to raise the awareness of Chinese CFC producers and users on the
importance of protecting the ozone layer and on the possible approaches to
solve the problem.
Currently, China like other countries, is extensively producing and using
ozone depleting substances for refrigeration, foam blowing, air conditioning,
cleaning, disinfecting, fire fighting and protecting, propelling and other
miscellaneous uses. Following the decentralization of ministerial power in
1984, all the industries mentioned above are managed separately and scattered
in terms of investment decisions, production planning and so on. Local and
provincial administrations usually put local interests and development plans
ahead of central planning directions. Therefore, the government needs to know
the details of the production and use of ozone depleting substances in China,
-------
-3-
the costs for converting to non-ODS and very importantly the international
assistance and aids that would be required.
NEPA does not currently have the capacity in financial resources,
expertise and management capability to independently undertake the study.
Moreover, because of the political and commercial sensitivities of the issues
involved, NEPA and other Ministries want an unbiased body like UNDP which is
also the representative of UNEP in China along with donor countries to provide
assistance.
From November to December 1989, an international expert team invited by
UNDP visited China for the establishment of the project. The aim of the
project is to provide the decision makers of China as well as the UNEP Working
Group with a feasibility study and policy options concerning the control and
final elimination of the ozone depleting substances including production and
use, the costs involved in conversion to other non-ODS and products, as well
as the international aids required and to propose a plan of action including
projects to be launched and assisted by multi- or bi-lateral aids.
After 20 days of hard work, the basic findings are as follows:
1. China currently produces three of the controlled CFCS: they are
CFC-11, CFC-12 and CFC-113. Production is under the administration
of the Ministry of Chemical Industry. At present China has 30,000
tonns CFCS production capacity and the practical production was
about 20,000 tonnes in 1988 and 1989 respectively. However, China
also imports CFCs, especially CFC-11 and CFC-12. The total amount
-------
-4-
of import CFCs reached approximately 20,000 tonnes in 1989. That.
means China's average consumption of CFCs is about 0.04 kilogram per
capita per year in 1989.
2. Currently about 44% of total CFC consumption is in refrigeration,
air conditioning manufacturing and servicing. More than 40% of the
total consumption of CFCs are used as blowing agents in
manufacturing rigid and flexible foams. Almost 90% of the total
CFCs are used for manufacturing refrigerators, air conditioners, and
other refrigeration equipments suggesting that the future trend of
the growth of CFC use will remain high following the modernization
of the nation's industry and people's living conditions.
3. Until 1988 the possession of household refrigerators was about 20
million units. And the 1988's refrigerator production stood above
8.8 million units, plus 2 million imported refrigerators, there was
a big leap of overall possession of refrigerators between 1988 and
1989 alone.
The future trend of refrigerator production rate will fluctuate
between 3-7 units a year. However, the production capacity will
remain 12 million units a year. Compared with the total number of
Chinese households this figure is still lower than the future
demand. We could expect that the focal point of future CFC
consumption in China will still be at the section of refrigerators,
air conditioning and foam blowing.
-------
-5-
Finding substitutes for CFC-11, CFC-12 will be essential for China
to reduce the consumption of CFCs.
4. In addition to refrigeration and air conditioning, attention must be
paid to foam blowing. For example, rigid polyurethane foaming for
s
the purpose of insulation has big potential market in China
following the reform of industries and energy efficiency, the
flexible foaming will develop rapidly following the improvement of
the household furniture, the development of packaging industries and
so on.
In general, CFCs use is expected to increase 7-10% annually during ,
the 1990s.
Referring to solvents, aerosols, cleaning agents, and halons, the
i
application of CFCs will continue increasing at a rate of about 7%
annually based on the present low level of consumption as a starting
point.
5. CFC substitute production: China produces about 10,000 tonns of
HCFC-22 annually. At the present time most of the chemicals are
used as a feedstock for "Teflon" production. The application of
HCFC-22 for refrigeration needs to be further developed. China also
produces about 100 tonns of HFC-152a as refrigerant to apply for
experiments. The preliminary results showed very promising
-------
-6-
possibility to create a pilot project to apply the HFC-152a to
household refrigeration.
Referring to the country specific study, what we are going to do next.
After the preliminary study of UNDP export. Mission, the project design has
been worked out in order to drive overall and more precise information on this
regards.
The project is composed of three phases: in the first phase NEPA will
collect statistical and substantive information on ODS production and use in
compliance with the "national studies: proposed outline." I do think every
country has its own specific condition, this outline will only provide the
basic requirement needed for the consideration by the international community
in order to gain assistance and aid. For the completion of the information
collection NEPA has to cooperate with various Ministries and do a lot of
organizational and standardizational work, for this purpose financial
assistance is necessary for NEPA success.
The second phase is designed for the international expert team to arrive
in China for additional information and evaluation of the technical
feasibility and the step-wise strategy for phasing out the controlled CFCs and
costs involved. This is really a very complicated process to complete in
China.
-------
-7-
In the third and last phase, the integration of respective reports will
be completed and submitted to UNEP for financial and technical aid and
assistance.
Finally, regarding the country specific study in China, I do think the
Chinese situation is staying at a preliminary stage. Through our meeting I am
able to learn a lot from your practice and experience. It is very valuable
for implementing the study in China.
Thank you.
-------
II
CASE STUDY COORDINATION WORKSHOP
BRASIL
SOURCES OF INFORMATION
BUSINESS SURVEYS
- SUB COMMITEES
- CFC PRODUCERS
- TRADE ASSOCIATIONS
- GOVERNMENTAL STATISTICS
GOVERNMENTAL DATABASE / PROJECTIONS
-------
Ill
CASE STUDY COORDINATION WORKSHOP
BRASIL
INDUSTRY INVOLVEMENT
Q JOINT PARTICIPATION WITH THE BRAZILIAN DELEGATIONS
TO THE PROTOCOL MEETINGS
D SUPPLY TECHNICAL EXPERTISE, GENERAL DATA AND
OTHER RESOURCES TO DEVELOP TECHNICAL REPORTS
D CONFERENCES / WORKSHOPS
SEMINAR "CFC'a, ALTERNATIVES AND STRATEGIES"
MARCH 08/09 - SAO PAULO
D MONTHLY TECHNICAL MEETINGS AT ABINEE
SINCE MID-1987
D LIASON ACTIVITIES WITH GOVERNMENT AGENCIES
-------
IV
CASE STUDY COORDINATION WORKSHOP
BRASIL
PROGRESS
- CFC GROUP WITHIN ABINEE
- CFC's ELIMINATED FROM COSMETICS AEROSOLS
(BUTHANE/HCFC's) v
x
- INTRODUCTION OF ALTERNATIVE BLOWING AGENTS FOR
FOOD PACKAGING FOAMS
- EARLY STAGES OF DEVELOPMENT OF CFC
RECOVERY SYSTEMS
- ELECTRONICS / REFRIGERATION INDUSTRY
"QUEST FOR TECHNICAL DATA"
- RESOURCES AVAILABLE
• COMPRESSOR DESIGN AND MANUFACTURING CAPABILITY
• FLEXIBLE PRODUCTION FACILITIES
• WELL ESTABLISHED COMPONENTS SUPPLIERS
• ACCESS TO TECHNOLOGY FROM PARENT COMPANIES
-------
STATUS OF CASE STUDY: BRAZIL
, i
'}
[I
1}
Mr. Alberto Carrizo
White-Westinghouse Climax
Brazil
-------
I
CASE STUDY COORDINATION WORKSHOP
BRASIL
ORGANIZATION
PROJECT TEAM
- LEADERSHIP
IBAMA (BRAZILIAN ENVIRONMENTAL AGENCY)
- GOVERNMENTAL AGENCIES;
- FOREIGN AFFAIRS
- HEALTH MINISTERY
- INDUSTRY & TRADE MINISTERY
- ASSOCIATIONS;
- ABINEE; ELECTRICAL AND ELECTRONIC INDUSTRY
- ABRAVA; REFRIGERATION, AIR CONDITIONING AND HEATING
- ABIPLAS; PLASTICS
- ANFAVEA; AUTOMOTIVE MANUFACTURERS
- IBF; INSTITUTE OF COLD TECHNOLOGY
- TECHNICAL"ADVISORS:
Dr. SUELY CARVALHO; SAO PAULO UNIVERSITY, CNEN
-------
Feron 11 4436 Tons
Feron 12 3453 Tons
Feron 22 446 Tons
Others (F 502 + F 114 +..) 453 Tons
Total 8788 Tons
4. The Eg. venture in limiting the emission of CFC which
I already related in various international forums, is
worth to be repeated for consideration towards application
in other developing countries.
5. On February 23rd 1981, the Eg. Ministry Of Industry.
(MOI) received an alert from the USEPA. through the Eg.
Embassy in Washington as to CFC's and their harmful
effects on human health and the restrictions to be imposed
on their outlet uses particularly in aerosols.
^
6. MOI. appointed an adhoc committee, (Decree, MOI; 638/81)
joining in its membership the chairmen and technical
directors of the CFC consumer units in the fields of
refrigeration, Air-conditioning, aerosols, foam Plastics,
....etc). The committee was reformed (Decree MOI; 446/86)
joining to its membership representatives of other
conserned bodies; Federation of Industry, Ministry of
Health, General Organization for Standerzation. I should
remember that I had the privilege to act as technical
rapporteur of that committee.
7. The committee performed a number of technical and
economical studies taking into consideration the probability
of the difficulty of future importation of such substances.
Also the probability that its procurement will be confronted
with a rapid price escalation. (It its worth to declare
that committee was totally right in its prediction, the
price of importation of one kg of CFC increased from LE 0,9
in year 1985 up to LE 3.7 in 1989).
-------
8. The committee performed a number of technical and economical
studies, put forward a number of recommendations to MOI.
inter-allia the following:
a) No new permits or licences should not be given to projects
that depend in their production on the use of CFC as
well as non agreement to extensions of such existing
projects.
b) Introducing other substitutes for CFC that are locally
available or abundant and easy to procure, as well as
studying the possibility of introducing legistlation
banning the use of CFC's in such activities where
substitutes are available and cost effective as well as
the possibility of imposing taxes on CFC importations
& incentives for substitutes.
c) Proposing the implementation of a procedural system
that could enforce the disposal of salvaged equipment
holding CFC and residuals thereof.
9. The committee found that LPG = liqufied Petroleum gases
(mainly propane & pentance) could be used as a cost
effective substitute to CFC's in Aerosol industry. It is
locally available and far cheaper than CFC's.
10. "Kafr El Zayat" Company for pestisides was the first company
that changed over to use LPG in 1984. Other public sector
companies have followed its example. Today (1990) all
public sector companies use LPG as propellant in Aerosols.
Also 3 of the private sector companies have changed over to
LPG.
11. Here it is clear that LPG has succeeded as subsitute in
Egypt because it was more cost-effective than its CFC's
counterpart otherwise they would have not so quickly
widespread.
-------
- 4 -
12. This fact is in conformity with the report of the techn.
committee chaired by Ms Ingrid Kokeritz (Sweden)
concerning the uses of substitutes for CFC's in aerosols
such as hydrocarbons, propane and butane (page iii):-
The Hydrocarbon cost per kilogram is however, substanitally
lower than that of CFC's(20-30% of the current cost of
CFC's). In most cases, a conversion to hydrocarbons will
therefore result in a net gain for the producer and a
cheaper product for the consumer.The lower cost of hydro-
carbons where suitable supplies of these propellants
exists, may be especially important to developing countries.
13. It is also in conformity with the EPA report R & D N° 60012-
89-062 (2) Page "5":
In the U.S., hydrocarbon propellants cost less than 20% of
the rapidly escalating costs of CFC's. Approximately 30% of
U.S.aerosols are pressurized with propane, butane, isobutane
or their blends.."
14. I think that a regulatory fee and auction system on the
production of CFC halons are very well justified. This is
contrary to the position of the U.S. council for International
Business that cited in their publication of Sept. 89 ' that
their argument is that the outcome is likely to slow progress
for U.S. companies towards development of alternative products
and place them at a competitive disadvantage vis avis
production in other countries.
15. My own information is that Norway has already passed a bill
to impose fees on CFC's & CFC products. Such Action should be
well spreaded and introudced by all countries on equal bases
so as to leave no space to competitive disadvantage. I
strongly push for a global tax or fee or any auction system
on all controlled substances so as to modify economic
appraisals of the substitute (and weight their balance).
-------
- 5 -
16. To phase out CFCs we should find and examine substitutes
for its uses in all activities, not only aerosols but also,
foam plastics, refrigerators, air conditioners.etc.
It is estimated that •our production capacity of refrigerat.
will reach about 750*000 units/yr of houshold units, 15'000
deepfreezers and 9'000 Exposition or commercial unit. The
installed capacity of Ai'r conditioning of various types will
be equivalent to about 130.000 units window type 2*5 HP.
There is the argument that such units run in closed circuits
but how about leakage and dissipation in repair & maintenance
Another problem is foam plastics and styropore. It is a
rapidly growing sector, not only in Egypt, but also in all
developing countries: Egypt's national output of foam plasti
and styropore totals to about 10.000 tons/yr.
17. The world community is looking for a total phasing out of
CFC's. All nations are consolidated to face this global
challange. In this respect I would quote EPA Administrator
(4)
William Reilly in his memorandum about the unbridled
enthusiasm of the EPA international front for all the World
solidarily towards CFC and climate change problem and in ful-
support of the U.S. policy in that a field. He clearly stated
that the President Bush 5 points on the international
front, the first was committing the nation to the full phase
out of CFC's towards the end of the century.
Report by the technical options committee on Aerosols,
sterilants and miscellaneous uses.
E.P.A. Research & Development;
Aerosols Industry success in reducing CFC propellants usage
EPA-60012-89-062. November 1989.
Prepared by Air & Energy Engneering Research Laboratory.
Summary of International Environmental Issues and Positions
of the US Council for International Business:-
"Environmental Challenges for Industry" September 1989
1212 Avenue of Americas New York 10636-1689.
Memorandum of USEPA Washington DC. dated September 7, 1989
Subject six Month Update by Administrator J.W.Reilly.
-------
STATUS OF CASE STUDY: EGYPT
Dr. Ahmed Amin Ibrahim
Consultant, Egyptian Environment Affairs Agency
Egypt
-------
Facsimile (202) 382 6344
To: Eileen Clausen Director Office Of Air & Radiation EPA.
Some Remarks on Strategies of
Limiting the uses of CFC's
Presented by Ahmed Amin Ibrahim
To EPA Workshop January 15-17, 1990 Washington.
1. Egypt was one of the first countries that signed the
Vienna convention; March 22nd 1985 and the Montreal
Protocol September 16th 1987; Egypt ratified both on
August 8th 1988. In its consolidation with the
International Community Egypt has taken intiatives in
limiting the emissions of the controlled substances
(which are the CFC's).
2. The Montreal Protocol came into force on January 1st
1989; and requires the following:
a) Freeze at 1986 consumption and production levels of
the controlled substances (CFC 11, 12, 113, 114, 115)
on the basis of their relative ozone depletion
weights (O.D.P.)
b) By 1993 reduce the emission of controlled substance
to 80 %.
c) By 1998, a further reduction by 20% to limit the
controlled substance to 50%.
3. Egypt does not manufacture any of the controlled sub-
stances (CFC's) but totally depends on importation to
fullfill its needs. The import figures ware 8788 tons
in 1982 and dropped sharply to 2163 tons in 1985.
This was due to the efforts undertaken to use CFC's
substitutes in producing Aerosols with the following
breakdown as to form grade classification as regards
the 1982 figure:-
-------
UI. CONCLUSIONS
THE PROTECTION or THE OZONE LAYER RULES OUT THE POSSIBILITY OF
"TAIR" SHARES Or OZONE DEPLETING COMPOUND USE. ALTHOUGH NOST Or
THE CHLORINE IN THE ATMOSPHERE IS DUE TO EMISSIONS FROM DEVELOPED
COUNTRIES HUSjT ALSO STOP THEIR PRODUCTION AND CONSUMPTION OF THESE
SUBSTANCE'S . "
2- IT IS NECESSARY TO TIGHTEN THE IMPLEMENTED MEASURES TO REDUCE
OZONE DEPLETING COMPOUND EMISSIONS AND TO TAKE ALL NECESSARY
ACTIONS TO ACHIEVE THE REDUCTIONS NEEDED.
3. THE CASE STUDY UNDERWAY IN MEXICO MILL EVALUATE THE PRESENT AND
FUTURE DEMAND Or OZONE DEPLETING SUBSTANCES AND THE ECONOMIC
NEEDS ASSOCIATED WITH THE IMPLEMENTATION OF THE MONTREAL PROTOCOL.
THE STUDY MILL ALSO PROVIDE USEFUL INFORMATION ON NEM TECHNOLOGIES
AND APPROACHES USED IN MEXICO.
-------
ADAPTING TECHNOLOGY TO DEUELOPING
COUNTRV NEEDS
MEXICO CAN BE A SOURCE OF NEU AND ADAPTED TECHNOLOGY TO PROTECT THE
OZONE LAVER
THE MEXICAN DESIGN APPROACH HAS PROUED TO BE COST-EFFECTIUE AND SAFE
THE MEXICAN KNOU-HOU MAY BE USEFUL TO OTHER DEUELOPING COUNTRIES
-------
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
SOURCE AND REDUCTION OF AVOIDABLE HALON EMISSIONS
INDEX : 1989 EMISSIONS = 100%
| |lO YEAR HYDROSTATIC
TESTING
^= 3 YEAR MAINTENANCE
HH! RECHARGE SERVICE
[LEAKING EQUIMENT
TESTS AND DEMONS-
TRATIONS
TRAINING
EXTINGUISHING
1890
1991
1992
1993
1894 2000
-------
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
SOURCE AND REDUCTION OF AVOIDABLE HALON EMISSIONS
BASE EMISSIONS 19^9*100%
SOURCE:
FIRE EXTINGUISHING
TRAINING
TESTS AND DEMONSTRATIONS
LEAKING EQUIPMENT
RECHARGE SERVICE
3 YEAR MAINTENANCE
1989 1990 1991 i??? 1993 1994-— 2000
' ' "
J
IO YEAR HYDROSTATIC
TESTING
TOTAL 1989 %
J-l
*<*
I'l'l'l
ELIMINATING TRAINING WITH I2OI
AND 1301 EXCEPT FOR THOSE
APPLICATIONS CRITICAL TO LIFE
SAFETY.
COMPLETING ELIMINATION OF
SALES TESTS AND DEMONSTRA-
TIONS ALTERNATIVES MEANS,
SUCH AS VIDEO TAPES, FILMS,
TRANSPARENCIES. AND PHOTO -
GRAPHS CAN BE USED.
STRICTLY COMPLYING WITH EXTIN
GUISHER QUALITY NORMS TO
AVOID EMISSIONS FROM FAULTY
EQUIPMENT.
IMPLEMENTING GAS RECOVERY
SYSTEMS DURING RECHARGE OF
EXTINGUISHING EQUIPMENT.
USING GAS RECOVERY DURING
MAINTENANCE AND HYDROSTATIC
TESTING OF EXTINGUISHING
EQUIPMENT.
-------
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
SOURCE AND REDUCTION OF AVOIDABLE HALON EMISSIONS
INDEX: 1989 EMISSIONS = 100%
| ||Q YEAR HYDROSTATIC
TESTING
^=3 YEAR MAINTENANCE
; RECHARGE SERVICE
LEAKING EQUIMENT
HI TESTS AND DEMONS-
TRATIONS
TRAINING
EXTINGUISHING
YEAR 1989
1990
1991
1992
1993
1994 2000
-------
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
SEDUE REDUCTION IN CFC USE FOR AEROSOL PRODUCTS MANUFACTURING
AEROSOL PRODUCTION
60
A NNUAL% CHANGE
TOTAL CANS
YEAR MARKET WITH CFC'S
1988 8.7 -20.7
1989 3.8 -I- 1.6
1990 5.1 -50.0
1991 4.8 -48.3
#:;:;:;: TOTAL PRODUCTION
;| CANS WITH CFC S
1988
1989
1990
1991* INCLUDES MEDICINALS AND OTHER
HISTORICAL AND PROJECTED PRODUCTION EXEMPT PRODUCTS
&
1987
INSTITUTO MEXICANO DEL AEROSOL. A.C. CAMARA NACIOMALOE LA INDUSTRIADE PERFUMERIA Y COSMETICA CAMARA NACIONAL Of. LA IMOUSTHIA OE TRANSFORMACION
MEXICAN AEROSOL INSTITUTE NATIONAL CHAMBER OF THE PERFUME AND NATIONAL CHAMBER PF INDUSTRIES
COSMETIC INDUSTRY
-------
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
S^D(?e REDUCTION IN CFC USE FOR AEROSOL PRODUCTS MANUFACTURING
400
YEAR
376
CFC-II AS PROPELLANT
1987 1986 1989 1990 1991
HISTORICAL AND PROJECTED CONSUMPTION
ANNUAL % DECREASE
YEAR
1988
1989
1990
1991
% DECREASE
16.2
6.6
48.9
40.0
•:S::i: CONSUMPTION
SOURCE:CKC PRODUCERS
-------
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL
seoue REDUCTION IN CFC USE FOR AEROSOL PRODUCTS MANUFACTURING
CFC-12 AS PROPELLANT
10OO
-------
MEASURES TO BE IMPLEMENTED TO ADDRESS
<
GLOBAL UARMING
MEXICO UILL IMPLEMENT A PROGRAM TO PRESERUE AND IMPROUE THE EFFICIENCV
OF FOSSIL FUEL UTILIZATION
MEXICO IS UORKING TO IMPROUE ITS UATER SUPPLY MANAGEMENT
ENERGY EFFICIENCY AND MEASURES TO ADDRESS AIR POLLUTION UILL BE
ENCOURAGED
-------
ADAPTING TECHNOLOGY TO DEUEL.OPING
COUNTRV NEEDS
MEXICO CAN BE A SOURCE OF'NEU AND ADAPTED TECHNOLOGY TO PROTECT THE
OZONE LAYER
THE MEXICAN DESIGN APPROACH HAS PROVED TO BE COST EFFECT IUE AND SAFE
THE MEXICAN KNOU-HOU MAY BE USEFUL TO OTHER DEVELOPING COUNTRIES
-------
ATTACHMENT 4
-------
TERMS OF REFERENCE FOR THE CASE STUDIES
I. EXECUTIVE SUMMARY
STUDY METHODOLOGY
The feasibility study should be conducted in phases:
1) Generic Use Pattern Analysis (determine where and how, how much of
these chemicals are used and their source of supply and distribution,
i:e., produced locally/imported/exported, etc.) using published
statistical summaries and estimates by chemical producers, distributors
, and user association if possible or estimates based on estimates of
production of products containing CFCs or products made with but not
containing CFCs. Also, prepare an estimate of current and future needs
(for the next ten years) taking into account national policies, economic
plans or projected growth in demand.
2) Sector Specific Use Pattern Analysis (analyze how these chemicals
are used within the sector and evaluate the options for: retrofitting
plants to use alternative "environmentally friendly" technology; using
alternative chemicals; manufacturing alternative products; maximizing
conservation measures (recycle, recapture, re-use); or other mitigative
measures (example no clean fluxes, etc.). Determine both the short and
long-term alternatives and potential technological modifications for
manufacturing processes, etc.
3) Assess the Cost Implications for country-wide compliance with the
Montreal Protocol. (Determine costs on a sector basis for a 10 year
period, including anticipated increases in costs for chemicals,
servicing, maintenance, new products, etc.)
4) Develop a Feasible Compliance Schedule (taking into account the
equipment acquisition times, etc.). Identify options to implement the
report conclusions and recommendations including sources of new
technology and financing. Develop a realistic timetable for achieving
compliance with the Montreal protocol.
Capital Investment (including application engineering)
New,Facilities
Retrofit
Decommission
Research, Pilot Plants, and Demonstration
Operating Costs
Chemical Inputs and Labor
Energy (including consideration of global climate change)
Maintenance
-------
II. INTRODUCTION
A. Purpose and Scope
B. The Role of CFCs and Halons in Stratospheric Ozone Depletion
C. The Montreal Protocol and Subsequent Developments
1. The Montreal Protocol
2. Ozone Depletion Potential (OOP) and Global Warming Potential
(GWP)
3. CFC and Halon Use in (Country Name)
4. Global and CFC and Halon Use
5. Other Chemicals of Concern
D. National Policy on Ozone Layer Protection
E. National Advantage of Ozone Layer Protection
F. National Circumstances Likely to Influence Technology Transfer
1. Fire Codes
2. Solvent Specifications
3. Free Trade Zones/Off-shore Facilities and Ships
4. Logistics
5. Occupational Health and Safety
6. Domestic Content Rules
7. Import Restrictions
G. National Case Studies as a Means to Facilitate Technology Transfer
III. PRODUCTION AND CONSUMPTION OF CHLOROFLUOROCARBONS AND OTHER
OZONE-DEPLETING COMPOUNDS
A. Production Levels and Status of Current Production Capacity
1. Historic, Current and Planned Production Levels
2. Capacity and Location of Existing Facilities and Capacity under
Construction
3. Age and Flexibility of Existing Production Facilities
B. Trade of Ozone Depleting Chemicals and Products
1. Imports and Exports (with reference to Protocol Membership)
2. Prices and Import Tariffs and other Regulations (such as CFC
taxes)
C. Consumption by End Use
IV. TECHNOLOGY AND EQUIPMENT CHARACTERISTICS IN CURRENT END USES
(Includes discussion of existing manufacturing facilities)
A. Refrigeration, Air Conditioning, and Heat Pumps (including estimates
of CFC contained in existing equipment)
-------
B. Aerosols and Sterilants
C. Solvent Cleaning
D. Foams
1. Flexible Polyurethane Foams
2. Rigid Polyurethane Foams
3. Phenolic Foams
4. Extruded Polystyrene
5. Polyolefin Foams
E. Halon Fire Extinguishing Agents
1. Halon 1301 (including estimates of "banked" halon)
2. Halon 1211 (including estimates of banked halon)
3. Halon 2402
V. ESTIMATED FUTURE CHLOROFLUOROCARBON NEEDS
A. Methodology for 10-Year Projections
B. Projected Compound Demand by End Use
VI. OPTIONS TO REDUCE CHLOROFLUOROCARBON USE; RECYCLING, ALTERNATIVE
COMPOUNDS AND TECHNOLOGIES
A. Recycling and Other Conservation Practices
B. Chemical Substitutes
C. Product Substitutes
VII. TRAINING AND INFRASTRUCTURAL REQUIREMENTS
VIII. STRATEGY FOR COMPLYING WITH THE MONTREAL PROTOCOL: THE CASE OF
A. CFC Reduction Measures for the Short Term (1990-1995)
(Best Available Technology from January conference)
B. CFC Reduction Measures for the Intermediate Term (1996-2000)
C. CFC Reduction Measures for the Long Term (2000-2010)
IX. COSTS OF TECHNOLOGY TRANSFER
APPENDIX A: SOURCES OF NEW TECHNOLOGY AND TECHNICAL ASSISTANCE
-------
Aerosols Workgroup - Terms of Reference
SUGGESTION TO INTEGRATE DISCUSSION OF TECHNOLOGY AND EQUIPMENT CHARACTERISTICS
(SECTION IV) WITH OPTIONS (VI) AND RESPECTIVE COSTS (IX) WITHIN EACH SECTOR.
For example, the Outline for Aerosols would be:
III. AEROSOLS
A. Technology and Equipment Characteristics in the Aerosol Industry
B. Substitutes and Costs
i. Hydrocarbon Propellants
ii. Non-flammable Propellants
iii. Alternative Delivery Systems
For a projected mix of substitutes adopted estimate costs for Model
Plant Scenarios including:
• Capital Investment and Other Fixed Costs, and
• Operating Costs
C. Summary (sector specific)
Other Comments
CFC consumption estimates for aerosols obtained from CFC producers may
be cross-checked if the volume and type of aerosols manufactured with CFCs is
known. Even if this check cannot be performed, it is believed that
uncertainties of ± 20 percent in this sector-specific consumption estimate are
acceptable for the purpose of the case studies because conversion costs are
insensitive to total CFC volumes consumed, but rather depend on the number and
characteristics of aerosol filling plants.
-------
ATTACHMENT 5
-------
To be completed on Industry, application, company or site basis (If possible)
NATIONAL CFC STUDIES
PROPOSED FORMAT FOR SURVEY QUESTIONNAIRE
GENERAL INFORMATION
Company Name:
Address:
Survey Respondent:
Position:
Voice Phone:
Fax phone:
Number of Employees (1989):
Sales (FY 1989):
Date Founded:
Estimated Annual Consumption of the following compounds (in Metric Tons):
CFC-12 ; CFC-11 ; CFC-113
CFC-502
Halon 1301
; CFC-500 _
; Halon 1211
; Halon 2402
Methyl Chloroform
; Carbon Tetrachloride
Describe how the above compounds are related to your business (e.g., they form part of the final
products produced in your company, they are purchased by your customers to operate existing
equipment, etc.):
-------
-2 -
Please indicate which of the following applications describes your current use of
chlorofluorocarbons, and/or halons. Respond to this questionnaire at the indicated section:
[ ] A. Refrigeration
[ ] B. Aerosols
[ ] C. Solvent Cleaning (includes use of CFC-113, Methyl Chloroform, and Carbon
Tetrachloride)
[ ] D. Sterilants
!
i .
i [ ] E. Foams
i _
! [ ] F. Halons
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-3 -
REFRIGERATION
DOMESTIC/HOUSEHOLD REFRIGERATION
A. General Description of the Sector
1. A short description of the history of manufacturing refrigerators
2. Which are the critical parameters for the country in this sector?
3. The size and the structure of the industry:
Numbers of factories (licensed/joint ventures)
Installed production capacity per shift
Age of production lines and lifetime
Types of products manufactured (static, frost-free cooling)
Size (inner/brutto volume) of typical products
Direct labor and total number of employees involved
4. How many refrigerators/freezers have been produced during the last ten
years (specific data per year; imports and local data as well)?
5. How many refrigerators can be considered as 'installed* capacity?
What is an estimate for an 'installed' amount of refrigerant?
6. What is the production target for the year 2000 (as well as estimates for
import data)?
7. How much refrigerant (type of refrigerant, probably CFC-12) is used in
charging of the refrigerators, specifically the circuit of the appliances; typical
values of products; and furthermore
- Is the refrigerant produced domestically?
- If not, why is it imported?
What is the average refrigerant charge used (per unit of size)?
8. Which types of insulation are applied (type and quantity)
- e.g., volume of insulation per product?
B. Components (compressors) Manufacturing
1. Are components (heat exchangers and valves, not the compressors) made
in-site/locally or bought from external suppliers
information on the type of heat exchangers?
- information on manufacturing techniques
2. Are compressors made in-site/locally or bought from external suppliers?
In case of domestic compressor production
3. The size and the structure of the compressor industry:
« Number of factories (licensed/joint ventures)
-------
- 4 -
Direct labor and total number of employees involved
. Installed production capacity per shift
. Age of production lines and lifetime
. Capacities of compressors produced (cooling capacity)
4. Are compressor electric motors made in-site or bought externally?
5. How many compressors have been produced during the last ten years
(import and export data)?
6. What is the production target for the year 2000?
C. Other Topics
1. What is the future trend expected in manufacturing refrigerators:
Manufacturing technology change
• Types of appliances
• Typical volume of a refrigerator
2. (Optional) Which standards are applied in tests (ISO, NF, DIN, own)
• Inner and ambient temperatures
Which responsibility belongs to National Manufacturing Organizations?
3. How efficient is the service organization?
• How many servicing operations
• Amount of refrigerant (typical) used in servicing
• Is servicing performed via factory/brand organization
• Education level of servicing engineers
4. (Optional) How many refrigerators are being disposed of and what is the
future expectation? Will it be possible to collect disposed refrigerators? Now,
or in the future?
5. What is the average lifetime of a refrigerator (reasons for disposal)?
RETAIL/COMMERCIAL REFRIGERATION
A. General Description of the Sector
1. A short description of the history of manufacturing cabinets, stores, etc.
2. Which are critical parameters for the country in this sector?
3. The size and the structure of the industry:
. How many production sites.
Average size of a production site
I.1
-------
- 5 -
• Status of manufacturing technology.
• Direct labor and total number of employees involved
4. How many:
display cabinets
• Cold stores
• Ice makers
• Other equipment
have been produced during last ten years (specific data per year; also
import and local data)
5. What is the production expected for the year 2000 (as well as estimates for
import data)?
6. How much refrigerant (types, HCFC-22, CFC-12, 500, 502) is used in
equipment manufacturing (first charge whether it concerns domestically
produced refrigerant or import)? What is the charge used in the typical
products?
7. Which types of insulation are applied (type and quantity) (e.g., volume of
insulation per product)?
8. How many units have been installed (domestically produced or import)?
. Distribution with respect to age (10-20 years, 5-10, 0-5 years old)
• Typical charges of these units
9. Engineers involved and their education level:
• Education level of engineers
• National engineer societies (education level)
• Training courses
10. What is the future trend expected in manufacturing this equipment?
Manufacturing technology changes
Types and typical volumes
11. (Optional) Which standards are applied in tests (ISO, NF, DIN, own)?
• Inner, ambient temperature levels
Which responsibility belongs to National Manufacturing Organizations
B. Components (compressors) Manufacturing
1. Are components (like heat exchangers and valves, not compressors) made
in-site/locally or bought from external suppliers?
-------
- 6 -
Information on the type of heat exchangers
Information on manufacturing techniques
2. Are compressors made in-site/locally or bought from external suppliers?
In case of domestic compressor production
3. The size and the structure of the compressor industry:
• Number of factories (licensed/joint ventures)
Direct labor and total number of employees involved
• Installed production capacity per shift
• Age of production lines and lifetime
• Capacities of compressors produced (coding capacity)
4. Are compressor electric motors made in-site?
5. How many compressors have been produced during the last ten years (also
import and export data)?
• Separate data for each of the refrigerant types
6. What is the future production target (e.g., 2000)?
• Quantity concerned
• Shift from/towards other types
• Shift from/towards other refrigerants
C. Servicing
1. How efficient is the servicing operation?
• Amount of refrigerant (typical) used in servicing
• How many servicing operations per unit
• Amount of refrigerant used for servicing per year compared to the
charge of the unit
Is servicing performed via factory/brand organization
• General practice in servicing
2. What has been the amount of refrigerant used for servicing per year vs.
charge of equipment (split up to types of equipment)
3. Which kind of engineers perform servicing?
• Education levels (permanent education)
• Training on the job/service manuals
• Service engineers organizations
• Number of engineers involved
• Is there a shortage/surplus of engineers
4. Which are typical aspects of servicing and critical parameters (which
components fail, leak detection available)?
-------
- 7 -
5. Disposal:
What is the average lifetime of a unit (reasons for disposal)
How many units are being disposed of
Future expectations
-------
- 8 -
III. TRANSPORT REFRIGERATION
A. General Description of the Sector
1. A short description of the history of manufacturing transport refrigeration
equipment.
2. Which are the critical parameters for the country in this sector?
3. The size and the structure of the industry
. How many production sites
• Average size of a production site
• Direct labor and total number of employees involved
• Status of manufacturing technology
4. How many
• Units in trains
• Units in vans and lorries
• Units in ships
• Other equipment
Have been manufactured during the last ten years (specific data per year;
also import and local data)
5. What is the production target for the year 2000 (as well as estimates for
import data)?
6. How much refrigerant (types, HCFC-22, CFC-12, 500 or 502) is used in
equipment manufacturing (first charge; whether it concerns domestically
produced refrigerant or import)? What is the charge used in typical products
(indications as to size)?
7. How many units have been installed (domestically produced or import)?
• Distribution with respect to the age of the product (10-20, 5-10 and
0-5 years old)
• Typical charges of these units
8. Engineers involved and their education level, some information on
• Education level of engineers
(equal questions as in retail refrigeration)
9. What is the future trend expected in manufacturing this equipment
• Manufacturing technology change
• Types and typical volumes
10. (optional) Which standards are applied in tests (ISO, NF, DIN, own...)
-------
-9 - '
. Inner and ambient temperatures applied
Which responsibility belongs to the National Manufacturer Organization(s)?
B. Components (compressor) Manufacturing
1. Are components (like heat exchangers and valves, not the compressors)
made in-site/locally or bought from external suppliers
. Information on the type of heat exchangers
. Information on manufacturing techniques
2. Who provides the compressors
• Same structure as the retail refrigeration industry
• Differences
• What is the target for the near future
C. Servicing
1. How efficient is the service organization
. How many servicing operations per unit
. Amount of refrigerant (typical) used in servicing (separated to the
refrigerant type of equipment)
• The amount of refrigerant used for servicing per year compared to
the charge of the unit
. Is servicing performed via factory/brand organization
. General practice in servicing
2. What has been the amount of refrigerant used for servicing per year versus
new charging of equipment (split up to types of equipment)
3. Which kind of engineers perform servicing
Education levels
Training on the job/service manuals
Service engineers organizations
Number of engineers involved
Is there a shortage/surplus of service engineers
4.
5.
Which are typical aspects of servicing and the critical parameters (which
components fail, leak detection available, etc.)
Disposal
What is the average lifetime of a unit (reasons for disposal)
How many units are being disposed of/future expectations
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-10-
IV. AIR CONDITIONING
a. AC by the use of small and middle-sized units
b. AC by the use of large (reciprocal and centrifugal chillers)
(questions have to be answered separately for the two categories of equipment, small AC
requirement and large chilling equipment)
A. General Description of the Sector
1. A short description of the history of manufacturing air conditioning units
2. Which are the critical parameters for the country in this sector?
3. The size and the structure of the industry
• How many production sites
• Average size of a production site
• Direct labor and total number of employees involved
• Status of manufacturing technology
4. How manY AC-units have been produced during the last ten years (specific
data per year; also import and local data)
5. What is the production target for the year 2000 (as well as estimates for
import data)
6. How much refrigerant (types, HCFC-22, CFC-12, 500 or CFC-11) is used in
equipment manufacturing (first charge; whether it concerns domestically
produced refrigerant or import)? What is the charge used in typical products
(indications as to size)?>
7. How many units have been installed (domestically produced or import)
• Distribution with respect to the age of the product (10-20, 5-10 and
0-5 years old)
• Typical charges of these units
8. Engineers involved and their education level, some information on
Education level of engineers
National engineer societies (education level)
Training courses
9. What is future trend expected in manufacturing this equipment
Manufacturing technology change
Types and typical volumes
Size of production sites
10. (Optional) Which standards are applied in tests (ISO, NF< DIN, own...)
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-11 -
• Inner and ambient temperatures applied
Which responsibility belongs to the National Manufacturer Organization(s)
B. Components (compressors) Manufacturing
1. Are components (like heat exchangers and valves, not the compressors)
made in-site/locally or bought from external suppliers
• Information on the type of heat exchangers
• Information on manufacturing techniques
2. Are compressors made in-site/locally or bought from external suppliers
(abroad)
In case of domestic compressor production (in-site or not)
3. The size and the structure of the compressor industry
Number of factories (licensed/joint ventures)
Direct labor and total number of employees involved
Installed production capacity per shift
Age of production lines and lifetime (when installed)
Capacities of compressors produced (cooling capacity)
4. Are compressor electric motors made in-site?
5. How many compressors have been produced during the last gen years
(import and export data)
• Separate data for each of the refrigerant types
6. What is the future production target (e.g., 2000)
• Quantity concerned
• Shift from/towards other types
. Shift fromAowards other refrigerants
C. Servicing
1. How efficient is the service organization
. How many servicing operations per unit
• Amount of refrigerant (typical) used in servicing (separated to the
refrigerant type of equipment)
• The amount of refrigerant used for servicing per year compared to
the charge of the unit
. Is servicing performed via factor/brand organization
• General practice in servicing
2. What has been the amount of refrigerant used for servicing per year versus
new charging of equipment (split up to types of equipment)
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- 12-
3. What kind of engineers perform servicing
• Education levels
. Training on the job/service manuals
• Service engineers organizations
• Number of engineers involved
• Is there a shortage/surplus of service engineers
4. Which are typical aspects of servicing and the critical parameters
• Which components fail, leak detection available, etc.
5. Disposal
What is average lifetime of a unit
How many units are being disposed of/future expectations
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- 13-
V. AUTOMOTIVE/MOBILE AIR-CONDITIONING
A. General Information
1. A short description of the history of Auto-AC; are cars normally equipped
with AC units?
2. Which are the critical parameters for the country (comfort, humidity, etc.)
3. What is the number of cars equipped with AC:
. Tendencies in recent years
• Expected for the near future
. What is the lifetime of a car and what is the average lifetime of the
fleet equipped with air conditioning
4. Is there a significant amount of buses, railway carriages, etc. equipped with
AC and what is the trend for the near future (are units produced
domestically or imported)
5. Production figures
• How many cars are being produced domestically
(with and without AC)
. How many cars are being imported/exported
(with and without AC)
(some data for the last decade)
6. What is the production target for the year 2000 (as well as estimates for
import data)
7. How much refrigerant (type) is used for first charging the units and how
much is used for servicing; what is the total amount involved and is it
obtained from domestic sources.
What is the average charge used in the equipment
8. How many units are functioning (domestically produced or imported)
. Distribution with respect to the age of the unit/car (10-20, 5-10 and 0-
5 years old)
• Typical charges of these units
9. What is the future trend expected in manufacturing this equipment
• manufacturing technology change and types involved
10. In which way compressors are mounted in cars and what is the education of
the workers.
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-14-
11. Which standards are applied in tests (SAE, own...)
• Inner and ambient temperatures applied
12. How many cars are being disposed of each year (percentage equipped with
AC; can the refrigerant be collected)
B. Components (compressor) Manufacturing
1. Are components (like heat exchangers and valves, not the compressors)
made in-site/locally or bought from external suppliers
• Information on the type of heat exchangers
• Information on manufacturing techniques
2. Are compressors made in-site. locally or bought from external suppliers
3. The size and structure of the compressor industry
• Which percentage is licensed production
• Installed production capacity per shift
• Age of production lines and lifetime (when installed)
4. How many compressors have been produced during the last ten years
(import and export data)
5. What is the future production target (e.g. 2000)
• Shift from/towards other types
C. Servicing
1. Is servicing of the AC units performed by garages (percentage of total
number of activities; do it yourself attitude)
What is the amount of refrigerant used by garages for servicing compared to
the total amount used for servicing/refilling (disposable cans)
2. Which kind of engineers perform servicing?
• Standardized education levels
• Permanent education
• Training on the job/service manuals
3. What is the amount of refrigerant used for servicing per service center
(average garage)? What has been the tendency in the years 1986-89?
4. Which are the typical aspects of servicing and the critical parameters
• Which components fail, leak detection available, etc.
5. Is there a shortage/surplus of service engineers? Is there a service engineer
organization?
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-15-
AEROSOLS
1. Indicate the aerosol product categories manufactured in your facility and the approximate
wholesale value per unit (in local currency):
Wholesale Value
per Unit
Insecticides
Personal Products
Paints
Medical Products
Household Products
Automotive and Industrial Products
Other (please specify )
2. Estimate the total number of aerosols produced in your company in 1988 and the percent
exported to other countries:
• Approximately million aerosol units were produced in 1988 and percent of this
was exported to .
3. Estimate the overall future annual growth rate in demand for aerosols over the next 5 years:
• The estimated annual growth (decline) in demand for aerosols is estimated at %
4. What is the basis for changes in production of aerosols:
[ ] Purchasing power of the population
[ ] Availability of alternative products
[ ] Prospects of export markets
[ ] Other (please specify )
5. Of the total number of units manufactured in your facility, estimate the percent containing
chlorofluorocarbons and the type of theses aerosol products:
• percent of the total number of units manufactured contain CFCs. The product
categories formulated with CFCs include
6. What is the current price of aerosol-grade propellants in local currency:
CFC-11 /Kg CFC-12 /Kg
Isobutane /Kg Butane /Kg Propane /Kg
7. What would be the constraints for reformulating products using CFCs to hydrocarbon
propellants? If capital investment is required to modify existing manufacturing facilities, please
estimate the level of investment required?
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- 16 -
SOLVENT CLEANING
1. Of the total amount of CFC-113 consumed in the company, estimate the distribution of solvent
use by application:
Percent of Total Use
Methyl Carbon
CFC-113 Chloroform Tetra-
Chloride
[ ] to remove flux from electronic assemblies
[ ] metal cleaning _ _ _
[ ] precision cleaning (e.g., cleaning of disk drives) _ _ _
[ ] component drying _ _ _
[ ] other (specify: _ )
Total 100% 100%
100%
2. Which end-products are involved in the above uses:
[ ] Computers; [ ] consumer electronics; [ ] automotive components
[ ] telecommunications equipment; [ ] avionic instrumentation; [ ] military equipment;
[ ] other ( _ )
3. Estimate the number and type of solvent cleaning equipment produced every year and the
approximate value. Estimate the percent of total production that is exported and the number of
imported units (please include destination and origin of exports and imports).
Number of Units Value Units
produced annually per Unit % Exported-Destination Import ed-Origin
Cold cleaning
Conveyorized Vapor degreasing
Open top vapor degreasing
Solvent recovery systems
4. Provide the number and age of cleaning equipment in service:
Number of Units Percent of Total Stock
in Service 1-5 years old 6-10 years 11-20 years 21+ years
Cold cleaning
Conveyorized vapor degreasing
Open top vapor degreasing
Solvent recovery systems
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- 17 -
5. Consider all major solvents currently used for electronics and metal cleaning applications. What
is the approximate distribution of consumption by solvent type?
• CFC-113 accounts for % of the total solvent consumption.
• Methyl Chloroform accounts for % of the total solvent consumption.
• Carbon Tetrachloride accounts for % of the total solvent consumption
• Other solvents account for the remaining % of total solvent consumption.
6. Do you send out waste CFC-113 for recycle/recovery? If so, how much annually?
7. Are you aware of and for considering replacement processes/chemicals/technologies for the
above applications? If so, please describe.
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- 18 -
STERILANTS
1. For each of the following end-uses estimate the total number and type of sterilization chambers
in service and the approximate value of these units:
Number of Units Value per Unit
in Service
Hospital sterilization.
Commercial/industrial sterilization
R&D laboratories.
Other (please specify)
2. Indicate the approximate number of sterilization chambers purchased every year and the
expected growth in future sales:
Number of Units
Purchased Sales Growth
Hospital sterilization.
Commercial/industrial sterilization
R&D laboratories.
Other (please specify)
3. What percent of the local market is supplied domestically: percent.
4. What percent of local production is exported: percent.
5. Of the total volume of sterilant gases used, roughly estimate the percent associated with
mixtures containing CFC-12: percent.
6. What other sterilization methods are used for heat-sensitive devices:
[ ] Pure ethylene oxide
[ ] Formaldehyde
[ ] Ethylene Oxide and Carbon Dioxide
[ ] Other ( )
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- 19 -
FOAMS
1. Quantities and types of foam products manufactured and imported, blowing agents used,
and extent to which CFCs or other blowing agents or product substitutes are now
employed.
a. Polyurethane Foams
- Rigid Appliance Insulation
Rigid Insulation: building, piping, slabstock, etc.
Flexible
Packaging and Other
b. Extruded Polystyrene
- Packaging
- Insulation
c. Phenolic
d. Polyolefin
2. Projected foam demand by year until 2000
Basis for growth in demand
Domestic Consumption
- Exports
Projected sources for meeting future demand
- Expanded domestic production
Increased imports (possible sources)
Infrastructure requirements for expanded manufacturing and/or production
- Possible sources of technology
- Possible quantum of capital
- Govemment/private/international agency participation in expansion
3. Sources of current raw material for production
- Domestic production
- Imports and country of origin
4. Current domestic manufacturing facilities
Size and structure of industry (number of employees, sales, etc.)
- Age and expected life time of production facility
~ Is the facility under a licencing agreement/joint venture
Source and type of technology used
5. What are the critical parameters, factors of the product that are essential to the country.
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- 20 -
6. Characteristic of unorganized industry in the country
- Small plants
7. Identify near term substitutes
Chemical substitutes
- Process modifications or alternative technologies
Product substitutes
8. Availability of near term substitutes
9. Identify longer term options for both chemical substitution or process change.
L .
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- 21 -
HALONS
1. Is there a government agency or trade association responsible for fire protection? If so, list
name, address, phone number and fax number.
2. Are there any pieces of national legislation or regulations on fire protection that require
halon? If so, please list.
3. Imports/Halon
When did you first import halon?
How much halon is currently being imported?
- bulk
- in equipment
How much has been imported each year from initial date of import?
- bulk
- in equipment
4. Production/Halon
If there is any production facilities in your country, please estimate volume.
5. Production/Equipment
Does your country manufacture any fire protection equipment intended to contain halon? If
so, identify manufacturer, location, capacity and whether manufacturing
- 1301 systems
- 1301 portables
- 1211 portable extinguishers
- 1301 systems
- 2402 in any type of equipment?
6. Estimate bank of halon by examining use sectors. Specify use of -1301, -1211, -2402 within
each sector.
- Transportation
- Communications
- Utilities
- Financial services
- Primary industry
- Manufacturing industry
- Natural resource industry
- Petro/chemical
- Government services/military
- Health care
- Other
TOTAL
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-22 -
To check estimated bank, compare total to quantity imported from date of initial import.
6a. What percent of halon applications are in areas where a fire would pose direct threat to
human life and a large sector of your society and where no other extinguishing agent could
be used effectively?
7. How much halon is used to:
1301 1211 2402
I Fill new installations
Recharge existing installations
Testing/training
i
8. What major projects has your country committed to that will require halon?
i
8a. Provide a 5-year forecast of halon needs/commitments.
9. What national plans, if any, exist for reducing halon dependence?
10. Please provide any other information/suggestions for needed assistance.
-------
APPENDIX
-------
Replacement of CFC-113 in
Industry
Author:
Brian N. Ellis
(Protonique S.A., 1032 Romanel-sur-Lausanne)
Published by:
Federal Office of Environment, Forests and Landscape
3003 Berne
January 1990
-------
Preface
To protect the global ozone layer, the production and consumption of
a series of chemicals, such as chlorofluorocarbons (CFCs) and halons,
must be phased out. The great majority of industrial enterprises using
CFCs and halons are prepared to renounce them, but there is an obvious
lack of information on how to achieve this in practice. This booklet
contributes towards filling in this gap. The author is a renowned expert
in industrial cleaning and is recognised in the relevant international
professional circles. He has actively participated in the evaluation of the
possibilities for the substitution of CFC-113, within the framework of
the United Nations Environmental Programme (UNEP). The Federal
Office of Environment, Forests and Landscape is convinced that, by
supporting this publication, an important contribution to the
accomplishment of CFC replacement is being made.
Federal Office for Environment,
Forests and Landscape,
The Director
Professor Dr. Bruno Bohlen
-------
French executive summary
ES-2
-------
Executiv , :mmary
This booklet is intended primarily to guide Swiss
industry away from the use of chlorofluorocarbon
(CFC) and other polluting solvents, giving suggestions
as to how these products may be replaced by less
polluting ones. For the most pan, it is a re'sume' of the
Solvents Technical Options Committee Report of the
United Nations Environmental Programme, modified
to suit the Swiss context. Its structure follows a logical
sequence.
The first chapter is an introduction giving brief
indications as to why it is necessary to replace
CFC-solvents, touching on both the technical and the
legislative aspects with, obviously, a certain emphasis
on the Montreal Protocol, as well as the official Swiss
position, as defined by the Federal Council and
probable future legislation. The mechanisms of ozone
depletion and the greenhouse effect are also briefly
discussed.
Chapter two examines most of the practical products
that may be used for industrial cleaning, indicating their
individual advantages and disadvantages. The first
section discusses the two solvents which are restricted
under the current (1979) provisions of the Montreal
Protocol, CFC-11 and CFC-113. The next section
examines those solvents that are not yet restricted even
though there is every reason why they should be,
namely, carbon tetrachloride, 1,1,1-trichloroethane
(methyl chloroform), CFC-112 and certain HCFCs. All
of these will probably be included in the next revision
of the Protocol, scheduled for June 1990. Section 3 of
this chapter looks at other halogenated and
non-halogenated organic solvents. The last section
exposes water-based cleaning methods, with and
without diverse types of additives.
As CFC and other halogenated solvents become more
difficult to obtain, and more expensive, it will become
increasingly important to practice conservation. /. ,s
shown in the third chapter that savings of
-------
talian executive summary
-------
German executh ..mmary
ES-3
-------
Chapter IV. Substitution IV-1
IV. 1. General IV-l
IV. 2. Specific applications IV-l
IV. 2. i X.^uxing IV-l
IV'. 2. 1. Industrial deflating [\'-l
I\'2. 1. I. 1 The "no-clean"solution IV-2
IV 2. 1. 1. 2 Water cleaning with water-soluble fluxes IV-4
fV. 2. 1. 1. 3 Rosin flux and saponifier TV-6
IV. 2. 1. 1. 4 Hydrocarbon/surfactant cleaning of rosin fluxes IV-8
[V. 2. 1. 1. 5 Hydrocarbon and derivative cleaning of rosin fluxes IV-8
IV. 2. 1. 1.6 Permitted halocarbon blends IV-10
IV. 2.1.2. Artisanal defluxing rV-11
IV.2.2. Degreasing IV-ll
IV. 2.3. Precision cleaning IV-ll
IV. 2.4. Drying by solvents IV-12
IV. 2. 5. Textile dry cleaning IV-12
IV. 2.6. Particle removal IV-12
IV. 2. 7. Medical applications IV-12
IV. 2. 8. Vehicles for lubricants and adhesives IV-13
Appendix A, Properties of Halocarbons APP.A-1
R. References R-l
L. Useful lists of addresses L-l
L. 1. Government and official departments L-l
L.2. Private sector organisations L-l
L. 2.1. Chemical Industry L-l
L2.2. Electronics industry: L-l
L2.3. Precision industry: L-l
L 2.4. Dry cleaning: L-2
L.3. Experts L-3
Index IND-1
-------
Table of Contents
Preface by Dr. B. Bohlen i
Executive Summary (in English, Frenc. J-rnian and Italian) ES-1
D. Definitions D-l
Chapter I. Introduction M
I.I. Why? M
1.2. Historical background M
1.3. The Montreal Protocol M
1.4. The Helsinki Declaration, May 1989 1-2
1.5. Solvents Technical Options Committee 1-3
1.6. Future Decisions of the Parties to the Montreal Protocol 1-3
1.7. Swiss legislation [-3
1.8. The Mechanism of ozone depletion 1-3
1.9. Greenhouse effect 1-4
Chapter n. Products under question and others II-l
II. 1. Restricted solvents according to the Montreal Protocol (state of 1989) II-1
n. 1.1. CFC-113 II-;
n. 1.2. CFC-II II-L
II. 2. Ozone-depleting solvents not yet restricted according to the Montreal Protocol (state of 1989) II-1
II. 2.1. Carbon tctrachloride II-1
II. 2.2. 1.1,1-trichJoroethanc II-l
II. 2.3. CFC-112 II-2
II. 2. 4. Hydrochlorofluorocarbonsolvents (HCFCs) II-2
II. 3. Other organic solvents II-3
II. 3.1. Fluorinatedsolvents II-3
n. 3.2. Chlorinated solvents II-3
II. 3. 2.1. Practical aspects of chlorocarbons and hydrochlorocarbons II-3
II. 3.3. Non-halogenated hydrocarbons and their derivatives II--
II. 3. 3.1. Hydrocarbons //-'
II. 3.3. 2. Alcohols and other hydrocarbon derivatives //•-<
II. 3. 3.3. Practical aspects of hydrocarbons and derivatives II-4
II. 3. 3. 4. Hydrocarbon/surfactant blends II-?
II. 4. Aqueous systems 11-6
II. 4.1. General II-6
II. 4.2. Water quality II-6
II. 4.3. Drying II-
II. 4.4. Pure water cleaning II-""
II. 4.5. Water + detergents II-~
II. 4.6. Water +• saponiGers II-S
Chapter III. Conservation of CFC and other volatile solvents III-l
m. 1. General III-l
m. 2. Bottoms recovery III-l
HI. 3. Equipment siting HI-2
m. 4. Equipment maintenance III--
IH.5. Mokcularsieves III-2
III.6. Solvent handling Ill-:
III. 7. Equipment enhancement HI-3
in. 7.1. Freeboard HI-3
III. 7.2. Lid HI-3
m.7.3. Cooling coils IH-3
in. 7.4. Parts baskets HI-3
ni.7.5. Sprays IH-3
III.8. Oeanlngcycle HI-3
III. 9. Automatic handling "1-4
III. 10. Solventtype "I-*
III. 11. Solvent vapour capture HI-*
III. 11.1. Othersolvents HI-4
III. 12. Operator awareness and management HI-4
TOC-1
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D. Definitions
It is thought thaisome of the terms used in this booklet application. It has been a deliberate policy 10
-------
Hydrochlorofluorocarbon (F. hydrochjorofluorocarbone, D. iciiweise halogemcner FluorchJorkorUenwasservcif
(HCFQ a hydrocarbon where one or more hydrogen atoms, but not all of them, are replaced by
chlorine and fluorine atoms
Hydrofluorocarbon [F. hydrofluorocarbone, D. teilweise halogenierter FluorkohJenwasserstoff] (HFC) a
hydrocarbon wr . e or more hydrogen atoms, but not all of them, are replaced by fluonne atoms
Ionic contamination [F. contai._,nsiion ionique, D. ionische Kontamination od. Verunreinigung] residues on an
electronics assembly which will ionise in the presence of water. The measure of ionic contamination
is a standard procedure to determine cleanliness
Lifetime [F. durde de vie, D. Lebensdauer] in this context, the time, expressed in years, required for a substance
in gaseous or vapour form to break down in the atmosphere. As the decay is exponential, it is expressed
for convenience as the "folded-e" lifetime, that is until there is 1/e times the original quantity,
approximately 37%
Ozone [F. ozone, D. Ozon] Oj, an allotrope of oxygen. In the stratosphere, where it is generated by solar
radiation, it forms a barrier to high-energy ultra-violet (UVB) radiation. In the troposphere, it is a , .
highly toxic gas
Ozone depletion [F. appauvrissement d'ozone, D. Ozonabbau] an effect where stratospheric ozone is reverted to
oxygen by a catalytic reaction with chlorine or bromine, mainly derived from human activities, faster
than it forms ,
Ozone depletion potential [F. Potentiel d'appauvrissement de la couche d'ozone, D. Ozonschichtabbaupotential]
an index, referred to CFC-11 - 1, given to a substance, indicating its potential to deplete ozone in the
stratosphere. It is calculated by means of a small number of mathematical models from about twelve
parameters and is necessarily approximate as there are other undefined parameters involved < •
Ozone hole [F. trou d'ozone, D. Ozonloch] a loose term to describe a phenomenon where a high degree of ozone
depletion occurs over the Antarctic at the end of winter. It is caused by the combination of
meteorological phenomena with, principally, chlorine atoms
Ozone layer [F. couche d'ozone, D. Ozonschicht] a loose term to indicate the ozone contained in the stratosphere,
between 10 and SO km altitude .
Perchlorocarbon [F. pcrchlorocarbone, D. Perchlorkohlenwasserstoff] (CC) an organic substance where all the
hydrogen atoms of a hydrocarbon are replaced by a chlorine atom , .
Perfluorocarbon [F. perfluorocarbone, D. Perfluorkohlenwasserstoffj (FC) an organic substance where all the ,
hydrogen atoms of a hydrocarbon are replaced by a fluorine atom
Petroleum ether [F. e"ther de pe"trole D. Petrolather] a mixture of hydrocarbon petroleum distillates with boiling
points from 40* to 80*C, often selected over a narrow range
Petroleum spirits [F. essence de pe"trole, benzine D. Benzin, Petrolspiritus] a mixture of hydrocarbon petroleum k
distillates with boiling points from 80* to 150'C. Also used as a generic term for all fractions from
about 30* to 300*C
Precision cleaning [F. nettoyage de precision, D. Prazisionsreinigung] cleaning of ultra-precise components or
assemblies to defined limits
Product (F. produit, D. Produkt] a mixture of chemical compounds, often of a commercial nature, frequently
of indeterminate or secret composition
Rosin [F. colophane, D. Kolophonium] a mixture of natural organic acids obtained from pine trees used
extensively as a soldering flux. Its fluxing action is weak and activators are usually added
Soldering [F. soudage, brasage tendre, D. Lotenj the joining of two metals by a third, usually of low melting
point, whereby a chemical bond is formed at the interfaces by the formation of intermetallic
compounds. Soldering requires clean surfaces, hence one of the reasons for fluxes
Solvent [F. solvant, D. Losungsmittel] in this context, but not strictly correct, a liquid substance or a product
designed to dissolve specific contaminants
Stoddart solvent a type of white spirits used for dry-cleaning garments
Substance [F. substance, D. Stoff] a single chemical compound of a specific composition, as opposed to a
product
Surface insulation resistance [F. resistance de I'isolement de surface, D. Oberflachenwiderstand] (SIR) one of the
qualities of a good insulator is a high SIR. As the presence of contamination may reduce the SIR, the (
measure of it is a standard procedure to determine cleanliness
Surfactant [F. agent de surface, D. oberflachenaktiver Stoff] a substance with long molecules, one end of which
is lipophilic and the other hydrophilic. Surfactants reduce the surface tension of water with which , .
they are mixed and they form micelles which can emulsify many oils and greases. Surfactants are the t •
principal constituents of most detergents
D-2
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Terpenes (F. terpenes, D. Terpene] a family of volatile, odoriferous, cyclic hydroca:?ons •>• .;.-. :r.o .: —r.-.^..
formula CioHi6. There are (ens of types of terpenes with vanous solvent qualities. The rr.os;:'-- :
is alpha-pinene, the principal constituent of turpentine.
Terpenoid [F. [orpine, D. Terpenederivat] a derivative of a terpene (see hydrocarbon derivative)
Toxicity [F. toxicite" D. Giftigkeit, Toxizitat]a measure of the harm ihatasubr -e ,nay cause to any '.-.%•.-«;
species. Acute toxicity applies to the effect of a single dose, whereas c.aoiuc toxicity applies :o :.-.s
effect of repeated doses-over a period of time. As far as man is concerned, the major access pair^ o:
toxic substances are oral, respiratory and cutaneous
Volatile organic compound [F. compos* organique volatil (COV) D. Quchtige organischc Verbindung] (VCC a
loose term to designate a compound whose vapours will react with pollutants and oxygen, in :r.c
presence of light, to form atmospheric ozone. In the context of Swiss custom, the term means ar.\
organic compound that is easily vaporised, synonymous with hydrocarbon (q.v.)
Water-soluble flux (F. flux hydrosoluble, D. wasscrlosliches Flussmittel] a soldering flux, not necessarily
containing water, but whose residues after soldering are easily removed by a simple water wash
White spirits [F. white spirit, sangayol D. white spirit] a mixture of hydrocarbon petroleum distillates with boiiirg
points from 120* to 220'C
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Chapter I. Introduction
1.1. Why?
This booklet is a short re'sume' of why Swiss industry
must reduce its consumption of an environmentally
dangerous product, CFC-113, a chlorofluorocarbon or
CFC and popular as a cleaning solvent (plus some other
uses not relevant to this work). It is meant as an
introduction for industrialists as to means and methods
of substituting relatively harmless products for
CFC-113 with a brief discussion of the pros and cons
for each, as applied to each broad industrial sector. A
further utility will be to warn industry of what may well
become future problem areas, so that any substitution
methods adopted are chosen, as far as possible, from
those which are least likely to cause other problems of
an environmental nature.
I. 2. Historical background
In 1974, two American scientists, Molina and
Rowland, pronounced a hypothesis1 that CFCs could
provoke destruction of the ozone layer in the
stratosphere. This layer is one of the determining
factors for global climate and protects the biosphere
from intense UVB radiation and, without it, life could
not be supported on the earth's surface. It is very thin:
if all the stratospheric ozone in a column of a given area
was brought down to the earth's surface, it would form
a layer of an average thickness of 3-4 mm at
atmospheric pressure (300-400 Dobson Units).
However, this danger appeared at the time very
theoretical and only a few persons took it really
seriously. The first resultant measure was that the
Envi ronmental Protection Agency of the USA was able
to instigate legislation, passed in 1978, forbidding the
use of CFC propellant gases in most aerosol sprays.
Only a few other countries, notably Sweden, Norway
and Canada, followed suit within a year or so and no
other application was restricted.
In the mid 1980s, a British Antarctic Survey2
discovered that the-ozone layer was rapidly and
progressively diminishing at the end of each winter.
The immediate reaction of scientists was to revive the
theory that CFCs3'4 may be responsible for the ozone
hole which was later confirmed independently to exist5.
In 1987, an international meeting in Montreal, under the
auspices of the United Nations Environmental
Programme (UNEP), agreed on a Protocol6 which
defined the most dangerous products which were
known to be causing a degradation of the ozone layer.
their respective potential for such depletion. ar.u1 j.
programme for the reduction of their production ar.^i
consumption. Up to mid-1989, this was signed bv
nearly 50 nations and ratified by over 30 of ;r.e-
(including Switzerland) plus the European Economic
Community en bloc. It entered into force on the Is:
January 1989. Since 1987, much effort has beer, mac;
to confirm that the ozone layer is dirmr.isriir.a :.-.
thickness and not only over the Antarctic and :hat the
main cause of this depletion is indeed the chio—.e
resulting principally from the decomposition of CFCs
and other industrial chemicals in the stratosphere. Tr..s
has now been scientifically proved and confirrr.ed by
independent methods. Equally, it has been shown tr.it
the situation is even more serious than was initial;;,
believed and that the provisions of the Protocol a.-.-
woefully inadequate to stop future degradation, even or.
a long time scale (Figure 1-1).
As a result, a meeting was held in The Has-.e .-
Autumn 1988, at which it was decided :o set un
international committees of experts to stud;, •.-.:
situation and its evolution and who would" report on -.hi
state of the art to UNEP and the members of -.I-.,:
Montreal Protocol. These committees would cover a.I
applications of CFCs and similar chemicals and show
how to implement changeovers from these products to
other types of materials as painlessly as possible.
identifying which substances and products are :'-t
principal "culprits" and whether any others should be
restricted. These committees were formed very rapidly
and produced their reports in the record time of six
months. This is an indication of the urgency of '.r.e
situation.
In Spring 1989, the British Prime Minister. Mrs. M.
Thatcher, responding to "green" pressure, called an
informal international conference of scientists and
ministers at which it was confirmed that the situation
was grave. During the address pronounced by Swiss
Federal Councillor Mr. Flavio Cotti, he gave a warning
that Volatile Organic Compounds (VOCs) would not
be the most satisfactory substitutes for CFCs because
of the problems caused by them in the lower
atmosphere. At the same time, he announced :r.r.
Switzerland would substantially eliminate CFC and
halon usage by 1995 (85-90% reduction).
1.3. The Montreal Protocol
As stated earlier, the Montreal Protocol defines ;-.o
substances subject to restrictions and dangerous for:.-.;
-------
ll.I -r
Vtu>
Fig. 1-1. Forecast for Stratospheric Clx Progression
Key to Figure 1-1
The above figure demonstrates the different scenarii, calculated according to the best information available and to possible
reduction programmes of chlorine- containing substances. The Y-axis is in parts per milliard (U.S.A. parts per billion) of total Clx
concentrations in the ozone layer. As in all predictions, the premises on which the calculations are based can not be considered as
infallible, but they are sufficiently accurate to give a broad visual representation.
Curve 1. CFCs (all types) reduced on a global scale according to the current provisions of the Montreal Protocol and no increase
in production of carbon tetrachloride, 50% of the CFC market being replaced by HCFCs with an average OOP of 0.08.
Curve 2. As for curve 1, except for a total phase-out of all CFCs by year 2000.
Curve 3. As for curve 2, except for a total phase-out of carbon tetrachloride.
Curve 4. As for curve 3, plus no increase in production of 1,1,1-trichloroethane.
Curve 5. As for curve 3, except for a total phase-out of 1,1,1-trichloroethane.
Curve 6. As for curve 5, except for replacement of 20% only of the CFC market by HCFCs with an average ODP of 0.08.
Curve 7. As for curve 5, except for replacement of 35% of the CFC market by HCFCs with an average ODP of only 0.02.
Source: adapted from a presentation made by the U.S. EPA tothePartiesoftheMontrealProtocolatHelsitiki(1989).
ozone layer and a programme for the reduction of their
production and consumption. It is a long and complex
document and only the essential points, as applied to
solvents, will be discussed here. Only two CFCs
mentioned are usable as solvents, CFC-11 with an
Ozone Depletion Potential (ODP) of 1 and CFC-113
with an ODP of 0.8. The first-named is only rarely used
for cleaning purposes due to a very low boiling point.
It is estimated that at least 99.9% of the CFC solvents
are products based on the substance
1.1.2-trichloro-1.2.2-trifluoroethane, CzFjClj,
abbreviated to CFC-113. These two substances are
included in a "basket" with other CFCs which are used
for other purposes. This "basket" was agreed to be
subject to a reduction of the production and
consumption according to the following programme:
1 July 1989: reduction to the 1986 consumption
level, a de facto reduction of about
21%
1 July 1993: reduction to 80% of the 1986 level
1 July 1998: reduction to 50% of the 1986 level.
Further clauses in the Protocol permit revision of the
list of substances and the timetable of reductions.
It is therefore clear, as Switzerland ratified the
Protocol on the 28 December 1988, that Swiss industry
is committed to reduce its consumption of CFC-113.
In May 1989, the UNEP organised the first meeting
of the parties to the Montreal Protocol in Helsinki at
which it was agreed that further restrictions were
inevitable.
1.4. The Helsinki Declaration, May
1989
In substance, the Helsinki Declaration officially
recognised that the Montreal Protocol was inadequate
and it has paved the way to forcing the introduction into
it of other substances that research has shown to be
ozone depleters and to tightening the programme to a
complete phase-out of CFCs by the year 2000. It has
also foreseen the difficulties that under-developed
countries may experience in reducing their
consumption of the substances in question and is
1-2
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forcing research into means of low-cost technology
transfer into these nations.
1.5. Solvents Technical Options
Committee
The main task of the committee, formed as a result of
The Hague meeting, was to determine how to substitute
less environmentally harmful substances or products
for CFC solvents. This involved an examination of the
secondary implications, such as the cost of capital
equipment and exploitation, as well as the primary ones,
such as the environmental impact. As far as possible,
the objectives were to study all the known applications.
The second task was to scrutinise solvents that were not
restricted in the Montreal Protocol but were known to
be ozone-depleting and to determine whether and
where these, too, could be replaced by more benign
products.
The committee was formed in January 1989 under the
chairmanship of Dr. Stephen O. Andersen of the U.S.
Environmental Protection Agency. Twelve persons
(with three substitutes) contributed to the work of the
committee, from Canada, Japan, Sweden. Switzerland,
the United Kingdom and the United States of America.
The combined experience of the members of the
committee covers nearly every possible usage of
CFC-113 solvents and their substitutes. Their report is
beingpublished in 1989after five meetings . Copies (in
English) will be obtainable through the Federal Office
of Environment, Forests and Landscape. It is an
important work: the chapter headings are: Glossary.
Executive Summary, Introduction/Worldwide Use of
CFC-113, Electronics Industry Applications, Precision
Cleaning Applications, Metal Cleaning Applications,
Dry Cleaning Industry, Other Solvent Uses of CFC-113
and 1,1,1-trichloroethane, References and Appendices.
Two accompanying documents include reprints of cited
technical papers and commercial documentation
concerning products and machines which may be
considered for CFC-113 substitution purposes.
This booklet represents a short summary of the report
of the Solvents Technical Options Committee, as
applied to the Swiss context.
I. 6. Future Decisions of the Parties to
the Montreal Protocol
It is obviously impossible to forecast what the Parties
will decide in the future. What is known at the time of
writing is that the next Ordinary Meeting of the
contractual parties will be held in London in June 1990
with the firm intention of tightening the provisions of
the Protocol. As announced in the Helsinki Declaration,
it is almost inevitable that a complete phase-out of
CFCs by the year 2000 will be decided. What is
probable is that further sol vents will be restricted in one
way or another, including carbon tetrachloride,
1.1.1-trichloroethane, other CFCs, including CFC-112,
and some HCFCs.
I. 7. Swiss legislation
It is clear that pollution knows no political fror.::^
Switzerland, a small country with an ar.r.-a.
consumption of CFC-113 of less than 2000 :or.r.es. .s
not a major polluter but it has taken a firm siar.ce .-
favour of reducing this to a minimum, as pan of a
general programme towards a clean environment. Ai
stated above, the official position is quite clear: a
reduction of all CFC and halon usage by 1995 to a
minimum (at least 85-90% phase-down plus a virtual
phase-out by 2000). Any permitted exceptions to the
complete elimination will be clearly defined and baseJ
on sound technical reasons, as opposed :o purely
economical or commercial ones.
Obviously, no specific legislation has ye; beer.
introduced concerning CFC solvents. A Federal
Ordinance is intended, but it is unlikely that it will be
approved before 1991. It will mainly cover us;us
restrictions and recovery obligations.
In addition, a further point that should not be :gr.orei
is that some substitute solvents, notably hydrocarbons
and their derivatives classed as Volatile Orgar.:c
Compounds (VOCs), are equally under attack for beir.g
causal of tropospheric pollution by their vapours bc:r.;
subject to photochemical reactions with other
pollutants and oxygen, creating a risk of excessive
ozone levels and smog under unfavourable weather
conditions. Whereas legislation governing sue"
emissions of Volatile Organic Compounds is still ;n:'-s
infancy, industry should be aware that s'jch probie-s
exist and that it is planned that polluters will be macs
to pay for the pollution they cause. If it is envisaged :.-.3t
a substitution process will use such a VOC (e.g.
hydrocarbons, halocarbons, alcohols, terpenes.
petroleum spirits, etc.), it would seem wise to include
in the cost calculations a figure for some form of :ax or.
unaccounted substances and products and the cos; of
means to prevent the emission of such VOCs into the
atmosphere.
It is clear that any substitution method to replace the
CFC solvents must not engender any other legal
problems such as may be covered by other, existing.
laws, notably the Federal Ordinances on water
effluents8, onsubstances9 and on toxic products10i''. !n
addition, it must conform to the requirements of
industrial hygiene as laid down by the Swiss National
Accident Insurance Fund. The appropriate Cantonal
services should be consulted for further information on
all these requirements.
1.8. The Mechanism of ozone
depletion
It is not always clear why the presence of CFC
molecules in the stratosphere is so damaging. One of
the most frequently asked questions is why, if most of
the CFCs are used in the Northern Hemisphere, are the
most severe manifestations close to the South Pole1 A
very short explanation is felt to be necessary to help
1-3
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readers grasp the fact that the phenomenon is, indeed,
a global one.
If a CFC or a similar molecule reaches the
stratosphere intact by diffusion and global convection
currents, the ultraviolet radiation from the sun breaks it
down, liberating one or more of the atoms of chlorine.
Each of these acts as a catalyst (i.e. it enters into a
reaction without itself being destroyed) in such a way
that any atom of ozone it meets will break down into
oxygen and chlorine oxide. Two molecules of the latter
will break down, by radiation or contact with other
types of molecules, to form another molecule of
oxygen, thereby releasing the chlorine to restart the
cycle. It is estimated that each atom of chlorine will
destroy, on an average, 100,000 molecules of ozone
before it diffuses back to the troposphere where it will
be washed back to the earth by rain. How can a
substance whose vapours are much heavier than air
diffuse into the stratosphere? Why, if it does reach
there, has it manifested itself near the South Pole, which
is the farthest point from where it is used the most?
These are valid questions and difficult to answer in just
a few, simple words. First, time is on the side of the CFC
molecules. Unlike most other chemicals, this type of
solvent is remarkably stable. This means that it does not
break down readily when it encounters other
substances: it is exactly this quality that renders
CFC-113 so non-toxic. It is estimated that the average
"e-folding" (exponential decay) lifetime of CFC-113 is
nearly 100 years. This means that, if 1 kilogramme of
CFC-113 evaporates in 1989, about 370 grammes will
still be intact in 2089,135 grammes in 2189 and so on.
It is also estimated that the whole of the tropospheric
air mass only takes about a year to circulate vertically
from ground level to the bottom limit of the stratosphere
and down again, the mechanisms being diffusion,
winds, storms, convection etc. It takes about five years
to circulate horizontally over the whole of the global
surface. Penetration into the stratosphere takes typically
tens of years. The reason for the problem having been
discovered initially at the South Pole is because of a
particular meteorological phenomenon, called the polar
vortex12, which, over the few months of the polar
winter, prevents any admixture of renewed air and
allows the temperature to drop to very low levels. The
two phenomena together, combined with the presence
of nascent chlorine, result in massive local ozone
depletion. From an average of about 300 Dobson units,
one observation post at a latitude of 76'S has measured
a diminution to about half this figure over the last
twenty-five years. The figures are even worse as the
pole is approached. This explanation is very simplistic
and reference may be made to an excellent description
of the problem for those wanting more scientific
explanations of these phenomena12. In any case, it has
now been shown beyond all empirical doubt that the
"ozone hole" is not confined to the Antarctic. The
whole of the ozone layer is depleting, various estimates
having been made at approximately 0.2% per annum at
temperate latitudes, averaged over the last twenty
years13. The least depletion is in the rropics, where :.-.e
more intense radiation tends to re-ioruse depleted
oxygen back into ozone more readily.
The above explanation has been given to show the
mechanism when' .;, solvents, along with other
CFCs and similar ..neuiicals, which we use almost
without heed, have created the problem for which the
Montreal Protocol was elaborated to provide an answer.
I. 9. Greenhouse effect
Let it be quite clear. There is no scientific proof that
the so-called greenhouse effect has caused or is causing
any global climatic changes. There are, on the other
hand, strong suppositions that the earth is warming and
that this warming may be attributed to the greenhouse
effect. If this is so, then measures should be taken to
reduce it.
The media have published all kinds of alarmist figures
"proving" that the sea level will rise by up to 8 metres
and that at least half the land surface will be desenified
before the end of the next century. If the greenhouse
effect is proved to be real, there is no proof that these
scenarii will take place, even if there may be an element
of truth in them. The mathematical modelling of
climatic changes is so complex that no algorithm exists
that permit any but very approximate predictions. If
such an algorithm did exist, it would probably take the
fastest and most powerful computers longer to calculate
them than the actual changes themselves!
What is the greenhouse effect? The sun may be
considered as a black-body radiator with a temperature
of about 5.300K. At any one moment, half the earth's
surface is receiving the sun's radiation and is absorbing
it at an average energy of about 1 kW/m2, the rest being
reflected back to space. This causes the surface
temperature of the earth to rise, the average being
approximately 287K. The earth can be considered as a
partial black body radiator and the temperature balance
is achieved by the difference between the incoming and
outgoing radiation (first approximation, ignoring
geothermic and other terrestrial heat sources). The
incoming radiation is at short wavelengths which
penetrate most gases with very little attenuation.
Because of the low surface temperature, the outgoing
radiation is at long wavelengths. These are readily
absorbed by many atmospheric gases and, if this
happens, the energy can not be radiated out to space but
is absorbed in the troposphere in the form of an increase
in air temperature. From there, the transfer to water and
earth is evident.
The gas that is most frequently accused of this is
carbon dioxide, the balance of which may be upset by
the combustion of fossil fuels, deforestation, etc. Fossil
fuel combustion can act in two ways. First, there is the
direct production of the gas in large quantities.
Secondly, thereare certain quantities of acid-promoting
sulphur- and nitrogen-oxides which combine with ram
to form quite low pH precipitations. If these fall on
limestone ordolomitic rocks, these will break down to
1-4
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produce even larger quantities of carbon dioxide. It ;s
estimated that about 98% of global carbon is held in
such rocks. The volume percentage of carbon dioxide
in the atmosphere is about 0.034% but it is increasing
and it is to this increase that the theory of greenhouse
warming is ascribed.
It may be asked what all this has to do with solvents.
The answer is simple: CFC-113, along with all other
CFC gases, is an extremely powerful greenhouse gas,
stopping much radiation from the earth's surface. One
molecule of a CFC gas is estimated to have the same
effect as about 14,000 molecules of carbon dioxide,
varying slightly either way according to the
composition. In terms of weight, it is even more
dramatic: 1 kg of CFC-12, forexample, is equivalent to
8 tonnes of carbon dioxide14. In other words, it is
sufficient to have a concentration of 0.034%/14,000 =
0.024 ppvm to reach the same effect as carbon dioxide.
In places, this figure has almost been reached and the
global tropospner.c average :s cor^xeru:.. ,;>s •..-...-
only one order of magnitude from it. In other worCi. .:
the greenhouse effect is indeed shown to be caus;-g
increased global warming, CFCs would be response.e
for well over 15% of it Although a secondary reason,
it is yet another valid one why their production sho^.J
be reduced.
Many other solvents, halogenated or not, are a^so
hypothetically contributory in greater or lesser degrees
to this effect. One notable exception is
1,1,1-trichloroethane whose vapours have a
comparatively small effect on radiation at tl-.e
wavelengths concerned. Care should be taken that any
substitutes, including those under development, will
not be greenhouse gases. HCFC-141b, for example.
which is one of the candidates for substitute solvents,
has a relatively low, but not negligible, radiative forcing
potential.
Here in Switzerland, we can perhaps observe the effects of local climatic change better than in most other countries, by
noting the changes in glaciers. As one example, over the last hundred yean the bottom edge of the Furka glacier has risen
from the level of the village of Gletsch to higher than the Furka hotel. It is emphasised that this example docs not indicate
that the causal conditions are necessarily global.
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1-6
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Chapter II. Products under question and others
II. 1. Restricted solvents according to
the Montreal Protocol (state of 1989)
II. LI. CFC-113
This substance is the base for many popular solvent
products used in many branches of industry. The pure
substance is also used in some cases. In nearly all cases,
the commercialised products are sold under trade
names, the most well-known being Arklone, Delifrene,
Flugene, Freon, Frigen, Kaltron etc. (alphabetical
order). There are also a number of speciality chemicals
manufactured in smaller quantities containing a certain
quantity of CFC-113. These can often be identified by
the figure 113 somewhere in the designation or some
other indication on the label.
It is frequently blended with alcohols, ketones and
other halocarbon solvents. Depending on the chemical
composition of the blend and the use to which it will be
put, the manufacturers also add stabilisers, such as
rutrome thane.
The ozone depletion potential has been calculated at
a value of 0.8. This means that, if one kilogramme of
the substance will destroy 8/10 of the weight of ozone
that one kilogramme of CFC-11 or CFC-12 would, but
possibly on a different time scale. It is not possible to
visualise the importance of this ozone depletion from
such figures. It has been calculated, as a graphic
indication, that if one kilogramme of CFC-113 is
allowed to evaporate, it will destroy over a period of
time enough of the stratospheric ozone layer to cover
the surface area of a football field.
II. 1.2. CFC-11
As stated earlier, CFC-11 is occasionally used as a
solvent for a few specific applications. It is somewhat
better than CFC-113 for solvency and wets more
surfaces than its heavier brother. It is fairly mild
towards most thermoplastics. Its principal disadvantage
is that its boiling point is as low as 23.8'C, which makes
storage and transport problematic.
Its atmospheric lifetime is lower than that of
CFC-113, almost eighty years. Its ozone depletion
potential is 1.0 (in fact, the reference value), higher than
CFC-113 as it contains more chlorine per mole.
CFC-11 is a solvent whose high vapour pressure
makes it almost impossible to use without considerable
losses, even if precautions are taken to prevent
emissions. It is therefore to be highly discouraged.
II. 2. Ozone-depleting solvents not yet
restricted according to the Montreal
Protocol (state of 1989)
//. 2. /. Carbon tetrachloride
Carbon tetrachloride is another solvent which is a
heavy ozone depleter, even worse than CFC-113 and
CFC-11, as its OOP is about 1.18. However, ia use is
very strictly limited in Switzerland and the res; of the
Western industrialised community, because it is a
known carcinogen and liver poison. It has therefore
come as a surprise when analyses of gas samples from
the stratosphere have revealed that some 70.000:onr.es
per annum are being released into the atmosphere.
creating a significant part of the depletion. It is surmised
that this cheap, easy-to-manufacrure, solvent is $::'.:
being used in a few under-developed countr.es as we:;
as in some Eastern European nations. It is unlikely tha:
it would be possible for this substance to be used as j.
substitute for CFC-113 in Switzerland as the ir.dustr.a;
hygiene regulations15 are so strict as to effective;-/
preclude its use. Nevertheless it is good to mention :t
specifically to explain why it will probably be included
in the next revision of the Protocol.
Carbon tetrachloride is used extensively as an
industrial feedstock in chemical manufacture. Losses
from this usage are believed to be very low, despi:e
production figures in the USA and Europe in :hs
hundreds of thousands of tonnes.
II. 2. 2. 1,1,1-trichloroethane
Although 1,1,1-trichloroethane (also known as
methyl chloroform) has a relatively low OOP. various;-/
quoted at values from less than 0.1 to 0.18 (usually
taken as 0.15), the vast quantities used and emitted are
the cause for a total depletion in absolute weight
approaching that of CFC-113. For this reason, there is
pressure being applied to have its production and
consumption either limited to current levels or even
more restricted.
Most of this substance is sold under a variety of brand
names (e.g. Chlorothcne, Genklene, Prelete,
Propaklone, etc.). The commercialised products
invariably incorporate stabilisers, usually of the arrr.ne
type, and they are sometimes blended with hydrocarbon
solvents or their derivates to widen their dissolution
spectrum.
At the moment, there are not effective substitutes
available for all the applications of
1,1,1-trichloroethane based products, so it would seem
-------
very unlikely that dracoman restrictive measures will
be taken in the immediate future. On the other hand, it
is likely that the production will be frozen at, say, 1986
levels, so that expansion of its use will not be possible.
For this reason, it is not considered as a valid substitute
for CFC-113, quite apart from the moral aspect of only
partially reducing the ozone depletion.
Over the last few years, both the European and global
production figures have stabilised or even dropped
slightly. This is because a number of heavily consuming
processes have been modified (e.g., the development of
dry film resists in the printed circuit industry) and
equipment using it is better designed to reduce
emissions of the vapour16. In a few countries, this
tendency has completely reversed since early 1989
because the solvent is being increasingly used as a
substitute for CFC-113. This is exactly what the
Solvents Technical Options Committee has feared may
' happen and why they nave made it quite clear in their
report that they do not consider 1,1,1-trichloroethane to
be a valid substitute for CFC-113.
Another factor that it would be wise to consider
seriously before using or continuing to use
1,1,1-trichloroethane is that some industrial hygierusts
are posing serious questions regarding its safety. Like
all other hydrochlorocarbons and chlorocarbons, it may
cause liver lesions (cirrhosis) or can, at least, aggravate
the formation of such lesions if the worker is
predisposed towards them either through heavy
drinking of alcoholic beverages or from a genetic
history. It would seem likely that this solvent may attack
the central nervous system, particularly if blended with
methanol. There is also some discussion as to a possible
carcinogenicity, even though this does not seem likely
according to available evidence. The TLV in various
countries has been progressively reduced from about
500 ppm some twenty years ago to 50-350 ppm today
(Switzerland, 200 ppm) with tendencies to further
restrictions in the offing.
Users of 1,1,1-trichloroethane would be well advised
to start thinking in what measure they can reduce their
consumption. This can be done by two methods:
a. conservation (reduction of evaporated solvent)
b. substitution (where possible, change to
a non-polluting cleaning method).
It is almost certain that there will be restrictive
measures, sooner or later, so that it is not too early to
start thinking about bow to go about replacing this
solvent In the meanwhile, every effort should be made
to reduce the emissions by good conservation practices
and recuperation (see Chapter III).
77.2.3. CFC-112
CFC-112 is currently manufactured only in Japan and
is used in relatively small quantities. It is rather
expensive. However, it does present excellent
properties, especially for defluxing applications. The
only reason that it has not been manufactured and sold
on a wider basis is a question of price, typically 2-3
times that of CFC-113 but, as the price of the latter
increases, demand for the former may also ;ncrsi»e.
causing the price to drop. At least one senes of products
containing it has been sold in Switzerland (Alpha 1000
senes).
The OOP of CFC-112 is not known but an estimation
puts it at about 0.7, slightly less than that of CFC-113.
It was not included in the original Protocol "basket"
because the usage was so small, but concern is now
expressed because it will become more competitive.
For this reason, it is probable that the Panics to the
Montreal Protocol will include it in the next revision in
June 1990.
11.2.4. Hydrochlorofluorocarbon solvents
(HCFCs)
There are hundreds of possible HCFC compounds of
which about ten may be applicable to solvent cleaning.
Moleculariy, these substances are similar to CFCs,
except that one or more of the parent hydrocarbon
hydrogen atoms has not been replaced by a halogen
atom or, more simply, they are notperhalogenated. This
has a number of effects: firstly, the substances break
down more readily in the troposphere, forming
substances such as hydrochloric acid which are washed
to earth by rain (another problem!); secondly, by the
same token, they break down more readily in the body,
so are inevitably more toxic; thirdly, no matter how
short their lifetime, as the decay is exponential, a certain
number of molecules will reach the stratosphere, so that
they are all ozone depleters, but usually much less than
pure CFCs.
For the moment, no HCFCs have yet been
commercialised for solvent applications. About ten are
being investigated in the hope of finding a "drop-in"
replacement forCFC-113 which will have all its virtues
and none of its vices. This is a pious hope because, even
if a product is found that is technically and
lexicologically acceptable, the purchase cost will be at
least three times higher, possibly five.
The nearest ones, to date, have just been announced
in Japan, being HCFC-225ca and HCFC-225cbn. It
would seem that the physical properties axe remarkably
similar to those of CFC-113 in most respects. Their
ODPs have been calculated as fairly low, certainly less
than 0.1, possibly even 0.05. Their radiative forcing
potentials and chronic toxicities are net yet known.
Other possible HCFCs include HCFC-141b and
HCFC-123. These have estimated ODPs of 0.08-0.15
and 0.02-0.05 respectively, so the first-named can be
considered as similar to 1,1,1-trichloroethane and, if it
is put on the market, it must not be used
indiscriminately. They have respective radiative
forcing potentials of 0.037 and 0.045*C/ppvb(l in 109).
The ideal product would be a "drop-in" replacement
for CFC-113, that is one that can be exchanged for it in
all applications, used in the same equipment without
any modification, with a zero OOP, zero VOC
photoreactiviry, zero global warming potential and zero
toxicity. It is unlikely that such a solvent will ever
appear and it would display a remarkable optimism to
77-2
-------
wait for it! All the currently known HCFC candidates
as CFC-113 substitutes have ODPs in the range of about
0.025-0.15. These are too high to be able to be
considered as general substitutes. One source has
suggested thatO.02should be the tolerable maximum18.
This same figure has been selected as a discussion base
for the next Protocol revision.
Nevertheless, but only for those applications where
(here is no better alternative, these may present a
certain utility. In any case, economic considerations
must be taken into account. Even if these substances
pass all the tests necessary before they can be put into
production and are then produced at full scale, they will
cost between SFr 25.-- and 50.-- per kg to the end user,
not counting any potential taxes or recovery costs.
The acute toxicity of HCFC solvents under
consideration seems acceptable, but it will be several
years before we can leam whether they have an
acceptable chronic toxicity. This is a subject that
requires extreme prudence as the "safe" chlorinated
solvents of a few years ago are now considered as much
more dangerous, in the light of true experience. The
symptomatic development rate of liver lesions and
cancer is often a number of decades, so it would be wise
not to adopt these substances widely until we have
sufficient hindsight to give them a clean bill of health,
especially as there is a molecular resemblance to
chlorinated solvents. The real question lies in whether
it is possible to determine the chronic toxicity and put
these substances into production (assuming they pass
the chronic toxicity tests) in time to replace CFC-113.
This is doubtful.
At least two solvent manufacturers have announced
experimental blends of HCFC solvents with alcohols.
It would seem that these products fulfil some of the
requirements of CFC-113 replacements, at least on
paper. There is a specious argument applied to them:
the cleaning qualities of halogenated solvents is related
to the quantity of chJorine they contain. The OOP is also
in relation to the quantity of chlorine, amongst other
factors. By making the blends appear to have an overall
low OOP by diluting the high-chlorine HCFCs with
low-chlorine ones, MFCs (and their derivatives) and
alcohols, it would appear to be, at first sight, beneficial.
What is not mentioned is that it is probable that more
solvent blend will be required to achieve similar
degreasing qualities and quantities. For this reason,
solvent blends should be considered as having the same
OOP as the substance in it having the highest value.
II. 3. Other organic solvents
//. 3.1. Fluorinated solvents
Generally speaking, organic substances not
containing chlorine or bromine but containing fluorine
are considered to have zero OOP. For
hydrofluorocarbons (MFCs), this would seem
reasonable as fluorocarbons have a very small light
reactivity and hydrofluorocarbons mostly break down
in the troposphere. On the other hand. .: .s r.c: •:-"-."
whethersomeperfiuorinatedproducts, character.*" "•
extremely high chemical stabilities with lifetimes o:
many hundred years, would not cause atmosphere
damage, even if several centuries hence. On the other
hand, these products are generally useless as solve-a
unless blended with chlorine-containing solvents
Nevertheless, they are extensively used for other
non-solvent applications, some of which overlap the
CFC-113 area.
Hydrofluorocarbons (HFCs) are generally poor
solvents and perfluorocarbons even more so. One
perfluorocarbon has been proposed by an American
company to replace CFC-113 as the secondary blanket
on vapour phase or condensation soldering machines.
As its OOP is virtually zero and its stability higher, this
is seen as a positive step towards the elimination of
CFC-113 in a small application. It will certainly not
save on cost. HFCs have been proposed to dilute other
solvents in order to allow the blend to approach more
suitable characteristics for specific cleaning
applications or to render it more inert or to artificially
lower the OOP. Others have been proposed as rr.iij
solvents for specific applications. For example.
pentafluoropropanol (5FP)19, a new solvent under
development in Japan, may have useful characteristics
for degreasing delicate plastics, degreasing precision
parts with fluorinated oils, for cleaning optical
components, dry cleaning and a number of other
applications. Its OOP is zero and it is non-flammable.
Its spectrum of application is nevertheless'narrow, b.i
the substance may be blended with others to widen it.
//. 3. 2. Chlorinated solvents
Perchloroethylene and trichloroethylene have both.
very low ODPs, probably less than 0.01. They can
therefore be used with reasonable safety as far as tne
ozone layer is concerned. On the other hand, they are
both considered as chronically toxic and an American
rating as "probably carcinogenic" is under discussion.
The TLVs are low in most countries, typically
25-50 ppm and it is not impossible that they be placed
in a similar category to carbon tetrachlonde, with a
TLV of 10 ppm. in the future. This could be very
restrictive for future use. They are both photoreacu\e
VOCs, which may cause fun her res tnctive and possibly
Qscal actions to be applied in the future. It would seen
to be unwise to adopt these products as a substitute for
CFC-113 if there is any other choice, except as a very
short-term palliative. If they are used, assume the worst
concerning the toxicity and protect workers to the
maximum. By conserving the solvent in the machine.
rather than letting it escape, the environment, the
workers and the company expenses are all protected to
the maximum.
II. 3.2.1. Practical aspects of
chlorocarbons and hydrochlorocarbons
As previously discussed, chlorinated solvents sho-.o
not be considered as general substitutes for CFC-113.
77-3
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They are stronger solvents and have similar
applications to CFC-113 for degreasing most metallic
parts, but they are less suitable for use on many
synthetic polymers.
All these solvents are classed as non-flammable. This
does not mean that they can not burn: a mist of some of
the hydrochJorocarbons in air can even be explosive,
although perchlorinated solvents do not suffer from this
disadvantage.
It is to be expected that all chlorinated solvents will
become increasingly regulated in the short and medium
• terms, either because of their ozone depletion or
because more information is being acquired in respect
of the health and safety properties (or both). Whereas
no definitive information is yet available, it is probable
that stricter regulation will be pronounced in the first
half of the 1990s with some products. It would therefore
seem most unwise to expand cleaning in this direction.
//. 3. 3. Non-halogenated hydrocarbons and
their derivatives
II. 3. 3.1. Hydrocarbons
Light hydrocarbons are all toxic and flammable but
some petroleum spirits may be applicable to certain
degreasing operations. These are generally not
substances but distillates with a range of boiling points.
As a general rule and within any one family, the higher
the boiling point, the higher the flash point, so that it is
possible to choose the right compromise for each
application. These mineral spirits are variously
denominated, often arbitrarily, but usually go under the
heading "White Spirits".
Heavier hydrocarbons with higher flash and boiling
points can also be quite efficient solvents if handled
correctly. Their low vapour pressure which renders
them safer to use also makes drying problematic. One
way round this problem is to use them as a solvent and
then use a second, possibly less efficient, solvent but a
better, non-polluting, dryer to finish off the process.
Water is the obvious answer to this second phase.
For the lighter fractions, flame-proofing is required
on all equipment where they are used. Furthermore,
even if relatively low-toxicity types are chosen, they are
all VOCs and liable to restrictions.
II. 3. 3. 2.
derivatives
Alcohols and other hydrocarbon
Alcohols are excellent solvents for many
applications, including certain defluxing operations.
However, they do require enormous and expensive
precautions to be taken before they can be used for large
scale industrial cleaning. First of all, they are flammable
with flash points between 12* and 15*C (TAG closed
cup). This implies extreme precautions against fire,
such as nitrogen-purged, all-metal machines, oxygen
detectors, in-machine sprinklers, flameproof electrics,
intrinsically safe electronics, double air-lock entries
and exits, special conveyor types, infallible drying of
the parts, etc. If the alcohol is sprayed or jetted against
(he parts, ihe rebounding will cause a m;si ar.d an
aerosol to be formed. If this drifts, by any cause. ;~;o
the air, it becomes explosive. None of these problems
is insuperable but, together, they make capital
equipment expensive and a certain risk is always
inevitable if large quantities of alcohols are deployed.
Alcohols are also considered as VOCs, so that it is
certain that some discouragement will be applied to
their use in the future.
Which alcohols can be used as cleaning solvents?
Methanol is far too toxic (OFSP Class 3) and is the most
flammable. Ethanol would be ideal but for the fiscal
problems, especially if it was purified by distillation.
This leaves effectively the two propanoh. Isopropanol
(2-propanol) is cheap, easy to obtain and not
excessively toxic. This is the natural choice. A
propanol/water azeotrope is suggested for some
applications by one manufacturer.
Other derivatives employed for cleaning purposes
include various ketones, esters and, occasionally,
ethers. These also require similar precautions to be
taken.
//. 3. 3. 3. Practical aspects of
hydrocarbons and derivatives.
Various hydrocarbons have been used for cleaning
purposes for many years. Benzine (not to be confused
with the highly toxic benzene) is such a well-known
solvent Others include various mixtures of aliphatic
and aromatic petroleum distillates, usually fractions
with a narrow range of boiling points between 50* and
220'C. Most of them are poorly defined and can not be
classed as substances.
Some aromatic substances, the best-known being
toluene and xylene, are also used as effective low-cost
solvents although they are more toxic than many
aliphatic spirits.
Hydrocarbon derivatives, such as alcohols, ethers and
ketones, are popular solvents for certain applications.
Another class of derivatives are mixtures of esters
which are used in the manufacture of paint thinners and
for other specialised applications. In fact, the range of
possible halogen-free organic solvents is enormous.
It is a half-truth that all the good organic solvents are
either flammable or contain chlorine. Another
half-truth is that the better the solvent a hydrocarbon or
a derivative is, so is its boiling point and flash point
lower. A third half-truth is that the closer a solvent
molecule resembles another molecule, the more the
latter is likely to be soluble in it. Whereas these are not
inviolable rules, they contain sufficient elements of
truth to situate the usability of some products.
To dissolve petroleum oils, petroleum spirits are
amongst the best solvents, but they are poor for
dissolving rosin. On the other hand, the latter is soluble
in light alcohols and some terpenes. Cellulosic resins
are readily soluble in certain esters and so on. Some
fluorinated oils and other fluorbcarbons are only
soluble in fluorinated solvents. In other words, the
11-4
-------
t ,
solvent must be cnosen according to the nature of '.he
soil: there are no universal solvents.
All these products are flammable, most of them are
highly flammable, often with flash points below
ambient temperatures. This means that any means of
ignition in their vicinity could cause a Sre. Use of these
solvents should be governed by the utmost prudence
and only equipment designed for the solvent in question
should be used with them. In truth, it is a wonder that
there are not more industrial fires caused by the
unconscientious use of organic solvents.
Furthermore, all these substances and products are
toxic, to a greater or lesser extent. This should be even
more reason why their vapours and aerosols should be
contained, away from the nose of any operator.
Generally speaking, provided that the safety problems
can be kept under control, most current CFC-113
applications could be replaced by some form of organic
solvent of this nature. The solvent costs would
generally be favourable but this would be offset by the
increased capital equipment costs occasioned by the
safety aspects.
In certain cases, drying off the clean solvents at the
end of the process can present a problem. It is generally
undesirable to simply allow the parts to dry off in free
air, quite apart from the flammability difficulties, as the
vapours are polluting (VOCs). In addition, it is a waste
of solvent. Some alcohol machines avoid this problem
by vapour phase drying, in a similar way to that used
for halocarbon solvent degreasers, but this is usually
done in closed, nitrogen-purged, machines. Otherwise,
activated charcoal filters or water scrubbers may be
used, the latter with a separator if the solvent is
immiscible with water.
//. 3. 3. 4. Hydrocarbon/surfactant blends
If a suitable hydrocarbon or derivative can be found
to dissolve the soil and it is relatively non-volatile, it
could present certain advantages. If it is non-volatile, or
nearly so, at the temperature at which it is used, the fire
hazards are reduced. This is possibly conditional on no
mist being formed during a spraying operation, as mists
or aerosols of all hydrocarbons could be dangerous in
the right proportions. At the same time, the reduced
vapour content of the air round the cleaning equipment
will reduce the toxicity problems for the operator
(assuming the product is not inherently more toxic) and
also the air pollution problem (VOCs). Obviously, there
is a price to pay for these three important advantages
and this price is that the parts being cleaned will be
contaminated by a.solvent that will not readily dry off
and some means must be found to remove this solvent.
If the solvent is blended with a surfactant or detergent,
then it can be washed off with water which, in itself, is
sufficiently volatile that it can be dried off or,
preferably, blasted off. This will then leave the parts
being cleaned clean and dry. There are, nevertheless, a
number of provisos before such a process could be
practically admitted. The most important one is that the
rinse waters are environmentally harmless. What
exactly does 'Jus mean1 Vv'as:e -AJ:;: :r;-:~;r.i - . •
extremely complex subject but. bas.ci.... •..-_•
requirements are that water sent down ihe drain w... -::
harm any bacterial water treatment plant nor. jft.-r
passage through the plant, should it harm aquatic life or
make water courses chemically unsuitable for
consumption. To achieve these criteria, any r.cax.
metals must be limited to extremely low levels, in rr.os:
cases less than 1 pan per million (1 mg/1). Many rr.etais
are toxic to the bacteria necessary for sewage treatrr.e -.:
and will eventually be taken up in an alimentary chair.
(e.g. the famous case of mercury in fish from L^o
Le"man). The waste water must be neither too ac;d -or
too alkaline, otherwise it, also, could destroy trie
bacteria in waste water plants. Large quantities of very
hot water discharged close to a sewage farm could aiso
kill the bacteria cultures. Finally, and probably rr.os:
important of all, there is the notion of biodegradabilny.
Very briefly, this means that anything sent down a
public sewermust break down into harmless substances
as quickly as possible. In this case in question, -r.se
waters from this type of cleaning process contain :r.e
hydrocarbon, the surfactant and probably srr.a::
quantities of contaminants, often heavier hydrocarbon
or derivatives. Many hydrocarbons, such as crjCe o:i.
may take years to break down: this is why accidents
involving tankers are often dramatic. The fact that •>«>
can be mixed with detergents so that they become
water-miscible does not cure the problem; it or.:.
displaces it to a less visible position. It is therefor;
essential that the hydrocarbons used in these produce
are readily broken down by natural means. T'r-.e
surfactant itself must also degrade, preferably at abc.:
the same rate as orslightly slower than the hydrocarbon.
so thatthere is no preferential degradation, allowing the
hydrocarbon itself to separate and rise :o the u-aisr
surface.
The majority of the biodegradable hydrocarbons arc
those found in nature, usually of direct vegetable or
animal origin or synthetic look-alikes. Many miners;
hydrocarbons are almost non-degradable. Many
domestic detergents for floor cleaning, for example.
contain hydrocarbons such as terpenes from pine or
citrus trees, the smell of which is frequently disguised
by added synthetic pine or lemon perfumes. This
improves the spectrum of soluble soils and she
dissolving power for greasy dirt. The housewife may
believe, through poor advertising, that there is !err.on
juice in her dishwashing liquid and that this is an active
ingredient, but it is only the small quantities of added
limonencs that are helping hcr(but possibly not the skin
on her hands)! These terpenes remain bound in solution
by the detergents until they degrade. The degradation
process is a combination of anaerobic (in sewage
sludges), aerobic (in oxygenated treatment tanks) and
photochemical (daylight falling on the contaminated
water) processes. It requires a certain quantity of
oxygen. The biological oxygen demand is the quantity
of oxygen, expressed in milligrams of oxygen per litre
of waste water, required to produce aerobic bacten.::
77-5
-------
i i
//. 4. 3. Drying
Drying is the bugbear of all forms of water cleaning,
especially for precision applications. There are several
way "olvent displacement and absorption, etc.
Solvent manufacturers, aiming to sell their products,
have always cited that drying is extremely
energy-consuming, hence wasteful and costly. It
certainly can be but is not necessarily so. It is evident
that the energy required to evaporate 1 litre of water at
15*C is high (about 585 kcal or 2450 kJ). If the heat
transfer is 10% efficient, this would require nearly 6.8
kWh. One of the main problems of evaporative drying
is that, if a small quantity of solids remain in the water,
they will be deposited on the cleaned pan. This is not
always acceptable, so that the implication is that pure
water must be used in these cases with sufficient rinsing
that no significant contaminants remain.
On the other hand, to use mechanical means to
remove a similar volume of liquid from capillary spaces
may require only 0.01-0.1 kWh, depending on the
means and configuration. Drying is surely the most
critical area of all types of aqueous cleaning and should
be examined from case to case. The most usual means
of mechanical drying are by air blasting and
centrifuging, although a few other methods are
occasionally encountered. Other than the purely
energetic aspect, mechanical removal has a secondary
advantage in that any residual solids are removed along
with the water, reducing the tendency to form
"water-marks". This means that a lower quality of rinse
water can be used than would otherwise be possible,
sometimes even ordinary tap water. Where air blasting
is used, the design of the air knives is critical, especially
with conveyorised machines where any single pan
being dried may be subjected to the air blast for only a
second or two. The most successful systems depend on
very high air velocities with a reasonably long attack
time and variable angle attack. To illustrate the
potential deficiencies of such a system, the most
common air-knife drying encountered in everyday life
is found in car-washing tunnels. Because a car is large,
the air-knives are typically about 1 m 80 long and 25-30
mm wide. They act at about 10-100 cm from the surface
being dried and usually vertically. To limit the power
consumption, usually centrifugal ventilators of a total
of 2-20 HP, the average air velocity is generally less
than 50 m.sec'1 at the car surface. As the typical speed
of the vehicle through the tunnel is about 2 m.min , the
impingement time at any one point is about 2-3
seconds, allowing for fan-out from the nozzles and
deflected blast Even under these conditions, about 90%
of the residual water is removed for an energy
consumption averaging well under 1 kWh. In industrial
drying machines, the air velocity is often 4-5 times
higher, the action lasts up to 20 seconds and the angle
of attack is usually acute. Even with complex pans of
dimensions up to 500-1000 mm in the three axes,
mechanical drying up to 95-99% is commonplace. A
basket-load of assembled printed c-.rc-.;;^, :'o:c\_~: .
can be blast-dried in about 20 seconds :o -?~~. ,-j
remaining 3% being evaporative, for a :otai en^rcy
consumption of 500-700 Wh. As such a load may N:
about 2 m , the total unit consumption would be abc_:
3 Wh/dm2. If electricity costs are as high as 15 c.W-..
a standard Europa board (100 x 160 mm) wo-i
-------
digestion of the pollutants. It is usually expressed in the
oxygen requirements over flve days.
The anaerobic digestion in the sewage sludge at the
bottom of the sedimentation tanks breaks the
hydrocarbons down to lighter types, often producing
large quantities of methane and other light organic
gases. The sludge is periodically removed and a
percentage is recycled back to ensure the continuity of
the bacterial reproduction.
The organic solvents in this process must therefore
not only be harmless to the diverse bacteria, they must
also be active nutrients. All these requirements limit
greatly the range of suitable products that can be
employed as cleaning solvents. The spectrum of soils
that can be removed is therefore limited, especially if
the soils themselves must be essentially biodegradable,
as well. There exist a number of industrial terpene and
other hydrocarbon degreasing products of this type but
their use is generally fairly specific. One such
application that has created a certain controversy over
the past few years is the removal of residues of rosin
fluxes after soldering.
II. 4. Aqueous systems
II. 4.1. General
Under the heading of aqueous systems, pure water
and water plus additives are both treated. The term
"semi-aqueous" is best avoided as it has been applied
to various techniques bearing no relation with one
another. The category of hydrocarbon/surfactant blends
which require a water rinse after the solvent treatment
has been partially discussed in the last section, but the
actual water rinse belongs more to this one.
II. 4. 2. Water quality
Tap water is usually sufficient for the first stages of a
cleaning cycle. However, it is frequently necessary to
employ better qualities for at least the final rinse. The
main problem with tap water is the "hardness" or total
calcium and magnesium ion content. Several different
treatments are possible to render tap water more
acceptable. The easiest is thermal decalciOcation. It can
only be done where the hardness is due to bicarbonates
and, to a smaller extent, hydroxides of calcium and
magnesium. Heating the water will cause a certain
proportion of the lime to precipitate, this being removed
by filtration. It is not very effective, but can prevent
excessive precipitation in the cleaning machine itself.
At the same time, the hot water produced can be used
directly by the machine.
Water softening is well known and consists of
replacing the calcium and magnesium ions by sodium
ones. For electrical or electronics applications,
although there may be less visible residues on the
cleaned parts, the contaminants are strongly ionic and
very dangerous. This process is therefore restricted to
non-electrical applications. The essential point with
water softeners is to regenerate ;hem in time. T'rus is
usually done with simple salt which replaces the lime
in the softener zeolites with a stock of sodium ions.
The next process is reverse osmosis. Although.
strictly speaking, it is not a filtration, it appears to be
one in that impure water, applied to a membrane, passes
through as relatively pure, leaving the impurities on the
inlet side. The real mechanism is beyond the scope of
this work. Only softened and UV-sterilised water is
suitable. The purified water is usually improved by a
factor of 10-20 in a single installation. Water from
reverse osmosis is usually adequate for most
applications, including many electronics ones. For a
single cleaning installation, the capital costs are usually
too high, but the running costs are rather low.
Ion exchange is divided into two categories. Mixed
bed ion-exchange consists of a single column which is
sent to a specialist establishment for regeneration. It is
cheap to purchase, but somewhat expensive to run if
used for purifying large quantities of tap water. If used
for "polishing" reverse osmosis or separate bed
ion-exchanged water, the highest possible purity is
obtained at relatively low cost. Separate bed ion
exchange consists of two columns for removing anions
and cations separately. As it can be regenerated in situ
with low cost chemicals, it is the most economical
deionising system in the long term and it provides a
water quality adequate for nearly every application.
One question which comes up frequently is whether
watershould be used inopenorclosed circuits. A priori,
it would seem attractive if rinse water could be
repurified after use and sent back for reuse: there would
apparently be no waste water disposal problem and the
water (which may become a rare commodity)
consumption would be negligible. Unfortunately, life is
not so simple! In the first place, unless very
sophisticated purification systems are used, it is
possible that certain pollutants in the effluent may not
be removed. This would mean that these pollutants
would accumulate until the rinse quality became
inadequate. Secondly, the pollutants removed by the
purification system may be such that they would reach
such high concentrations that they would present
disposal problems. To take one example, products
which have heavy metal contamination from cutting
oils may be degreased in a detergent solution. The rinse
water will have detergents and heavy metal salts
dissolved in it. Some of the detergent surfactants will
not be removed by a separate bed ion exchange
installation, but the heavy metals will remain in it.
When it is regenerated, the heavy metal ions captured
by the column will be replaced by hydrogen ones from
the hydrochloric acid and the effluent will become
fairly concentrated metal chlorides, requiring special
disposal. Depending on the application, recycling rinse
waters should be limited to the range of 50-90% to
avoid these problems and the question must be asked
whether this partial advantage will justify the cost.
II-6
-------
treatment plant; the third phase was a full scale
changeover at one of the eight aircraft maintenance
plants.
The first phase identified six different solvents in
regular use fordegreasing, cleaning, mask removal and
paint removal and three were used for reference
purposes.
For the second phase, samples of each candidate
product were tested for solubility and then cleaning
ability with tour standardised "difficult" soils, namely,
a petroleum wax, a carbonised oil, a hydraulic
fluid/carbon mix and a carbonised molybdenum
sulphide grease. About eighty products passed these
two tests, including some which passed the cleaning test
two or three times under different conditions of use. A
standardised test method was developed to determine a
biodegradability index, using ordinary sewer sludge
with a 6 hour retention time and a measure of the COD.
•This reduced the number of candidate detergents to 32.
Corrosion testing to a standardised method was then
done with 15 common constructional metals including
copper, nickel, various aluminium alloys, various steels
and stainless steels, brass, inconel, monel, titanium and
magnesium. After undergoing these tests, only six
products were considered usable, of which five were
suitable for all metals. Before the phase 3 testing, more
extensive testing was done with two or three of these
detergents in order to determine how to go about the
practical work.
Phase three testing has been started and has been
running for about six months at the time of writing. Full
reports have not yet been made available, but interim
information would seem to show an overall cost saving
of the region of 10-15%, no worker health problems,
adequate cleaning quality and no special water
treatment problems. The Air Force Base concerned
already had its own sewage treatment plant and no
interference was observed from the technical cleaning
on the biocultures.
Similar work is now starting on the paint stripping
project.
This work is in the public domain and it is probable
that the complete database will become available at the
end of the solvent replacement project (a question of
months). It is mentioned here as an example of the
serious approach of this project and the fact that
industrial degreasing, including precision cleaning, can
be successfully done by aqueous methods.
Some detergents are restricted in :he;r .ise. In
Switzerland, there are some which are forbidden for use
in household washing-up products but are, for the
moment, permitted in industrial cleaners. It.is not
expected that this permissiveness will continue
indefinitely as the degradation products of these
detergents, octyl- and nonylphenoxylates, are much
more stable and toxic to some forms of aquatic life. It
is necessary to be aware that this differentiation of
applications is a legal anomaly.
II. 4. 6. Water + saponifiers
Saponifiers22 are chemicals that react with diverse
fatty acids, rosins and other natural resins, etc. to form
water-soluble soaps which are themselves somewhat
detergent. Caustic soda, for example, has been used
since time immemorial to solubilise vegetable and
animal fats and oils. Commercial saponifiers are much
more complex products, often based on aqueous
solutions of monoethanolamine or ammonium
hydroxide as well as the strong caustic alkalis,
depending on the applications.
One well-tried use is for solubilising wood rosin.
Rosin consists of an indeterminate mixture, of which
some 90-95% is a number of isomeric cyclic carboxyl ic
acids, normally almost completely insoluble in water.
These acids are easily saponified with
monoethanolamine and commercial saponifiers have
been available for this purpose for over 20 years. Their
efficiency, used under the right conditions, is extremely
good, producing residual contamination approaching
an order of magnitude better than cleaning with
CFC-113. If the rosin is used as an activated soldering
flux, the cleaning efficiency is even better as the
activators are readily neutralised and solubilised, which
is not necessarily the case with halocarbon solvents.
Used for this kind of application, the rinse waters
generally present no environmental problem. What is
more, even the actual wash waters can sometimes be
disposed of directly into public sewers under
well-defined conditions (see section IV-2). If not, a very
simple neutralisation is frequently the only water
treatment that is necessary.
As a general rule, saponifiers are not suitable for
mineral oil degreasing. However, saponifiers are
sometimes added to other detergents to broaden their
overall cleaning spectrum. Users are nevertheless
warned to leave such blending to the manufacturers
who, alone, are able to understand the reactions.
11-8
-------
Chapter IIJ
solvents
Conservation of CFC and other volatile
III. 1. General
As a short-term measure with CFCs and a long-term
measure with all other volatile solvents, conservation is
an important point to consider. If conservation had been
applied to CFC usage since the beginning, the problem
today probably would never have occurred.
Conservation is equally important with other
solvents. Unfortunately, their very cheapness has not
justified money being spent on preventing evaporation.
After all, if it cost, say, SFr 50,000 to install a solvent
recovery system with returns of less than 10,000 litres
of isopropanol per year, most economists would agree
that it was not worth it But those 10,000 litres per year
may cause untold other damage outside the factory
walls. In Switzerland, high ozone concentrations in
some towns and even in the open countryside are
becoming commonplace under certain weather
conditions and such VOC solvent evaporation is one of
the contributory causes.
In terms of solvent usage, various figures have been
proposed as to the fractions of CFC solvents that could
be recovered if the equipment was better designed,
maintained and used. The lowest is 40% and the highest
90% with an average of about 50-60%24. These figures
seem to be borne out with practical experiences.
Consider the case of a small, open-top, vapour
degreaser equipment used for manually defluxing
printed circuits. Average CFC-113 consumption with a
medium production rate may be 40 kg/week, of which
10 kg is recovered from the bottoms*.
III. 2. Bottoms recovery
This 10 kg in the bottoms is, at present, usually lost
as the product is either sent for incineration (causing
other pollution) or as a landfill where, sooner or later,
it will escape. If a recovery still was used, 9-9-5 kg
could be recovered and reformulated for reuse. In the
case of our example, this would make typical savings
of about SFr 1,500/annum including distillation costs.
If the total factory production quantities justified it. :he
recovery still could be internal. One American
company achieved savings of over S10.000.000 per
annum just by installing their own still and another.
smaller, one reached a savings figure of 543,000 per
annum by installing a secondary still uniquely for the
recovery of solvents from the bottoms of two primary
stills. If not, an external recovery service could do this.
In Switzerland, there is no well-organised
redistillationservicc forsmall users available. This may
be an excellent commercial proposition for a.-.
enterprising company willing to make the investment
and set up the collection and redelivery infrastructure.
On many occasions, small users have complained that
no means exist to recover used solvents. One possible
method is that a company could issue on loan specially
painted 200 litre drums with the solvent type clearly
marked. The user would undertake to put only that
solvent type in the drum (if he used several solver.:
types, he would have a drum for each). When the dr_~
was nearly full, he would telephone the service which
would collect it the next time there was swTicen:
material to collect in that geographical area. The whole
of Switzerland could be serviced with one truck or. a:
least a monthly collection. At the same time, he would
be issued with an empty drum. On arrival at the
recovery centre, a sample of each drum would be
analysed for solvent percentage and type. The
corresponding quantity of recovered and reconstituted
solvent would be delivered to him at the next delivery
in his area. If it is found that solvent mixtures are, by
accident, in his drum, the user would have to pay extra
for recovery or destruction.
Economically, such a recovery service would
possibly nothave been viable up to 1989. but the rapidly
increasing prices of CFC-113 based products should
now render it feasible. It is probable that ihe recovered
solvent could be sold to the users at about 90% of the
cost of new products at the 1989 prices, but this will
become increasingly attractive as prices nse further.
For chlorocarbon and hydrochlorocarbon solvents, the
economic viability can not be established at current
Bottoms: the residue in the boiling sump of a still or a vapour phase cleaning machine comprising the majority of the
removed contamination plus a certain amount of solvent.
i .
-------
pnccs, but it is possible that a legal obligation will be
declared necessary.
The real problem is for the user whose annual
consumption of any one solvent type is less than, say,
' CC ';g per annum. In this case, the use4 solvent should
. f- turned obligatorily to his supplier at the user's
expense. The costs for this service could be levied as
pan of the sale price.
III. 3. Equipment siting
All machines should be in a draught-free room,
preferably dedicated to their own use. The floor should
be level and covered with a solvent-resistant
impermeable surface, so that the solvent is not lost in
the event of spillage and can be recovered before it
evaporates. Ventilation should be by extraction at floor
level, but regulated for minimum throughput consistent
with operator safety. For large installations, the
ventilation should be equipped with activated carbon
filters. Thought should be given to transporting fresh
and used solvent to and from the room.
III. 4. Equipment maintenance
All equipment should be maintained on a regular
basis25. It is possible that up to 5-10% of all CFC-113
losses are due to almost imperceptible minor leaks.
Seals and gaskets should be regularly checked and
changed at least every year. Taps and valves are
notoriously dangerous and drain taps should have
solvent-tight plugs in them when not in use.
All equipment using halogenated solvents of all types
should be checked annually with a sniffer. This is a
small electronic device which sucks in air and indicates
whether it contains halocarbon vapours of any type. A
small flexible hose can be directed to every part of the
machine to locate even the smallest leak. Every user of
multiple or large installations should possess a sniffer.
Users of small installations should ask their equipment
or solvent supplier to do an annual sniffer check if it is
felt that the modest cost of the instrument can not be
justified.
III. 5. Molecular sieves
Most vapour degreasers are equipped with molecular
sieves for removing water from the solvent. It is
essential that these are correctly maintained, to ensure
maximum solvent life. The zeolite beads adsorb
considerable quantities of solvents as well as water. A
certain quantity of this solvent can be recovered by
initially placing the filter in a closed rec-.p'.en:
immediately on removal. Put in the new filter and run
up the machine. Transfer the filter rapidly from the
recipient into the vapour phase of the machine and keep
it there until it reaches the full vapour temperature.
Transfer it to the freeboard* zone and keep it there for
several minutes to allow the vapours to "drain" from the
filter. The recipient should also be emptied back
(vapours and possible liquid) into the machine. Note
that this technique is only usable where there is a sharp
differentiation between the vapour pressures of water
and the solvent, notably with CFC-113 and its blends.
Many machines are poorly designed and spillage is
inevitable when removing the molecular sieve for
maintenance. If it is not possible to modify the machine
to avoid this spillage, try and recover as much as
possible.
III. 6. Solvent handling
CFC-113 solvents are usually delivered in 20 litres
(30 kg) cans, 200 litres (300 kg) drums or in bulk
containers. Bulk containers are of two types. Pressure
containers present no problems provided they are never
opened to the atmosphere while the pressure gauge is
indicating a positive pressure. Other bulk containers
have breather valves, often fitted with desiccators, but
which let solvent vapours escape if the temperature
rises. This creates losses amounting to about 2% of the
stock per annum. Bulk tanks should never be situated
where the sun can shine on them or where other sources
of heat can cause solvent evaporation within the tank.
Drums and cans of all halocarbon solvents should
always be stocked in the coolest place possible and
neveroutside. When taken from the storage area for use,
they should be opened before the temperature of the
contents can rise. After use, they should be reclosed
tightly and taken back to the storage area. Never
transfer from the storage area to the usage area in an
intermediate recipient, even closed: the transfer losses
will be doubled. Drums should always be kept
vertically, tightly sealed, and never horizontally with a
tap.
Unless the equipment has special transfer pumps
incorporated, transferring solvents from or to drums or
cans should only be done with special pumps with outlet
pipes extending to the bottom of the recipient. This
ensures there is minimum solvent-air interface while
filling and emptying. On no account should solvent ever
be poured from one container into another. This applies
also when dirty solvent is removed from a sump: drain
taps are frequently placed where spillage is inevitable.
i .
Freeboard: this descriptive nautical term, frequently used in this application, is employed throughout this booklet to descri be
the distance between the upper level of the vapour in the vapour phase and the level of the upper surface of the opening
7/7-2
-------
i.
III. 7. Equipment enhancement
///. 7.1. Freeboard
• A number of minor modi fications of open-top vapour
cleaning machines can reduce th '-'em losses
dramatically. Undoubtedly, the me. .r.-ortant is an
increase of freeboard height. This is defined as the
vertical height between the top level of the vapour and
the lip of the machine. With most degreasers of more
than a few years age, this is woefully inadequate and
often so on more modem machines. If the height is less
than the width of the opening, then it is essential to
increase it. If it is less than the length, or even the
diagonal, of the opening, then it is desirable to do so.
Various freeboard heights have been quoted as being
ideal but the more, the better and the diagonal would
seem to be a good compromise. At the very least, the
freeboard should be at least twice the height of the
tallest parts to be cleaned or the opening width,
whichever is the greater. This improvement can be done
with a simple stainless steel box-form structure on all
four sides. It should be bolted down onto the original
upper surface, not forgetting a good gasket in a material
resistant to the solvent in use. A water-cooled
serpentine round the interior is desirable. The water
flow rate does not have to be high, so that the cost is
only SFr 1-3/day, less than a gain of half a kilogramme
of solvent. It should flow 24 hours/day, 7 days/week, as
long as the machine is filled. The water temperature
should be as low as possible and certainly less than 15*C
for CFC-113 installations. If, in summer, the
temperature rises slightly over this figure for a day or
two, this is not a cause for alarm, but if it consistently
rises, refrigerated cooling may be necessary. Of course,
the same applies if water-cooled condenser coils are
used, these being even more critical. The machine
should never be opened until all condensers and
freeboard coolers are at their minimum temperature.
///. 7. 2. Lid
Most equipment is fitted with a lipped, lift-off lid.
Every time this is lifted, most of the vapour in the upper
half of the machine is wafted away. The original lid
should be thrown away and replaced by a sliding lid that
causes no draughts when it is opened. A motorised lid
of a "Venetian blind'* construction is ideal, as the speed
can be regulated to ensure no vapour disturbance, the
gas-tightness can be good and it can be made to close
automatically if the operator has forgotten to shut it.
The lid must be kept closed at all times the machine
is not in use. If the lid is a two-pan sliding type, opening
from the middle, only the half of the machine in use at
a time need be opened. These halves can be
automatically -opened through the controller of an
automatic transfer system.
If the machine is equipped with additional freeboard,
it goes without saying that the lid should fit this new
top.
.-.«.-:
?c
e ..<
///. 7. 3. Cooling coils
If the machine has water-cooled or pia;r. :::'-.,;.•:.
coils, these should be kept cooled until all the so,v
in the machine is cold. If the equipment has
pump, then additional water-cooled coils sho
added for this purpose. If a water-cooled free boa r
added (see above), then the water Qow ra;e may -eeu
to be increased until the solvent is cool.
In all cases, it is desirable to fit flat water-cooling co. '.s
along the side or bottom of each sump. This ;s so that
the solvent is cooled as rapidly as possible wi-.c-
shurting the machine down and kept as cold as possible
until the heating is switched on again. The soier.o;^
valves controlling the water flow can be interlocks:;:
with the off position of the power switch.
///. 7. 4. Parts baskets
It is usual for the parts to be cleaned to be piacec1 -.-
baskets. These should be constructed of an open w.rt
mesh with as high an opening:wire diameter ratio as
possible, never of perforated metal plates. The basic;1.*
should be of a size that their length and their width :$
never more than two-thirds the length and width of the
smallest sump, to reduce the piston effect as they are
moved in the vapour zone. When cleaning small pars.
it is preferable to have only one layer in the basks:, so
that vapour can circulate freely in a vertical direction.
///. 7. 5. Sprays
The use of spray lances in open-top degreasers ;s rr.os:
undesirable. In the first place, they create turbulences
in the vapour phase, causing additional losses. In the
second place, they depress the vapour level, draw; ng a.:
into the machine. As the vapour level rises again after
the spraying is finished, air is pushed out, carrying w ith
it some vapour. In the third place, the sprayed solve n:
increases the solvent/air interface area, exaggerating
the evaporation.
III. 8. Cleaning cycle
In most cases, the cleaning cycle should consist of
lowering the basket containing the pans to be cleaned
at a speed of about 50 cm.min directly into the boiling
solvent This lowering should therefore take 1-2 mm in
most machines. The pans are kept there for at least the
length of time for them to reach the boiling point or until
the scrubbing action of vapour bubbles ensures an
adequate pre-cleaning. The basket is then hauled
upwards at the same speed until the bottom is just clear
oftheoverflowweir.lt is then displaced horizontally at
lOOcm.min"1 until it is over the cold distillate sump and
lowered in it at 50 cm.min"'. It remains there, with or
without ultrasonic agitation, until the parts are
uniformly at the same temperature as the cold solvent.
The basket is then hauled upwards again at '.he same
vertical speed until it is entirely in the vapour zone over
the distillate sump. It remains there until the rr.os:
thermally massive parts reach the vapour temperature.
m-3
-------
when the basket can be pulled upwards again at the
same speed, until the whole workload is in the middle
of the freeboard. For most pans, 2 minutes in the
freeboard is usually sufficient, to allow the vapour to
drop off the a«*r"blies, although complicated parts
with deep, bin
-------
extending the nouon to beyond the corporate walls ar.d produc3 arc rr.anuiac'.ured •A-.'.-O1.: '.r.c - _ : ~r ."
are already warning suppliers that they may be expected More important. Swiss industry ;s :r3C.::cr.^.'.. ,:r.j- - -
to certify that their products do not contain CFCs or use towards subcontracting parts of m a r.ui'ac •.-.-•.-.,:
them in their production. Obviously, there are very few processes. Subcontractors can always be chosen :':.:•-.
Swiss companies large enough to carry the weight the ranks of those who do not use CFC clear..r..;
required to force major suppliers into changing th« processes and companies providing subcontract;
production methods, but preference can always tx. services should inform their customers that tr.ev arc
given to suppliers who voluntarily state that their "CFC-free" (when they are, of course!1).
m-5
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This page is blank.
7/7-6
-------
Chapter IV. Substitution
IV. 1. General
Any substitution method or product must take into
account numerous parameters. Some of these are:
• Soil to be removed
• Ease of use
• Operator health and safety
• Environmental problems
• Cost
Each application has to be studied entirely on its own
merits. No single substitution method to replace
CFC-113 can possibly be the answer to all the current
uses of this solvent.
IV. 2. Specific applications
IV.2.1. Defluxing
IV. 2. 1. 1. Industrial defluxing
Industrial de fluxing is defined as the removal of flux
residues after soldering using ad hoc equipment
designed for that purpose. This is in opposition to
artisanal defluxing which is frequently employed in
small companies and even in larger ones for special
purposes, where trays of solvent and a brush are the
usual tools.
The most popular equipment in Switzerland for
industrial defluxing is the open-top vapour degreaser
with some commercial blend of CFC-113 with an
alcohol. With very few exceptions, these machines are
used for removing some form of rosin flux: very
occasionally, a synthetic activated flux (type SA) may
be used but this type will almost certainly disappear
from the market in the near future, because they were
developed to exploit CFC-113. This type of equipment
is frequently badly designed and it is probable that at
least 90% of the CFC-113 solvent losses from the Swiss
electronics industry, which in itself accounts for
60-70% of the total losses, is derived from this usage.
In the short term, as has been explained in the previous
chapter, it is possible to reduce these losses by at least
50%, but it would be better still if they were reduced by
100% by simply replacing the equipment to profit from
one of the substitute methods. A brief survey of
open-top vapour degreasers in ten Swiss factories,
taken at random from both the Eastern and Western
sides of the country, has shown that twelve out of a total
of thirteen machines are more than five years old, nine
more than ten years old and one was even 22 years old.
Furthermore, of these thirteen machines, three were
never designed for use with CFC-113 solvents.
although they were sold for this purpose. It would seer?,
that this kind of machine is kept in operation until it falls
apart. It is therefore not very surprising that the Sw;ss
electronics industry wastes something like SFr 6-"
million in solvents literally going into thin air. every
year.
Larger factories are equipped with conveyor.scd.
in-line machines where the output flows directly frc-
a wave soldering machine into the cleaning machine.
These machines are frequently badly maintained and .:
is not unusual, even with new ones, for them to w asti
quantities of solvent through gasket leaks, badly ciosi.-.i
taps or valves, etc. With this type of machine, the
average age in industry being between five ar.d ten
years, relatively little can be done to prevent ::-.j
inevitable operational wastage: the best that can be
hoped for until such time as they are replaced bv
machines using other processes is that active c.-.arco.l
filters are used to recover most of the losses. One of •.;-.:
tragedies is that this kind of machine also gives q-.i'.e
mediocre cleanliness results, as measured with eitne:
ionic contamination testers or surface ir.sula::or.
resistance analysers.
A handful of Swiss companies, both large and small.
have already very successfully adopted more modern
cleaning techniques such as aqueous and hydrocarbon
derivative (alcohol) cleaning. One group, renowned for
its quality, high-reliability products, has been
continually using water-soluble fluxes and aqueous
cleaning for defluxing since 1967 for most of ;^
production. At least half-a-dozen other Swiss
companies have been using it for over ten years. None
of these has experienced problems in terms of
soldering, cleaning or reliability of their produce.
rather the opposite.
On an international scale, aqueous cleaning has been
the workhorse method for many large multinationals
for up to 25 years. The first major company to put it into
production was Hewlett-Packard, followed by IBM.
ICL, Burroughs, NCR, Olivetti, Bull and many others.
It is estimated that about 40% of the US elec:ron;cs
industry production is cleaned in water.
To date, relatively little hydrocarbon or derivative
cleaning has been done. Three German companies have
developed alcohol cleaners but these are mostly being
used for evaluation purposes, as yet, one m Switzerland.
The hydrocarbon/surfactant technique has not yet rr.adc
any great penetration in Europe. Two chemical suppls
companies are experimenting with it and :: ;s
IV-1
-------
Permitted halocartxm solvent cleaning
Hydrocarbon,
etc. cleaning
Water
cleaning
Hydrocartaon/suriactant and water cleaning
Saponifier and water cleaning
Fig. IV-1. Schematic of substitution for defluxing
anticipated that they will both become commercially
available in Autumn 1989. It is known that two machine
manufacturers in Europe are developing equipment for
this method. The first is a French large-scale
conveyorised machine and the other a Swiss batch
machine for small and medium-sized applications (on
the same scale as open-top vapour degreasers). Several
North American companies are also developing
machinery.
There are six substitution methods27 (Figure IV-1)
open to the electronics industry and these will be
discussed in fairly full detail here, as it is in this sector
that the most important reductions in CFC-113 and
other ozone depleteis can be made. At the same time,
this industry, which is one of the most modern of Swiss
industries, is paradoxically one of the most
conservative and traditionalist, resisting change at all
costs.
The six methods are:
• 1. Not to clean (using so-called low-solids or
"no-clean" fluxes)
• 2. Water (using water-soluble fluxes)
• 3. Water + saponifier (using traditional rosin fluxes)
• 4. Hydrocarbon/surfactant + water (using traditional
rosin fluxes)
• 5. Hydrocarbon and derivative solvents (using
traditional rosin fluxes)
• 6. Permitted halocarbon solvent blends (using
traditional rosin fluxes)
IV. 2.1.1.1 The "no-clean " solution
Up to the time when printed circuits were adopted for
professional electronics, cleaning was required only for
exceptional conditions. This was because assembly was
done by soldering wires to discrete tags and both
spacing and leakage paths were long. The situation
changed dramatically with the advent of the printed
circuit and, especially, of machine soldering when
cleaning was deemed necessary for many applications.
The Germans developed a special rosin flux type for
those applications where cleaning was not absolutely
essential. This was adopted in DIN 8511 under the
designation F-SW32. Many users of this type of flux
made the mistake of trying to clean off the residues
using CFC-113 blends, forgetting that it was designed
not to be cleaned. Not only was this difficult, even
impossible, the residues after cleaning were frequently
very dangerous.
One of the difficulties with this type of flux, and other
rosin fluxes, was that automatic testing was rendered
difficult as the residual rosin prevented contact from
being made with the conductor pattern. In 1984, a flux
manufacturer in Germany developed and patented a
variant of this type of flux with solids as low as 2-8%,
as opposed to the traditional 15-35%. Although slightly
more corrosive than the older types, these fluxes did
allow reliable contact to be made for automatic testing.
/V-2
-------
Ultra high
< i
•I U1M.
tlf* iliiH.
"No-cLaon" flux usag«
-> - ipr»f. ui«.
0 f »~». •!*•.
3 i «..•
a • Hi«n
J- L«»
Since then, many other flux manufacturers have
developed various formulations of fluxes that are
variously described as "low-residue", "no-clean" and
even, untruthfully, "no-residue". Other doubtful claims
that have been made are that wave soldering washes off
all the residues or that the residues sublimate. These
fluxes all have total solids of less than 10% and are
activated mainly with strong mono- or dicarboxylic
acids. The actual rosin or, in some cases, synthetic resin
content is used as a matrix to encapsulate the dangerous
activators. This confers reasonable insulation resistance
to the residues. It must notwithstanding be realised that
none of these fluxes is harmless and all leave large
quantities of ionic contamination, measured from five
to thirty times that permissible under military
speciGcations (incidentally, this is another cause of
doubtful publicity as some military specifications are
worded in such a way that the less scrupulous flux
manufacturers have used a loophole to promote their
products).
Various mechanisms of breakdown of the old
F-SW32 fluxes are known and these can all be applied
to the newer fluxes, now known under the designations
of F-SW33 and F-SW34. The most common is that
rosin and some other resins oxidise on air contact (this
is why that beautiful amber lump that some people used
as paperweights became covered with a whitish powder
after a year or so). When this happens, the
activator-holding matrix is destroyed and the released
acids can cause damage. Even more dangerous is ros;.-.
hydrolysis caused by long-term contact with humid a;r
Another problem can be caused by prior contamination
on the parts being soldered upsetting the matrix.
Unfortunately, none of these effects is revealed b>
accelerated testing, except possibly the last-named :n
some circumstances.
The use of this type of flux is perfectly acceptable
where long-term reliability is of little interest.
particularly where the circuits are designed for use
indoors in temperate climates or in air-conditioned
rooms. It is doubtful whether they can be employed for
most professional applications. They should most
certainly be avoided for life-dependent application
(military, aerospace, automotive, life-supporting
medical uses, etc.). They are not recommended for
other high-reliability usage, especially if for use
outdoors or in industrial locations. Figure IV-2 shows
that usage of these fluxes is rising in the quality
spectrum, but a ceiling is being approached.
One reason sometimes quoted for cleaning off f.ux
residues is that the thick, sometimes sticky, residues of
the more mildly activated fluxes were anaesthetic. Tr.i
newer low-solids fluxes leave residues that can \ar>
from visible but not especially unaesthetic to almost
invisible to the naked eye. As a general rule, they ar?
not usually sticky to the touch.
IV-3
-------
Fig. rV-3. Technical usage of water-soluble fluxes
This graph is based on the following assumptions:
1. that the military approve of them in DEF-STAN 00/10-3 (1986)
2. that the equipment used is suitable for SMD cleaning
3. that some other approvals will be accorded by 1990
The overlap area of "current usage" and "probable usage" is dependant on future approvals. At the time of writing, these fl axes
are not approved for general use by the U.S. military authorities, but they will possibly be approved for limited use within a short
period.
The actual mise-en-service of these fluxes requires a
certain apprenticeship28, as they are not "drop-in"
replacements for conventional types. In particular,
foam maintenance and solids-contents adjustment are
difficult and differ from traditional techniques.
Machines may have to be modified. All soldering
machine parameters are more difficult to optimise. Flux
consumption will be greater and, being more expensive,
the savings by not cleaning will not be as great as
originally imagined.
Another variation on this same theme is being
proposed in conjunction with a new wave soldering
technique, inert gas soldering. This is similar to
ordinary wave soldering except that the whole of the
inside of the machine is nitrogen purged. As the solder
itself does not oxidise under these conditions, the flux
has less work to do and lower quantities are claimed to
be necessary. It is being proposed to use small quantities
of rosin-free carboxylic acids as flux in certain cases.
This technique is interesting but certainly not safer: one
company (telecommunications) experimentally using
inert-gas soldering has reverted to "low-solids" fluxes
in such a machine. As the machines are expensive and
the running costs high, it is likely that this technique
will be reserved for special applications.
In conclusion of this section, low-residue fluxes not
requiring cleaning offer the ideal way of not causing
pollution by a cleaning process. It is also the most
cost-effective process. Under no circumstances should
these fluxes be solvent cleaned as the residues are
partially insoluble. If necessary, some (but not all) types
can be successfully saponifier-cleaned. Their use is
restricted to relatively low-reliability applications or
where a short life-time is acceptable. For fully
professional applications, they should only be adopted
with prudence and circumspection after lengthy field
tests under real operating conditions for at least the
expected life-time of the electronics. They should never
be used for life-dependent applications. Above all, read
manufacturers' data sheets and publicity with a
sceptical mind as many of the claims made are either
exaggerated or untruthful.
IV. 2.1.1.2 Water cleaning with water-soluble
fluxes
This is what most experts foresee as being the most
likely to become the popular method for professional
wave-soldering applications with small inroads into
other soldering methods. It has a long and good track
record and is thus a proven process. Its advantages are:
• very cost effective, especially for large systems
• the most reliable soldering process
• easy to obtain good ionic cleanliness levels
• machines for all sizes of lines available
• conforms to some military specifications
• often usable with SMT
• little or no waste water treatment required (machine
dependent).
-------
On :he other hand. its disadvantages are:
• drying may be problematic, depending on machine
design
• effective water-soluble flux solder pastes and wires
difficult to obtain
• COSB forsmall users may be slightly higher than 1986
CFC-113 usage (probably similar to projected 1990
costs)
• treatment of tap water usually required
• with a few flux and substrate combinations,
degradation of printed circuit insulation resistance.
Figure IV-3 shows the increasing universality of this
type of flux.
The choice of cleaning machines forall types of water
cleaning is critical. There are four basic types of
purpose-built machines available on the market:
• low-volume "dishwasher" types
• high-volume professional batch machines
• low-volume conveyorised machines
• high-volume in-line machines.
The "dishwasher" types, as the name implies, uses the
principle of the domestic dishwasher modified for this
application. As a general rule, standard dishwashers are
not suitable for complete wash-and-dry cycles. For
conventional assemblies, this type of machine gives
excellent results, but very few are suitable for SM
assemblies. Their principal disadvantage is that they
take typically at least 1 hour for cleaning and drying a
load of, say, 1 m2 of circuits, if they dry at all. They
present no specific pollution problems as the wash
water is completely renewed with each batch and there
is no accumulation of pollutants. It is extremely
unlikely that the wash water would ever fail to meet
Federal requirements either in terms of heavy metal
content, pH or biodegradability. On the other hand,
these machines consume large quantities of water
(typically 20-40 1/m2) which is expensive if deionised
and they are quite energy-inefficient (drying is
evaporative and the machine itself with all the residual
water has to be dried as well as the circuits). The capital
cost of a machine is typically similar to that of a small
open-top degreaser (SFr 10,000-25,000). Some
machines rinse in a closed circuit through a DI column,
but their spray energy, hence cleaning quality, is
reduced and the cost of column renewal is high as all
the ionic rinse contaminants are ion-exchanged. On the
other hand, the non-ionic contaminants are not
eliminated. The successive rinse system is more
efficient except for water consumption.
The high-volume professional batch machines (some
of them are of Swiss manufacture) are suitable for all
types of circuits, including SM types. They are
characterised by low water and energy consumption
and extremely efficient cleaning and drying. They can
handle the full outputof a wave soldering machine with
typical throughputs of up to 20 m2/h (about 5 m2/h for
SM assemblies). With water-soluble fluxes, the waste
water is never likely to present a pollution problem as
the wash water is constantly renewed by the rinse water
and goes to waste while it is still very dilute. This type
of machine generally has high purr.p e-erj.js •.-.?»_ .
2 HP), making for efficient washing. The -*i?r. _--
nnse water circuits are completely independent, so :.-._:
the open-circuit rinse water is totally unpolluted u.-.::!::
reaches the circuits being rinsed, making ' . -ma::
rinse-water consumption (typically 5 1;,. ,. Sorr.e
machines have an optional feature of injecting a srr.a.:
percentage of isopropanol in the nnse water v.-.:-
several benefits. Drying with this type of machine :s
achieved in a separate compartment or machine. The
best ones have rotary air-knife drying which blasts over
90% of the residual water from the circuits within a few
seconds (even from connectors and from under SMDsl.
followed by an energy-conserving hot-air drying for
removing the residual moisture. This results in the best
drying of any system. These machines are more
expensive than the previous type, usually within the
price range of SFr 20,000-60,000, but the running COSLS
are considerably lower, as well as being able to har.d'.e
many times the quantity of circuits.
The low-volume conveyorised machines can not be
used in-line with a soldering machine as their conveyor
speed is too slow. They are typically capable o;
cleaning up to a maximum of about 10 m'/h. The
cleaning and drying efficiencies are usually mediocre.
They are frequently based on redesigned printed circuit
etching machines. One, American, design is
custom-built with the conveyor inclined to give better
draining flow. Some types may present a pollution
problem: if the wash water is in a closed circuit without
automatic renewal or with a low renewal volume. ;: ;s
probable that heavy metals will accumulate in :t to
beyond Federal limits. In this case, the water rr.ust be
treated before it is evacuated to dram. If this is no;
possible, then it must be sent to a specialist company
for treatment. The usual way of reducing metal content
is by precipitating the metal hydroxides in an alkaline
medium, prior to neutralisation. This involves a large
and costly installation and often causes difficu:::es ;.-,
eliminating the sludge. Analtemative method, suitable
for small plants, is by recirculating the waste liquor
through an electrolytic cell until all the metals art
deposited on a stainless steel cathode, with a
columbium (possibly titanium) anode. This method has
been experimentally tried in the USA. by an EPA
sponsored project. It is claimed that up to 90% of the
metal (copper, tin and lead) is easily recovered
(although for another application) but actual figures
were not reported. Capital costs could be as low as
53*500, not counting the installation costs. The water
consumption of such machines is variable according :o
the design. Energy consumption is usually fairly high.
Capital costs are reasonable in absolute terms, but
perhaps high in relation to the quality of the results (SFr
35,000-60,000).
The high-volume in-line machines are usually very-
large, very expensive and not always efficient. The
basic problem is that a large solderinz machine may run
at a conveyor speed of, say, 2 m.min . It is obvious that
an in-line cleaning machine must run at the same speed.
rv-s
-------
IS*. INC 19M t3M
Fig. IV-4. Technical usage of sapooifler cleaning
This graph is based on the following assumptions:
1. the approval to MIL-P-28809 is subject to interpretation.
2. that extended approval to MIL specifications will be accorded by 1990.
3. the approval to DEF-STAN 00/10-3 (1986) is normal.
The overlap zone is a function of the interpretation of current and future specifications.
If the cleaning process takes, say, 3-4 minutes, as may
be required for saponification on SM assemblies, this
means that the cleaning compartments must total 6-8 m
long, plus the rinsing and drying modules. This makes
for extremely expensive machinery. Obviously, if the
conveyor speed can be reduced to 1 m.min'1 and it is
known that the cleaning process can be achieved in, say,
1-2 min, as is usually the case with water-soluble
fluxes, the problem can be resolved more easily. These
machines give mediocre to very good cleaning results,
depending on the machine design and conditions of use.
On the other hand, it is rare for the drying to be very
good and most users would be wise to consider it as a
pre-drying. Pollution may sometimes be a problem and
the same remarks is in the previous paragraph apply.
The range of prices for these machines is very wide,
typically from SFr 100,000 to over 500,000.
No matter which type of machine is used, one of the
potential problems is foaming. This is more likely to
occur if a water-soluble soldering oil is used in such a
way that it comes in contact with the circuit to be
cleaned. These water-soluble oils are readily
biodegradable and are more economical than the
non-degradable mineral oils but it is a fact that they do
have this disadvantage. Foaming can usually be
controlled with the addition of a few drops of octyl
alcohol in the wash water (do not use silicone based
foam-depressants). If not, a tap water pre-rinse to drain
may be necessary.
Another problem that sometimes occurs with these '
fluxes when using batch machines is that the wait time
before a load is ready to be washed may be sufficiently
long that the solder joints may be superficially attacked,
giving a matt result. This can be avoided by keeping the
circuits to be washed in a tank with a dilute solution of
a commercial chelating neutraliser based on
ammonium carbonate until sufficient have accumulated
to Oil a basket At the same time, it improves the
cleanliness of the circuits at very little extra cost. On the
other hand, it is probable that heavy metals may
accumulate in the neutraliser bath which should be
correctly destroyed. Chelating neutralises based on
EDTA salts should be avoided, as they may not conform
to the Federal Ordinance relating to Environmentally
Hazardous Substances (maximum concentration in the
as-delivered neutraliser 0.5%)
FV. 1.1.1.3 Rosin flux and saponifur
Rosin is not soluble in water. If treated with a suitable
alkali, similarly to vegetable oils being treated with
caustic soda in soap making, it forms a soap which can
dissolve in water. This process, called saponification,
has been used in the electronics industry for many years.
The alkali used is based on an organic substance called
monoethanolamine (MEA). It is sold in a concentrated
form by most of the flux manufacturers. Cleanliness
levels obtained, with good equipment, are usually better
than (hose obtained with organic solvents, as carboxy 1 ic
acid activators are also easily saponified, whereas their
IV-6
-------
ant- -,d«o.
• tc. )
( Of c. *Q. .
< TOO
toe
Fig. IV-S. Technical usage of hydrocarbon/surfactants
This graph is based on the following assumptions:
1. that competitive products will become commercially available in 1990
2. that these products become approved to diverse specifications by 1992
3. that production costs will prove to be too high for any but professional applications and will be initially underestimated
4. that no unforeseen hazards are discovered and no major accidents occur due to the use of hydrocarbon'surfacan: cleaners
solubility in solvents is limited. The equipment that can
be used is generally identical to that mentioned in the
previous section. An important point to note is that
saponification is not an instantaneous reaction and
times of two minutes are typical with conventional
circuits and longer for SM circuits, provided that the
mechanical energy of the machine is high. The
equipment must be dimensioned to take this into
account.
In terms of pollution, the only major differences
between the previous case and this one are the alkalinity
(pH) and the biodegradability of the used saponifier
solution. This problem can be divided into two
categories, for batch machines and conveyorised
machines. Both types of batch machines dump about 5
litres of used wash solution per cycle. This solution has
a typical pH of 10.5-11, which is outside the Federal
limits (from 6-6.5 to 8.5-9.5, according to local
conditions). Its biodegradability is more variable and
this is only regulated by the cantonal authorities, except
in the case of direct disposal in a watercourse. In reality,
it is extremely unlikely that direct dumping of such
small quantities of entirely biodegradable waste
products will be the cause of any problems, and is not
environmentally worse than the used wash water from
a domestic dishwasher. Many cantonal authorities will
grant a discretionary derogation for the use of such a
small machine without water treatment, provided that
application is made prior to its being put into service
with a saponifier. If this is not the case, a small
neutralising installation can be used to correct the pH
before dumping to drain. The larger installations •* her:
up to several hundred litres of saponifier solution are
used and dumped will certainly not be the subject of
derogations. As such solution is obligatorily circulated
in the machine, heavy metal levels will also be a
problem. If the factory has an industrial water treatment
plant, this can usually handle such waste without
difficulties. If not, the uscdsaponifiershould be put into
drums and sent to a competent company for destruction.
This technique is fairly universal in its applicability
and, provided suitable machines are used, ,s
particularly useful for cleaning circuits which hase
been reflow soldered with a solder paste. It covers a
wide range of applications (Figure IV-4).
Use of saponifiers with polyimide substrates and
certain types of thick film circuits is not recomme nded.
as the alkalinity may present compatibility problems.
On the other hand, most commercial saponifiers are
buffered in such a way that they will not attack light
(amphoteric) metals or component markings. Dyed
metal, such as cooling radiators for power
semiconductors, especially if conversion coated rathe:
than correctly anodised, may lose some of the colouring
matter.
The cost of this process is slightly higher than thai of
the previous one, the only major differences being that
of the purchase of the chemical and waste water
treatment, if any.
IV-7
-------
The industrial hygiene aspects of saponifier cleaning
must be examined. The concentrated and diluted
products are strong irritants, so that suitable protective
clothing, including gloves and goggles, is de rigueur
when handling them. MEA fumes are highly toxic, but
if the commercial products are used correctly, it is
unlikely that concentrations would become dangerous.
In any case, the smell is so unpleasant that it seems
unlikely that high concentrations would pass unnoticed.
Nevertheless, good ventilation of the cleaning area is
required.
IV. 2,1.1.4 Hydrocarbon!surfactant cleaning
of rosin fluxes
This technique is relatively new. It was first
announced in the USA about two years ago. Two
products have appeared on the European market in
experimental quantities. One of these is based on a
terpene principally distilled from orange peel and the
other is another type of hydrocarbon. It is too early to
give definitive information on this type of process, but
it appears to be technically very promising. There still
remain a number of unanswered questions.
Figures published by both manufacturers suggest that
the ionic contamination levels with this process can be
up to an order of magnitude better than with straight
CFC-113 blend cleaning. Even if we discount the fact
that these figures are probably laboratory results
obtained under the best conditions, there would seem
little doubt that it is a valid cleaning process. Results
obtained by users in the US A and Japan would seem to
confirm this fact. It seems a process panicuiarly
indicated for SM cleaning. It will probably be too
expensive for usage on mass production articles and it
is expected that it will find its place in the upper third
of the quality spectrum (Figure IV-5). Subsequent
expansion will tend to be upwards.
What is sure is that this process is expensive. The
solvent itself is expensive, even though it can be used
for a longer time before it has to be discarded. Even
more important is the fact that machinery cost is
doubled for in-line machines and about 50% higher
(estimated) for batch systems. The overall costs would
approach the double of the elimination of water-soluble
fluxes. To understand this, it must be realised that two
distinct operations are necessary. The Grst is the solvent
cleaning. This is then followed by a water rinse and dry.
The solvent cleaning machinery is divided into two
categories. The conveyorised, in-line machines are
usually provided as two, separate modules. The solvent
module uses high pressure jets to dissolve the rosin flux
residues. As this creates a fine mist which can be
explosive under some conditions, the machines are
usually nitrogen purged (requiring a large nitrogen
supply system which may be quite expensive to run).
Various safety devices are consequently necessary. As
the solvent is a VOC pollutant, the nitrogen outlet has
to be equipped with a water scrubber to prevent the mist
from dissipating in the atmosphere. Batch machines,
which are currently more experimental, use an agitated
soak technique for the solvent phase. This elimina:es
the problem of mist formation and it reduces the
flammability difficulties to zero, as the open-cup flash
points of these solvents are very high rO'-140'Q and
the volatility very low. In both cases, qucous phase
is done in machines similar to thuse previously
described.
Other than the VOC pollution, which is easily
handled, water pollution remains a thorny problem. In
the USA, it would seem that the rinse waters are
permissible pollutants. They are not so clearly defined
in Europe. For batch machinery, the quantities involved
would be so small that there should be no difficulty (see
the previous section) and it is expected that cantonal
authorities would raise no objections (note the case is
not covered by the Federal Ordinance). For
conveyorised equipment, two problems may arise. The
first is that of a biodegradability of the rinse waters
which would seem to be on the limit of what is currently
acceptable, typically up to five times more severe than
human faecal matter. The second is that not all
surfactants that may be used are themselves fully
biodegradable, although there is no reason to believe
that the commercial products contain such detergents.
There are a number of unknown factors regarding the
health and safety aspects. The products used are not
common as concentrates for such industrial processes
and relatively little is known about them. At least one
component is known to be an allergen in remote cases
and is an irritant. Fortunately, the smell of this
substance is so bad that it would seem unlikely that
dangerous quantities would accumulate in the operator
environment. It is probable that we shall have definitive
answers to these questions within a few months.
It would seem that this process is amongst the more
promising of the new ones for those cases where good
cleanliness is important and cost is of secondary
importance.
IV. 2.1.1.5 Hydrocarbon and derivative
cleaning of rosin fluxes
This implies cleaning in volatile, flammable solvents.
Theoretically, there is no reason why this should
present any major difficulty that standard industrial
processes do not already handle. Alcohol has, for
example, been distilled for many years without major
catastrophes happening. The real problem is that a
printed circuit with its components is not the same thing
as the walls of a still. It has many interstices which trap
contaminants and solvents. At least three German
manufacturers offer equipment for this purpose but it
must be said that these must be considered as at least
semi-experimental. For this reason, it would be unwise
to install them without adequate Ore precautions
external to the machines. In Japan, for example, such
machines have to be installed in separate bui Idi ngs wi th
a 20 metre Ore break round them, at least for the
moment. This extreme case is also partially due to the
high earthquake risk.
IV-8
-------
"0
a.
Fig. IV-6. Technical usage of alcohol cleaning
This graph is based on the following assumptions:
1. that alcohol cleaning is approved to diverse specifications by 1992
2. that no major accidents occur, due to the use of alcohols
3. that the costs will be initially underestimated.
Usoqe ros.n flux +• CFC-113 & 1.1.1-TCA
Fig. IV-7. Technical usage of ozone-depleting solvents
This is the reference diagram, based on the written standards and norms usual for industry up to 1986.
This graph is based on the following assumptions:
1. the price of CFC-113 will rise considerably from 1989 onwards
2. that either economic or legal considerations will enforce a de facto phase-out by 1995
3. that industry will not react fast enough after CFC-113 cleaning becomes economically non-competitive to prevent
cleaning costs
7V-9
-------
u
a
g s
tow t«l«CO«*»1
:««u»tfiot
• 1C •
Lout
(Prof. au4
-------
stabilisers. On she whole, the cleaning quality obtained
is probably not quite as good as with CFC-113 blends,
but sufficient for many applications. Their high activity
may cause damage to some components. This type of
solvent blend is sometimes used as either an anisanal
(see next section) cleaner or for cold cleaning in "kiss"
machines (underbrushing). Those solvents based on
1,1,1-trichloroethane can also be used for vapour phase
flux removal but the high temperature makes the
solvent very aggressive towards many synthetic
polymers. Wherever possible, it is recommended to
avoid using these solvents as a replacement for
CFC-113 and the more they arc used for this, the more
likely they will become subject to severe restrictions
within the Montreal Protocol.
However, it is possible that some HCFC blends may
be usable within a few years for special applications.
The most promising ones, at the moment, would seem
to be based on HCFC-225ca or HCFC-225cb, but it is
unlikely that blends containing these substances will be
available before the mid-1990s, assuming that the
toxicity testing passes without problem (Figure IV-8).
It is therefore Utopian to defer a decision to change from
CFC-113 type solvents because another similar one
may become available in the indefinite future. In any
case, all halocarbon solvents will, sooner or later,
disappear from the market and all the new ones will be
very expensive. If it is felt that no alternative exists for
CFC-113 or any other halocarbon solvent for a specific
application, ask for confirmation from an expert before
thinking about applying for a derogation. It is very
likely that an alternative exists for defluxing.
IV. 2. 1. 2. Anisanal defluxing.
Hand cleaning printed circuits is not easy under the
best conditions. Fortunately, very few companies have
used CFC-113 for this as the costs are so high because
of the extreme volatility of the products in open trays.
More popular are the chlorinated solvents blends, but
the use of these also must stop within the short- to
medium-term for reasons of either the environment or
toxicity (or both). Isopropanol is an effective and cheap
substitute for this type of cleaning, provided that it is
executed, including the drying, in an efficient
flameproof fume cupboard. The best method is
probably saponiGcation followed by water rinsing, but
this, also, should be done in a fume cupboard but not
necessarily flameproof. As the products used are hot
and irritant, it is necessary to protect the operator from
accidental contact with them by supplying adequate
protective clothing.
TV. 2.2. Degreasing
General degreasing can be replaced by aqueous
degreasing, using one or more of the hundreds of
detergents on the market. As each type of soil may
require a fairly specific type, it is better to consult
suppliers for advice before starting a frantic race to try
to find the "best" one. See the section on detergents in
Chapter II.
For degreasing with solve-a oi.-.er •..-._-. Jr J -. . '• -.
same general remarks apply as for *ii:Vj.x:r.£. ;\^\-
that saponifiers are not applicable to rerr.ov..-.; —.r.o:_.
oils and greases. See the general discussion in C'r.jp:;:
II.
IV. 2.3. Precision cleaning
This can be defined as cleaning to micrometre jr
angstrom cleanliness levels. This can be :n
ultra-precision mechanics, optical applications, etc,
Precision cleaning, as opposed to degreasing, is aiu a\ s
done in clean-room conditions. Traditionally, CFC-i 13
has been considered for many years as the ideal solvent
for precision cleaning, although there has been a trer.c!
away from it in recent years for some application.
Unfortunately, there are hundreds of precision cleaning
applications which would be too long to enumera:e
here. Each one has its particularities which renders the
choice of CFC substitutes more difficult.
Also traditionally, precision cleaning has often been
done with small bench-top ultrasonic tanks. preser.:;.-g
the worst conditions for CFC emissions. Any charge
must therefore involve not only the solvent, but also t-e
method. It may transpire, for example, that some special
applications may require the use of HCFCs as an
alternative to CFC-113. These will be too expensive to
simply let evaporate in a bench-top cleaner.
Many, probably the majority, of the applications may
be replaced by some form of aqueous cleaning, usir.z
detergents. This may require systems w;1.:-.
ultra-filtration on incoming 18 megohm-cm water w;:r.
a special distribution network.
One example of the success of replacing CFC-113 by
water is with hard disc drives. A large manufacturer has
done this very successfully with even better results than
obtained before. Inenial guidance and navigational
systems for aircraft have also been successfully cleaned
with aqueous systems, not only with better cleanhneii
but also faster results.
For paniculate contamination, filtered.
contaminant-free air has been found as effective as
CFC-113 for semiconductor reticle masks, cathode ray
tube shadow masks and electron guns. All these
examples have been accomplished with cost savings.
Optical parts have also been successfully aqueously
cleaned before vacuum coating or other operations.
However, some glasses may be degraded by pure water
or alkaline detergents. Tests are therefore essential.
Dryingof optical parts is often critical and CFC-113 has
been the preferred method (see next section).
Many other applications have been convened from
CFC-113 to some other method but there are a few
others for which no replacement technology exists, as
yet. For these, exceptional cases, it is hoped that one of
the new HCFCs or 5FP may offer the solution or
solutions. In the meanwhile, CFC-113 will continue :o
be used provided that utmost measures are taken to
minimise losses.
For fuller details of the applications me- -r.ed ;n :h;s
section and other precision cleaning _:pncauor.$.
F/-11
-------
reference can be made to the Summary Report of the
UNEP Solvents Technical Options Committee.
IV. 2. 4. Drying by solvents
CFC-113 has been used in two ways for precision
drying. The first is by pumping pure CFC-113 upwards
over the article to be dried. Any water will be displaced
upwards and will flow over a weir into a separator. The
second method uses a CFC-113/surfactant mixture
which emulsifies the water into a micellic solution. In
both cases, the drying is completed by passing the part
through a conventional CFC-113 vapour phase
degreasing process.
Hot air blasting has replaced these successfully in
many applications, including the disc drive cleaning
mentioned in the previous section. It is applicable also
to drying some optical parts.
Another mechanical method which can be very
'effective without high energy requirements is by
centrifuging. Small mechanical parts with an intricate
shape, including blind holes, can usually be very
successfully dried in suitable equipment. The cost of
centrifugal drying is extremely small.
Evaporative drying is also useful but is costly and
energy-consuming and may leave drying marks on
ultra-precision parts.
There are two methods of chemical drying which are
successfully applied. They are analogous to the two
CFC-113 methods. The first is to use a downward
current of certain aromatic hydrocarbons in a tank with
a perforated false bottom. The water is washed off and
carried downwards where it can collect under the false
bottom and periodically drained via a tap. This is
followed by a second, possibly a third, similar tank,
from which the water-free pan can be taken out and
placed in a drying compartment which will collect the
solvent vapours. This method is frequently used to
prevent oxidation of base metals after a chemical
cleaning operation, where a water-wet part on exposure
to air will cause almost instantaneous reoxidan'on. It can
also be used to lacquer chemically cleaned parts as a
temporary protection barrier it is sufficient to add a
small percentage of compatible lacquer to the final
solvent bath. The most popular solvent for this
application is toluene, but only pure grades should be
selected. Many commercial toluenes contain
considerable quantities of other hydrocarbons which
may be more hydrophilic, destroying the water
displacement properties.
The other method is to use two or three successive
baths of isopropanol. The water will dissolve readily in
this alcohol. The problem is, as in the case of
CFC-113/surfactant method, how to remove the water
from the solution in order to continue using it. The
answer is to pass the alcohol continuously through a
narrow-range zeolite molecular sieve which will
selectively adsorb the water. The sieve will require
frequent regeneration and replacement.
Both these methods have the disadvantage '.ha:
low-flash point flammable solvents are used and the
appropriate safety measures must be taken.
FV. 2.5. Textile dry cleaning
This is a difficult situation for which there is no
ready-made answer. Most dry-cleaning is done today
using perchloroethylene. Anyone entering a
dry-cleaning shop must be aware, from the smell, that
the operators are exposed to solvent vapours. Questions
are being asked as to the toxicity of these vapours.
A few, modem, machines use 1,1,1-tnchloroethane,
which has a high OOP and is also under question for its
toxicity.
Some garments, notably suedes, leathers and very
delicate textiles, can only be cleaned in CFC-113,
whose OOP is unacceptable, or a few mild hydrocarbon
solvents.
The latter method uses a petroleum distillate known
as Stoddard solvent. This is a white spirit which is
reasonably effective and usable for most garment types.
Its major disadvantage is its flammability.
It is possible that one or more of the new HCFC
solvents may present some hope for special cases but
the question must be asked whether the public will be
willing to pay the price of cleaning with them, unless
new dry-to-dry machines can be designed with
quasi-zero losses. Another factor that must not be
ignored is that many operators, especially in smaller
establishments, try to increase the throughput by
removing clothes from the machines before they are
dry. New machine designs should have an interlock
preventing such misuse. It must not be forgotten that
these new solvents, if they become acceptable with a
very low OOP and a low toxicity, may cost twenty times
the price of perchloroethylene.
It is recommended that all garment manufacturers
should be made aware of these changes that will be
expected to take place over the next decade, so that they
can adjust to the requirements of how their products
may be cleaned.
As stated at the beginning of this section there is no
ready-made answer even less is there a miracle answer
and both the cleaners and the public must be reconciled
to a forced change in their habits and probably increased
costs.
IV. 2.6. Particle removal
Because of its high density, CFC-113 allows
non-metallic particles to be floated off parts. Excellent
results have been obtained with good cost reductions by
simple high-velocity ultra-filtered air jets. See section
IV.2J.
IV. 2. 7. Medical applications
The most important medical application of CFC-113
is cleaning needles before sterilisation. Short, wide bore
needles present no specific problems if they are one of
the all-metal Luer lock or slip types; almost any
cleaning method is usable. Plastic hub throw-away
rv-n
-------
types must use a cleaning method compatible with the
plastic used. This rules out stronger organic solvents.
The aspect ratio of some needles is most unfavourable.
There is no difficulty in causing an aqueous cleaner to
enter such needles. The capillary effect will do it
automatically. The problem is how to rinse it out
afterwards.
One suggestion is to robotise a system which takes
each needle individually, after bulk cleaning of the
exterior, and mounts.it on one of a series of Lucr lock
receptacles through which a high pressure detergent
solution is passed. This is replaced by high pressure,
pure water in sufficient volume to ensure that no
detergent remains in the bore. Finally, clean, hot air is
blown through the bores to remove the water after
which the robot removes the needles for the next
process stage. This technique could not be applied to
slip needles unless a retention jig holds them in place,
as the pressures involved would shoot them off the
adapters.
Other medical cleaning with CFC-113 is performed
to many surgical implants, implements and
instruments. In most cases, there is little reason for this
choice other than simple convenience. However, where
certain plastics are used, notably plasticised flexible
pipes, there is a certain concern that inherently
solvent-soluble plasricisers may leach into vital fluids.
For this reason, CFC-113 flushing is used, this solvent
being unlikely to degrade the polymers themselves. It
has been found that a 50% by volume alcohol
(ethanol)Avater mixture will do the same work. A
subsequent rinse with pure or 90% alcohol will aid
drying by warm air. The resultant pipes will be
sufficiently sterile for most applications if the outside
is treated at the same time. Ethylene oxide sterilisation
of plasticised polymers is usually undesirable.
Ethylene oxide is a popular sterilising compound. It
is a gas at room temperature (boiling point variously
given at 10.5* and 13.2*C) and forms a very explosive
mixture with air. It is soluble in most solvents but, being
highly reactive, it is difficult to conserve it. For this
reason, it is sometimes used in mixture with an
ultra-pure grade of CFC-113 which acts as an inert
liquid vehicle. Water can also act as a vehicle, but it
must be ultra-pure and neutral. Ethylene oxide will
react with many acids and bases so that small
excursions of pH are inadmissible. It is foreseen that
perfluorocarbon and hydrofluorocarbon vehicles,
which are generally inert to vital fluids, could replace
CFC-113 for this application, these having zero OOP.
For gaseous sterilisation, carbon dioxide is a good
vehicle.
FV. 2. 8. Vehicles for lubricantsandadhtsi'. a
CFC-113 is occasionally used as a vehicle :::
lubricants or as a corrosion inhibitor during cutting
operations. One example is for the lubrication ot
ultra-miniature ball bearing assemblies used :"or
instrumentation. The penetration of even a '.run oil car-.
not be ensured, so that the oil is dissolved :n a
pure-grade, inert solvent. CFC-113 is the usual choice.
The ball race is sprayed with this mixture whicr.
penetrates to leave a microscopic oil film on all the
surfaces after the solvent has evaporated. Many
solvents could be used for this purpose. For space
applications, low vapour pressure oils are essential and
these are pcrfluorinated lubricants which are insoluble
inall the usual non-fluorinated solvents. It is hoped that
one of the HCFCor HFC products in development will
be able to replace CFC-113 as a vehicle for this specific
application.
As one example of a cutting aid, during drilling of
blind rivet holes in aircraft manufacture, :hey are
sprayed with CFC-113 to flush out possible
corrosion-causing products and to cool the cutting tool.
The rivet slug is inserted while the hole is still we:. It ;s
probable that the CFC-113 may be able to be replaced
by an HFC solvent or an HFQHCFC blend, both of
which will be even more non-reactive.
CFC-113 is occasionally used for the manufacture of
speciality self-adhesive tapes, although it is :oo
expensive for extensive use. 1,1,1-tnchloroethar.e :s
more commonly used but this is also ozone-depletir.g
and can only be used for applications where adequate
ventilation and solvent recovery can be ensured. Wats:
based systems have been developed for most tape types
but suffer from the disadvantage of slower production
rates. For ordinary adhesives. resins, lacquers and
paints, it is rare for halocarbons to be an essential
vehicle and there is a distinct tendency towards
solvent-freeorwater-vehicledsystems.This is a rapidly
advancing area of technology and it is foreseen that very
few applications will obligatorily require
ozone-depleting vehicles by the mid-1990s. What is
more is that far fewer will require VOC solvents, er.her.
Another vehicle application is for single page
deacidification. Books which must be conserved for
over, say, 100 years, may be mass treated using a
suspension of suitable chemicals in liquid CFC-12.
Single pages are more easily treated with such a mixture
in CFC-113. As the major quality required with such a
vehicle is complete inertness, it is easily envisaged that
one of the perfluorocarbons would be ideal for this
purpose.
fV-13
-------
Thjs page is blank.
[V-14
-------
Appendix A: Properties of halocarbons.
The following table gives the most up-to-date
estimations of the boiling point, the ozone depleting
potential, the global wanning potential and the folded
e lifetime of the principal halocarbons relating to
cleaning and similar applications. Boiling point apart,
these figures are calculated from theoretical principles
using mathematical modelling. It should be noted that
there are several algorithms used for such models and
the results do not always agree. It is therefore possible
that small differences may be observed between what
would seem to be the same information from different
sources. In practical terms, these differences are
negligible, as the premises used in making the models
are not always very clearly defined.
If no figure is given in the following tables, it means
that the information is not available. If a figure is given
between round brackets Q. it means that this figure :s
an estimation, between square brackets [], it means t.u.2t
this figure is little better than an inspired guess and :s
subject to confirmation.
Desig-
nation
1. CFCs
CFC-11
CFC-12
CFC-112
CFC-1123
CFC-113
CFC-113a
2. HCFCs
HCFC-21
HCFC-22
HCFC-122
HCFC-123
HCFC-132b
HCFC-141b
HCFC-225ca
HCFC-225cb
HCFC-226
3. Halons
1211
1301
4. Other halocarbons
1,1,1-trichloroethane
Carbon tetrachloride
Chloroform
Perchlorethyfene
Trichlorethylene
Formula
CFCla
CF2CI2
CCI2F-CCI2F
CCI3-CCIF2
CCI2F-CCIF2
CCI3-CF3
CHCI2F
CHCIF2
CClF2-CHCI2
CHCI^CFs
CH2CI-CCIF2
CH3-CCI2F
CF3-CF2-CHCI2
CCIF^CF^CHCIF
CHF2-CF2-CCIF2-
CF2BrCI
CF3Br
CCI3-CH3
ecu*
CHCb**
CCI2=CCI2**
CCI2=CHCr
Boiling
point
+24
-30
+92
+48
+46
+9
-41
+72
+29
+47
+32
+51
+56
+21
0
-60
+74
+77
+60
+ 121
+87
OOP
1.0
1.0
[0.7]
0.8
0.85
0.05
(0.02)
(0.1)
[0.05]
[0.05]
3.0
10.0
0.15
1.2
[<0.01]
[<0.01]
GWP tlle,
1.0 74
3 111
1.3 100
t
0.35 20
0.02
0.09
25
110
0.024 7
0.35 60
* Known carcinogen
** Suspected carcinogen
APP. A-l
-------
R. References
1. Molina, MJ. & Rowland, F.S., 'Stratospheric Sink
forChlorofluoromethanes: Chlorine Atom-Catalysed
Destruction of Ozone', Nature, 249, pp 8.10-812
(1974)
2. Farman, J.C., Gardiner, B.G. & Shanklin, J.D.,
'Large Losses of Total Ozone in Antarctica Reveal
Seasonal CIO* NOX Interaction', Nature, 315, pp
207-210(1985)
3. McElroy, M.B., Salawitch, RJ., Wofsy, S.L. &
Logan, J.A., 'Reductions in Antarctic Ozone due to
Synergistic Interactions of Chlorine and Bromine',
Nature, 321, pp 756-762 (1986)
4. Sanders, S.P. & Friedl R.R., 'Kinetics and Product
Studies of the CIO and BrO Reaction: Implications
for Antarctic Chemistry', Submission to Ceophys.
Research Lett. (1988)
5. United Kingdom Stratospheric Ozone Review
Group, 'Stratospheric Ozone 1987', Her Majesty's
Stationery Office, (1987)
6. UNEP, 'The Montreal Protocol on Substances which
Deplete the Ozone Layer', (September 1987)
7. UNEP Solvents Technical Options Committee,
Summary Report, (1989)
8. Ordonnance sur le ddversement des eaux usfes,
814.225.21 (1975, rev. 1985)
9. Ordonnance sur les substances dangereuses pour
1'environnement, 814.013 (1986 rev. 1988)
10. Loi fdddrale sur le commerce des toxiques, 814.80
(1969 rev. 1985)
11. Ordonnance sur 1'interdiction de substances
toxiques, 814.839(1971, rev. 1984)
12. United Kingdom Stratospheric Ozone Review
Group, 'Stratospheric Ozone 1988: Mechanisms for
Generation of the Antarctic Ozone Hole', pp. 11-20,
Her Majesty's Stationery Office, (1988)
13. Brune, W.H., Toohey, D.W., Anderson, J.G.,
Danielson, E.F. & Starr, W., 'In-situ Observations of
CIO in the Wintertime Northern Hemisphere: ER2
Aircraft Results from 21*N-6rN Latitude', Polar
Ozone Workshop, NASA Conference Publication
10014, Washington, D.C. (1988)
14. United Kingdom Stratospheric Ozone Re1.-.;:•..
Group, 'Stratospheric Ozone 1988: The Greerj-.o_si
Effect of CFCs and Substitutes' p 49, Her Majcstv';
Stationery Office (1988)
15. Seell.
16. European Chlorinated Solvent Association. 'A
Review of 1,1,1-trichloroethane (metSiyi
chloroform)' (July 1989)
17. Asahi Glass Company Ltd, Press release on
Substitutes for CFC-113 (February 1989)
18. US EPA James Hemby (see Fig. I-lj
19. Daikin Industries Ltd, Data Sheet.
PentaQuoropropanol, (1989)
20. See 16.
21. Carpenter, C. 'Biodegradable Solvents'. A;r
Engineering and Services Center.
AFESC/RDVS, Tyndall Air Force Base, Fl. (1
22. Ordonnance sur revaluation de la d£gradab i!
agents de surface contenus dans les demerger.is
rev. 1980)
23. Ellis, B.N., 'Cleaning and Coniarnir.a:;
Electronics Components and Asserr.b
Electrochemical Publications Ltd. (1986) '
[also available in German as 'Reisiger. :- c;r
Elektronik', Eugen G. Leuze Verlag (19S9^j
24. See 7.
25. Directorate, Commission of the E-jropsi-
Communities, 'Code of Practice for the Des;g-..
Construction and Operation of CFC-113 De ersase rs'.
EUR 9510 EN, (1984)
26. Clementson, J., 'CFC-113 Conservation a-i
Recovery Practice in Europe', Technical
Proceedings, Substitutes and Alternatives to CFCs
andHalons, Conference and Trade Fair (1988)
27. Ellis, B.N., 'Safety and Environmenial Problerr^ of
Cleaning Printed Circuit Assemblies', Technical
Proceedings, Joint IPC, EIPC and PCIF Conference.
The Future of PCBs, Helsingor, Denmark (1988)
28. Toubia A., 'Low Solids Content Fluxes', Circu-:
World, Vol. 15, No. 2, pp 17-18 (1989)
force
HQ
989 1"
r.edes
o- :
lies'
R-l
-------
L. Useful lists of addresses
L. 1. Governn aad official departments
Federal Office for Environment, Forests and Landscape (BUWAL)
Haliwylstrasse 4
3003 B«me
Telephone: 031-61 93 49
Federal Office for Public Health
Toxic Products Division
Bollwerk 27
3001 Berne
Telephone 031-61 96 40
Swiss National Accident Insurance Fund
6002 Lucerne
Telephone: 041-21 5111
L. 2. Private sector organisations
L, 2.1. Chemical Industry
Schweizerische Gesellschaft fur Chemische Industrie (SGCI)
Nordstrasse 15
8035 Zurich
Telephone: 01-363 10 30
L, 2. 2. Electronics industry:
Groupement de 1'Electronique de Suisse Occidentale (GESO)
place de la Gare 10
1001 Lausanne
Telephone: 021-23 47 26
Schweizerisches Automatik Pool (SAP)
Bleicherweg 21
8022 Zurich
Telephone 01-202 59 50
Verein Schweizerischer Maschinenindustrieller (VSM)
Kirchenweg 4
8032 Zurich
Telephone: 01-47 84 00
L.2.3, Precision industry:
F
-------
Chapter IV.
Index
A
active charcoal filter II-5,
adhcsives
aerosol sprays
alcohols 1-3,
ammonium hydroxide
aqueous cleaning
automatic handling
automatic PCB testing
B
benzine
biodegradability
detergents
hydrocarbon/surfactant blends
hydrocarbon/surfactant cleaning
saponifier
soldering oils
bottoms recovery
bulk containers
CFC-113
c
carbon dioxide
carbon tetrachloride
caustic soda
CFC-11
CFC-112
CFC-113
"drop-in" replacements
legislation
lifetime
recipients
substitution by HCFCs
trade marks
cleaning
needles
water-soluble fluxes
cleaning PCBs
water consumption
climate
communications to operators
condensation soldering
secondary blanket
conservation
CFC-113 recovery service
recovery, chlorinated solvents
container venting
cooling coils
III-2, III-4.IV-1
IV-13
1-1
n-4, rv-g, rv-12
n-s
II-6
in-4
rv-2
II-4
n-s
II-5
rv-8
IV-7
IV-6
m-i
in-2
1-4
n-i
II-8
II-l
II-2
II-l
II-2
1-3
1-4
III-2
rv-n
n-i
rv-i3
IV-4
IV-5
1-1,1-4
m-4
II-3
n-2, ra-i
in-i
111-1
III-2
III-3
cost
alcohol cleaning
aqueous degreasing
automatic transfer system
bottoms recovery
centrifugal drying
dry-cleaning with HCFCs
evaporative drying
HCFCs
hydrocarbon/surfactant cleaning
hydrocarbons and derivatives
"no-clean" fluxes
panicle elimination
saponifier cleaning
Swiss solvent losses
vapour phase soldering
water-soluble fluxes
Cotti, F., Mr.
cutting aids
cycle, saponifier cleaning
cycle, solvent cleaning
D
defluxing
aqueous
artisanal
CFC-112
hand
hydrocarbon/surfactant
hydrocarbons and derivatives
industrial
water
degreasing
aqueous
detergents
drums and cans
dry-cleaning
drying
air blasting
by CFC-113
centrifugal
chemical
energy conservation
energy consumption
evaporative
hydrocarbons and derivatives
water
tI-4. [V-iO
II-3
III--:
in-:
IV-12
IV-12
iv-i:
n-:
IV-8
n-5
IV-4
IV. 11
iv--
iv-:
II-3
IV-4 - IV-5
i-:
IV-13
IV-7
III-3
11-6
IV-1
IV.l.IV-ll
!i-:
IV-11
IV-l
II-4. IV-1
IV-1
IV-1
II-7, IV-ll
II-7. I\'-ll
in-:
IV-12
II-7.IV.12
IV-12
IV-12
IV-12
IV-5
II-7
II-7.IV.12
II-5
II-7.IV-5. IV-12
Index-1
-------
-------
pans baskets
PCB substrates
compatibility with cleaners
pentafluoropropanol
perchloroethylene
for flux removal
peril uorocarbons
petroleum spirits
See also white spirits
polar soils
polar vortex
precision cleaning
2-propanol
See isopropanol
pumping solvents
R
reliability
water-soluble fluxes
residual contamination
rosin
hydrolysis
oxidation
rosin fluxes
saponifier cleaning
s
saponiflers
seals and gaskets
self-adhesive tapes
siting equipment
SMT
See surface mounting
sniffer
solder pastes
soldering
inert-gas
"no-clean" fluxes
water-soluble fluxes
water-soluble oil
solvent cleaning cycle
solvent cooling
solvent filling
solvent handling
solvent type losses
solvent vapour capture
solvent vehicles
solvents on parts
Solvents Technical Options O
spray lances
sterilisation
Stoddart solvent
See also white spirits
stratospheric chlorine
subcontractors
substances
legislation
substitution
electronics industry
suppliers
III-3
IV-7
n-3, rv-ii
surface mounting
cleaning water-soluble fluxes
hydrocarbon/surfactant cleaning
water-soluble fluxes
II-3, IV-12 "-witching off solvent machines
IV- 1C
II-3 T
II-4
II-7
1-4
rv-ii
in-2
IV-4
ri-8, iv-i, rv-3 - rv-4
rv-3, rv-io
IV-3
rv-45
n-s, iv-6
ui-2, iv-i
IV-13
m-2
in-2,ra-4
IV-5
IV-4
IV-4
IV-4
IV-6
III-3
in-3
ra-2
in-2
m-4
ra-4
rv-i3
m-4
tmittee 1-3, II-2, IV-12
m-3
IV-13
1-2
III-5
1-3
IV-1
IV-2
m-5
taps and valves
taxes
terpcnes 1-3, II-4
Thatcher, M., Mrs.
toluene
toxic products
legislation
toxicity
carbon tetrachloride
HCFCs
hydrocarbons and derivatives
in dry-cleaning
per- and trichloroethylene
saponiGers
1,1,1-trichloroethane
1,1,1-trichloroethane
for flux removal
substitute for CFC-113
trade marks
trichloroethylene
u
underb rushing
V
vapour phase soldering
secondary blanket
VOC
See volatile organic compounds
volatile organic compounds
alcohols
conservation
HCFCs
hydrocarbon/surfactant blends
hydrocarbon/surfactant cleaning
hydrocarbons
hydrocarbons and derivatives
per- and trichloroethylene
solvent vehicles for adhesives, paints etc.
w
water
quality
water effluent II-5, II-7, IV-5,
legislation
saponifiers
water-soluble fluxes
water scrubbers
water treatment
water-soluble fluxes
white spirits
'A' -5
LV.S
[V-4
III-3
m-2. iv- :
1-3
- II-5, IV-3
1-1
II-4.IV. 12
1-3
II-l
11-3
II-5
IV- 12
II-3
IV-3
II-2
ii-i, rv-i:
IV-10
11-2
II-l
II-3
IV- 11
II-3
I-1.I-3
n-4. rv-io
III-l
II-2
II-5
' IV-3
II-4
II-5
II-3
IV-13
II-7
IV-7 - IV-8
1-3
II-S
IV-4
II-5, IV-8
II-7, IV-5
IV-l.IV-4
II-4, IV- 12
lndex-3
-------
II
CFC ALLIANCE
SPECIAL BULLETIN
2011 Ey« StrMt, N.W., Fifth Floor, Washington, D.C. 20000
0«e«mb«r,l989
THE NEW CFC TAX
The Omnibus Budget Reconciliation Act of 1989 imposes a new excise tax on certain ozone-depleting chemicals and on im-
ports of products made with or containing such chemicals. The Treasury Department and the IRS have begun the process of im-
plementing the new tax and expect to publish guidance for taxpayers on a variety of issues relating to the tax before the end of
1989.
The following is an explanation of the new tax. The explanation is based on the best information currently available. Until the
IRS publishes guidance on the tax, however, a number of the issues discussed in this paper will remain uncertain. Before rmdring
business decisions that could be affected bv the resolution of these issues, taxnaven should seek independent Drofessional advice
Taxable Chemicals
Taxable Events
The bill defines eight chemicals as ozone-depleting
chemicals and applies the new tax to them. The eight chemi-
cals are those subject to production limitations under the
Montreal Protocol and the implementing EPA regulations.
The chemicals are the following:
CFC-11 (trichlorofluoromethane)
CFC-12 (dichlorodifluorometbane)
CFC-113 (trichlorotrinuoroethane)
CFC-114 (1,2-dichIoro-l, 1,2,2-
tetrafluoroe thane)
CFC-115 (cfltoropentafluoroetbane)
Halon-1211 (bromochlorodifluoromethane)
Halon-1301 (bromotrifluoromethane)
Halon-2402 (dlbromotetrafluoroethane)
Additions to this list of taxable chemicals can be made
only by Congress. Therefore if other chemicals become sub-
, ject to the Montreal Protocol or to other production limita-
tions, chose chemicals would not be subject to the tax unless
Congress takes legislative action.
The bill excludes from the definition of ozone-depleting
chemicals those chemicals produced outside the United
States and not imported into the United States. Thus, ozone-
depleting chemicals produced outside the United States by a
U.S. taxpayer are not subject to the tax unless imported into
the United States.
The tax is imposed in three instances:
Sale or uae hv manufacturer, producer, or Importer.
The principal taxable event is the sale of ozone-deplet-
ing chemicals after December 31,1989, by the manufac-
turer, producer, or importer of the chemicals. The tax
also will apply where the manufacturer, producer, or im-
porter of ozone-depleting chemicals uses the chemicals
after December 31,1989, instead of selling them.
Sain or us* of Imported products for which ozone-
ri»nlt>ting rhftnlpaU are production material. In order
to reach indirect imports of ozone-depleting chemicals,
the tax applies to the sale or use by an importer, after
December 31,1989, of imported products for which any
ozone-depleting chemical is used as material in the
manufacture or production process.
Ownership of floor stocks. The tax is imposed on
stocks of ozone-depleting chemicals owned by any per-
son (other than the manufacturer, producer or importer
of the chemicals) on January 1,1990 if the chemicals are
held for sale or for use in further manufacture. The tax
also is imposed on stocks of taxable chemicals held for
the same purposes on January 1 of each year 1991
through 1994 if the tax rate for such chemicals increases
on that date.
These three taxable events are explained in more
detail below.
Persons Required To Remit the Tax to the IRS
nr ma. The producer, manufac-
turer or importer of the chemicals is liable to the IRS for
-------
UJAJU uic
ui inc iiiemicais oy
such person.
Imported products. The importer of taxable imported
products is liable to the IRS for the tax upon the sale or
use of such products by the importer.
Floor *tnrk«. The owner of the chemicals on January 1
of each applicable year is liable to the IRS for the floor
stocks tax.
Calculation of Amount nf Tat
The amount of the tax is determined under the following
formula:
Pounds of
Tax*
Base Tax Ozone-Depletion
Amount X Factor X Chemicals
This formula applies in all instances and to all ozone-
depleting chemicals except, as described in more detail
below, batons and chemicals used in the manufacture of rigid
foam insulation. Thus, the formula applies in the normal
case of the sale or use of chemicals by the producer, in the
case of the floor stocks tax. and in the case of imported
products. In the latter case, the formula applies to the quan-
tities of ozone-depleting chemicals used as material in the
manufacture or production of the imported products.
Baae Tax Amount
The bill designates a specific base tax amount for the
years 1990-1994 and provides for an increase of 45 cents for
each year beyond 1994. The base amounts through 1999 are
as follows:
1990
1991
1992
1993
1994
$L37
U7
1.67
2.65
2.65
Factors
1995 $3.10
1996 3.55
1997 4.00
1998 4.45
1999 4.90
cnermcaii suojeci to tne uix. cnanges in ine
factors can result only from Congressional acaon.
Application of the Tax on Sales by the Producer
In 0s -e of the regular tax on sales of ozone-depleting
che. 13 by the producer, the bill applies the tax to the
quantity actually "sold." Thus, for example, under the
plain meaning of the bill, tank truck heels and other
similar quantities are not taxaole until and unless they
are sold.
Although the bill is silent on the precise calculation of a
producer's taxable sales volume, the normal procedure
in the case of other federal excise taxes is to calculate the
volume on a net basis - that is, gross sales volume less
returns and adjustments. An IRS official has indicated
informally that this normal calculation should apply.
In calculating the tax, fractions of pounds of chemicals
are not rounded The partial pounds are multiplied by
the same ozone-depletion factor and base tax amount as
whole pounds.
The bill is silent on the issue of when a sale is deemed to
occur for purposes of the tax. In the absence of specific
rules, general tax rules probably would apply. Under the
general rules, the IRS examines the substance, not the
form, of a transaction to determine whether a sale has oc-
curred. In such an examination, a sale generally is
deemed to occur when the benefits and burdens of
ownership are transferred, not merely when paper
evidence of the sale is executed. This standard also
would be relevant for determining ownership of taxable
chemicals for purposes of the floor stocks tax.
Each ozone-depletion factor represents the comparative
potential ozone-depletion resulting from the same weight of a
given chemical. The factors are as follows:
Halon 1211 3.0
HalooOOl 100)
Halon 2402 6.0
CFC-11
CFC-12
CFC-113
CFC-114
CFC-115
1.0
10)
OJ
1.0
0.6
The ozone-depletion factors designated in the statute are
those specified in the Montreal Protocol. Like the list of
Application nf the Tax on Imported Products
For imported products, the bill provides that the tax is
equal to the amount of tax which would be imposed if
the chemicals that were used as material in the manufac-
ture or production of the products had been sold in the
United States.
To calculate the quantity of chemicals used as material
in the manufacture or production of imported products,
the Secretary of the Treasury is directed in the bill to
choose one of three methods:
A. Data Provided by Importer. The Secretary can
accept data the importer supplies showing the
volume of chemicals used as material in the produc-
tion process.
B. Domestic Industry Norm*. If the importer fails
to provide sufficient data, the Secretary can calculate
the chemical amounts based on standards of use in
the equivalent domestic industry.
D«camtMM989
Page 2
-------
C. Fivf Percent nf Appraised Value. The bill also
provides thai, if necessary, the Secretary can bypass
the foregoing procedures and impose a tax equal to
five percent of the value of the imported product.
This provision is intended to serve primarily as an in-
centive for importers to come forward with evidence
as to the amount of ozone-depleting chemicals in
their products.
Treasury Department economists nave begun work to
compile a list of imported products for which ozone-
depleting chemicals are used in the production process,
and to determine the average quantity of the chemicals
so used in each product.
The Secretary of the Treasury also is authorized to
prescribe regulations exempting products that use de
minimis amounts of ozone-depleting chemicals as
material in the production process. However, no such de
minimis exception applies if the ozone-depleting chemi-
cals are used for purposes of refrigeration or air con-
ditioning, creating an aerosol or foam, or manufacturing
electronic components.
Annllcattnn of the Floor Stocks Tag
As stated previously, the floor stocks tax is imposed on
January 1 of each year 1990 through 1994 on any ozone-
depleting chemical owned by any person (other than the
manufacturer, producer, or importer) on such date and
held for sale or for use in further manufacture. The
amount of the floor stocks tax is as follows:
1990: The amount of tax that would have been im-
posed if the chemical had been sold during 1990.
1991-1994: The excess of the tax that would have
been imposed on the sale of the chemical by
the manufacturer, producer or importer on January 1
of that year, over the tax, if any, previously imposed
on the chemical.
The floor stocks tax is applicable to wholesalers.
retailers, distributors, contractors, and any other type of
business that holds stocks of ozone-depleting chemicals
for sale or for use in further manufacture.
The bill contains no exemption from the floor stocks tax
for small businesses or for businesses that hold de mini-
mis quantities of chemicals. The IRS is considering the
possibility of instituting exemptions administra-tively.
The tax applies only to stocks of chemicals-held Jor sale
or for use in further manufacture. However, the bill does
not contain a definition of the term "use in further
manufacture." The term probably is best read as denot-
ing direct, proximate use in an actual manufacturing
process. (If the bill had been intended to have a broader
meaning, it probably would have been drafted to apply
to stocks held "by" a manufacturer or simply "by" any
business.) An IRS official has informally agreed with
this conclusion; it is unclear, however, as to whether the
IRS will publish any detailed guidance on this issue in
the near future.
• Assuming the above imerpreLaiion of ine term j^ T.
further manufacture" is correct, then, as an example.
stocks of chemicals held for use as a solvent in a
manufacturing process probably would be taxable, as
would stocks of chemicals held by a manufacturer of
refrigeration equipment for use as a refrigerant in er .
mem made by the company. However, stocks of ch a:
cals held for use other than a direct use in a
manufacturing process » for example, stocks of chemi-
cals held for use in cooling systems for a factory -
probably would not be taxable. Stocks of chemicals held
for use in routine factory maintenance also might not be
taxable.
• The bill is drafted to apply the floor stocks tax only to
ozone-depleting chemicals themselves and not to
products that contain ozone-depleting chemicals (in con-
trast with the treatment of imports). Thus, generally
speaking, the IRS probably does not have the power to
apply the tax to such products. In administering the tax,
however, the IRS probably does have the power to
prevent taxpayers from abusing the purpose of the floor
stocks tax through abnormal business practices.
The bill is silent as to the tax treatment of chemical
blends consisting partly of taxable chemicals and partly
of non-taxable chemicals. The IRS also has not indi-
cated any position on this issue.
The IRS is expected to publish guidance on the payment
procedures for the floor stocks tax by the end of the year.
As in virtually all other federal taxes, it is expected that
the responsibility for reporting and paying the tax will be
the taxpayer's. In other words, the taxpayer's legal
liability to pay the tax arises under the legislation and
will not depend on identification or contact of the tax-
payer by the IRS. According to an IRS official, the floor
stocks tax probably will be payable on IRS form 720.
which is the excise tax return. The IRS will revise the
form to accommodate the floor stocks tax.
The following are examples of the computation of the
floor stocks tax:
A. A dealer holds 200 pounds of CFC-115 for sale
on January 1,1990. The floor stocks tax will equal
$164.40(51.37x0.6x200).
B. ABC Company holds 300 pounds of CFC-12 on
January 1,1993 for use in further manufacture. ABC
Company purchased the chemical in June 1992. The
floor stocks tax will equal S294. That amount is the
difference between the tax that would be imposed if
the initial sale of the chemical had occurred on
January 1.1993, $795 ($2.65 x 1.0 x 300) and the tax
previously imposed in 1992, $501 ($1.67 x 1.0 x
300).
C. A dealer holds 400 pounds of halon 1211 for
sale on January 1,1990. No floor stocks tax is im-
posed because, under the bill, halon 1211 is not
treated as an ozone-depleting chemical until January
1,1991.
D. A dealer holds 400 pounds of halon 1211 for
sale on January 1,1991. The floor stocks tax will
equal $100. That amount is the difference between
the tax that would be imposed if the initial sale of the
Page 3
December 1989
-------
haJon had occurred on January 1, 1991, S100 (25
cents/lb. x 400 Ibs.) and the tax already imposed, SO.
E. XYZ Company holds 500 pounds of halon 2402
on January 1.1994. XYZ Company purchased the
chemical in 1992. The floor stocks tax will equal
$7.825. That amount represents the difference be-
tween the tax that would be imposed if the initial sale
of the chemical had occurred on January 1.1994,
$7,950 ($2.65 x 6.0 x 500) and the tax previously im-
posed on the sale of the halon 2402 to XYZ Com-
pany in 1992, $125 (25 cents/lb. x 500 Ibs.) Note:
No floor stocks tax was imposed in January 1.1993
because the tax rate for halons, 25 cents/lb., remained
the same.
the producer to the. exempt user and on sales to a
wholesaler or distributor who intends to resell to the ex-
empt user.
The exemption fo' of ozone-depleting chemicals
for feedstock use a. /ii s only if the parties to the transac •
lions meet registration requirements to be prescribed by
the Secretary of the Treasury. See the sppurat^ discus-
sion of the registration requirements helnw
If tax is actually paid on chemicals used as a feedstock.
the user is permitted to obtain a refund of the tax from
the IRS.
Export
frnm
The bill provides five full or partial exemptions from the
tax, as follows:
• Chemicals produced from recycling.
• Chemicals used as feedstocks.
• Exports.
• Halons.
• Chemicals used in the manufacture of rigid foam insula-
tion.
These exemptions apply in all instances where the tax ap-
plies (Le., the regular tax on sale or use, the tax on imported
products, and the floor stocks tax). The exemptions are ex-
plained below. Note that no exemption exists for sales of
chemicals to a federal, state, or local governmental agency.
Recycling exemption
The bill fully and permanently exempts from the tax
chemicals diverted or recovered in the United States as
pan of a recycling process. In effect, this exemption
simply treats a recycling operation as not production or
manufacture of ozone-depleting chemicals for purposes
of the tax.
Chemicals recovered by the original producer of the
chemicals from loading operations, tank truck heels, and
similar sources probably do not qualify for the recycling
exemption (assuming such chemicals had not previously
been taxed). Such chemicals probably would be treated
as normal taxable chemicals when sold by-the producer
thereof.
Feedstock Exemndon
The bill also fully and permanently exempts from the tax
any ozone-depleting chemical used and entirely con-
sumed in the manufacture or production of any other
chemical.
The bill implements the feedstock exemption by permit-
ting sales of chemicals for feedstock use to be made tax-
free. The exemption applies both on direct sales from
The bill provides producers of ozone-depleting chemi-
cals with a partial exemption for exports. The exemp-
tion consists of a base portion and an additional portion.
The base portion of the export exemption is the percent-
age of the producer's yearly production equal to the per-
centage of production the producer exported in 1986.
The percentage calculation of the base portion is made
using ozone-depletion factor adjusted pounds, as fol-
lows:
Percentage Allowed =
1986 Ozone-depletion factor adjusted pounds exportt
1986 Ozone-depletion factor adjusted pounds produce
Ozone-depletion factor adjusted pounds (ODFAPs) are
calculated by multiplying the number of pounds of each
chemical (pounds exported if calculating the numerator.
pounds produced if calculating the denominator) by the
chemical's ozone-depletion factor. The ODFAPs for
each of the eight chemicals are then added together to
determine the total ozone-depletion factor adjusted
pounds.
The bill provides that the determination of the level of
exports of each producer for 1986 is to be determined
based on data published by the EPA.
The second part of the export exemption relates to
production increases destined for export Under the
Montreal Protocol and implementing rules, the EPA is
authorized to grant additional production allowances to
U.S. producers for the explicit purpose of export Those
exports are exempt from the tax.
The bill indicates in a cross reference that producers of
ozone-depleting chemicals have the discretion to transfer
pan of their export exemptions to third parties.
Ozone-depleting chemicals used as a material in the
manufacture of products that are exported are not ex-
empt from tax under the bill.
Halnn
Halons receive favorable treatment through 1993. After
1993, they are treated the same as all other ozone-deplet-
ing chemicals. The treatment for 1990-1993 is as fol-
lows:
-------
1990: All sales and uses of halons are exempt from
tax. The term "ozone-depleung chemical" does not
include halon-1211, halon-1301 or halon-2402 for
the year 1990.
1991 -93: Taxed at a rate of 25 cents per pound,
without adjustment for ozone-depletion factor.
(Note: the bill actually expresses this preferential rate
in terms of varying percentages of each year's
regular tax rate, rather than as a 25-cent-per-pound
rate.)
Rlirid Foam IninlaHnn Exemption
Chemicals used or sold for use in the manufacture of
rigid faun insulation receive preferential treatment
through 1993.
Procedi rally, this preferential treatment is structured in
precise! / the same manner as the feedstock exemption.
so that producers are permitted to sell chemicals at the
preferential rate for use in making rigid foam insulation.
Such sales can be made both to direct users and to
wholesalers and distributors who intend to resell to rigid
foam makers. As in the feedstock exemption, the IRS
will ifnnn
-------
lOlfT CONO
lit Sntion
HOUSE OF REPRESENTATIVES
REPORT
101-386
OMNIBUS BUDGET RECONCILIATION ACT
OF 1989
CONFERENCE REPORT
TO ACCOMPANY
H.R. 3299
NOVEMBER 21. 1989.—Ordered to b« printed
0«c«mbtrl989
-------
"Subchapter D—Ozone-Depleting Chemicals. Etc.
"Set:. $681. Imposition of lax.
"Sec. 168J. Dtfinitiora and specie/ ni/«s.
-SEC. tan I. IMPOSITION OF TAX.
"ia) GESERAL RULE.—There is hereby imposed a tax on—
"(1> any ozone-depleting chemical sold or used by the manu-
facturer, producer, or importer thereof, and
"tl) any imported taxable product sold or used by the import-
er thereof.
"fbJ AMOWT OF TAX.—
"in OZONE-DEPLETING CHEMICALS.—
"IA) IN GENERAL.—The amount of the tax imposed by
subsection (a) on each pound of ozone-depleting chemical
shall be an amount equal to—
"(i) the base tax amount, multiplied by
"(iiJ the ozone-depletion factor for such chemical.
"(B) BASE TAX AMOUNT FOR YEARS BEFORE 1995.—The
base tax amount for purposes of subparagraph (A) with re-
spect to any sale or use during a calendar year before 1995
is the amount determined under the following table for
such calendar year
"Caltitdar ynr Bait tax amount
1990 or 1991 SI.JT
199X 1.67
199J or 1994 165.
"(C) BASE TAX AMOUNT FOR YEARS AFTER last.—The base
tax amount for purposes of subparagraph (A) with respect
to any sale or use during a calendar year after 1994 shall
be the base tax amount for 1994 increased by 45 cents for
each year after 1994.
"(2) IMPORTED TAXABLE PRODUCT.—
"(A) IN GENERAL.—The amount of the tax imposed by
subsection (a) on any imported taxable product shall be the
amount of tax which would have been imposed by subsec-
tion (a) on the ozone-depleting chemicals used as materials
in the manufacture or production of such product if such
ozone-depleting chemicals had been sold in the United
States on the date of the sale of such imported taxable
product.
"(B) CERTAIN RULES TO APPLY.—Rules similar to the
rules of paragraphs (2) and (3) of section 4671(b) shall
apply.
"SEC. 4t8t. DEFINITIONS AND SPECIAL RULES.
"(a) OZONE-DEPLETING CHEMICAL.—For purposes of this subchap-
ter—
"(1) IN GENERAL.—The term 'ozone-depleting chemical' means
any substance—
"(A) which, at the time of the sale or use by the manufac-
turer, producer, or importer, is listed as an ozone-depleting
chemical in the table contained in paragraph (2), and
"(B) which is manufactured or produced in the United
States or entered into the United States for consumption,
use, or warehousing.
"(2) OZONE-DEPLETING CHEMICALS.—
"Common name- Chtmieal nomtnelaturt:
CFC-11 tnchlorofluoromttHant
CFC-12 dichtondifluoromettiane
CFC-113 trichlorotnfluorotlHant
CFC-1U IJJickloro-lJ.lJ-tttm-fluorottHane.
CFC-11S chlorvptntafluoroetHant
Halon-1111 bromocHlondifluoromttfiane.
Halon-MOl bromotnfluoromitHant
Page 7 December 1989
-------
"Common name: Chtmicai nomenctaturt:
Haton-.'AO'.' dibromotetrafluorottHane.
"ibi OZONE-DEPLETION FACTOR.—For purposes of this subchapter,
the term 'ozone-depletion factor' means, with respect to an ozone-de-
pleting chemical, the factor assigned to such chemical under the fol-
lowing table:
"Oton»-
-------
then an amount equal to the tax so paid shall be allou-ed
as a credit or refund /without interests to such person in the
same manner as if it were an overpayment of tax imposed
by section 4681.
"fj) EXPORTS.—
"IA) I\ GENERAL.—Except as provided in subparagraph
(B>. rules similar to the rules of section 4662
-------
"fiii on the sale during 1990 by the manufacturer.
producer, or importer of any substance—
"(I) for use by the purchaser in the manufacture
of rigid foam insulation, or
"(ID for resale by the purchaser to a second pur-
chaser for such use by the second purchaser, or
"fui} on the sale or use during 1990 by the importer
of any rigid foam insulation.
Clause shall apply only if the manufacturer, producer, and
importer, and the 1st and 2d purchasers (if any) meet such reg-
istration requirements as may be prescribed by the Secretary.
"(2) TREATMENT FOR 1991, 1992, AND 1993.—
"(A) HALONS.—The tax imposed by section 4681 during
1991. 1992, or 1993 by reason of the treatment of halon-
1211, halon-1301, and halon-2402 as ozone-depleting chemi-
cals shall be the applicable percentage (determined under
the following table) of the amount of such tax which would
(but for this subparagraph) be imposed.
Tht opplttabtt ptntntagt a.
•In Ou out of- For tain For nia For sain
in w* ca** or- orutt or at or at
during during during
l$il 1W 133J
Halm-lilt SO J.O JJ
Halan-lJOl l.» li 10
Haton-UOi JO -'••> l.f-
"(B) CHEMICALS USED IN RIGID FOAM INSULATION.—In the
case of a sale or use during 1991, 1992, or 1993 on which no
tax would have been imposed by reason of paragraph (1XB)
had such sale or use occurred during 1990, the tax imposed
by section 4681 shall be the applicable percentage (deter-
mined in accordance with the following table) of the
amount of such tax which would (but for this subpara-
, . ffmnht ft* rmnn«**V
"In the ewj* of Tht applicable
tale* or u<« during: ptirtntaat it:
1991 m
193J ij
19SJ 10.
"(3) OVERPAYMENTS WITH RESPECT TO CHEMICALS USED IN
RIGID FOAM INSULATION.—[f any substance on which tax was
paid undr-r this subchapter is used during 1990, 1991, 1992, or
1993 by any person in the manufacture of rigid foam insulation.
credit or refund (without interest) shall oe allowed to such
person an amount equal to the excess of—
"(A) the tax paid under this subchapter on such sub-
stance, over
"(B) the tax (if any) which would be imposed by section
4681 if such substance were used for such use by the manu-
facturer, producer, or importer thereof on the date of its use
by such person.
"Amounts payable under the preceding sentence with respect to
uses during the taxable year snail be treated as described in sec-
tion 34(a) for such year unless claim therefor has been timely
filed under this paragraph.
"(n) IMPOSITION OF FLOOR STOCKS TAXSS.—
"(1) JANUARY i, 1990, TAX.—On any ozone-depleting chemical
which on January 1, 1990, is held by any person (other than the
manufacturer, producer, or importer thereof) for sale or for use
in further manufacture, there is hereby imposed a floor stocks
tax in an amount equal to the tax which would be imposed by
section 4681 on such chemical if the sale of such chemical by
the manufacturer, producer, or importer thereof had occurred
during 1990.
Pagtio
-------
"t2> OTHER TAX-INCREASE DATES.—
"(A) IN GENERAL.—If, on any tax-increase date, any
ozone-depleting chemical is held 'by any person father than
the manufacturer, producer, or importer thereof) for sale or
for use in further manufacture, there is hereby imposed a
floor stocks tax.
"(B) AMOUNT OF TAX.—The amount of the tax imposed by
subparagraph (A) shall be the excess (if any) of—
"(ij the tax which would be imposed under section
4681 on such substance if the sale of such chemical by
the manufacturer, producer, or importer thereof had oc-
curred on the tax-increase date, over
"(ii) the orior tax (if any} impoted by this subchapter
on such substance.
"(C) TAX-INCREASE DATE.—For purposes of this para-
graph, the term 'tax-increase date' means January 1 of
1991, 1992, 1993, and 1994.
"(3) Dux DATE.—The taxes imposed by this subsection on Jan-
uary 1 of any calendar year shall be paid on or before April 1 of
such year.
"(4) APPLICATION OF OTHER LAWS.—All other provisions of
law, including penalties, applicable with respect to the taxes
imposed by section 4681 shall apply to the floor stocks taxes im-
posed by this subsection."
(b) CLERICAL AMENDMENT.—The table of subchapters for chapter
38 is amended by adding at the end thereof the following new item:
"SUBCHAPTER D. Ozone-depleting chemicals, etc."
(c> EFFECTIVE DATE.—
(1) IN GENERAL.—The amendments made by this section shall
take effect on January 1, 1990.
(2) NO DEPOSITS REQUIRED BEFORE APRIL 1. 1990.—No deposit
of any tax imposed by subchapter D of chapter 38 of the Inter-
nal Revenue Code of 1986, as added by this section, shall be re-
quired to be made before April 1, 1990.
(3) NOTIFICATION OF CHANCES IN INTERNATIONAL AGREE-
MENTS.—The Secretary of the Treasury or his delegate shall
notify the Committee on Ways and Means of the House of Rep-
resentatives and the Committee on.Finance of the Senate of
changes in the Montreal Protocol and of other international
agreements to which the United States is a signatory relating to
ozone-depleting chemicals.
• * *
Coherence report language follows
Page 11 December 1989
-------
4. Excise Tax/Fee on Ozone-Depleting Chemicals
Present law
The use or manufacture of chemicals which deplete the earth's
ozone layer is not subject to specific Federal taxes or fees.
House bill
In general
The House bill assesses an excise tax on the sale or use by a pro-
ducer, manufacturer, or importer of certain ozone-depleting chemi-
cals. The amount of tax is determined by multiplying a base tax
amount by an "ozone-depleting factor."
Chemicals subject to tax
The specific chemicals subject to tax are CFC-11, CFC-12, CFC-
113, CFC-114, CFC-115, Halon-1201, Halon-1301, and Halon-2402.
Base tax amount
For calendar yean 1990 and 1991, the base tax amount is $1.10
per pound of ozone-depleting chemical; for 1992 the base tax
amount is $1.60 per pound; for for 1993 and beyond, the base tax
amount is $3.10 per pound. The base tax amount is indexed for in-
flation occurring after 1989.
Ozone-depleting factors
The ozone-depleting factors for the chemicals subject to tax are
those specified in the Montreal protocol.
Exemption* and reduced rates of tax
The House bill provides exemptions for feedstock chemicals, recy-
cled chemicals, and chemicals exported subject to Environmental
Protection Agency regulations.
The House bill also exempt! from tax in 1990 CFCa used in the
production of rigid foam insulation and all halons.
The House bill provides for a reduced rate of tax in 1991 through
1993 for CFCs used in the production of rigid foam insulation and
all halons.
Imports
The House bill applies the tax to any ozone-depleting chemical
which is imported into the United States and to any product or
substance imported into the United States in which a taxable
ozone-depleting chemical was used in the manufacture or produc-
tion.
Effective date
The House bill is effective for ozone-depleting chemicals sold or
used after December 31, 1989. In addition, a floor stocks tax is im-
posed on ozone-depleting chemicals held by a person other than the
manufacturer or importer on January 1, 1990. A floor stocks tax is
also imposed on each subsequent change in the tax rate for any
taxable chemical. The initial deposits of taxes due need not be
made until April 1, 1990.
Senate amendment
In general
The Senate amendment contains two provisions pertaining to the
taxation of ozone-depleting chemicals: one reported by the Commit-
tee on Finance and the other reported by the Committee on the
Environment and Public Works.
The Finance Committee provision is generally the same as the
House bill.
The Environment and Public Works Committee provision im-
poses a fee on the production, importation or distribution of ozone-
depleting chemicals. The fee does not depend upon the ozone-de-
pleting factor of the chemical. The fee is generally related to prof-
its earned on the production of such chemicals.
D«x»mt»ri989 Page 12
-------
Chemicals subject to tax
The Finance Committee provision is identical to the House bill.
The Environment and Public Works Committee provision is the
3? a the House bill. In addition, the Environment and Public
Wc-te. provision permits the Administrator of the Environmental
Protection Agency to add chemicals to the list of chemicals subject
to the fee.
Base tax amount
The Finance Committee provision imposes a base tax amount
which is similar to the House bill. For calendar year 1990, the base
tax amount is $1.07 per pound of ozone-depleting chemical; for
1991, the base tax amount is $1.12 per pound; for 1993, the base tax
amount is $1.67 per pound; for 1994 and beyond, the base tax
amount is $3.15. The base tax amount is not indexed for inflation.
The Environment and Public Works Committee provision im-
poses a fee. The fee is the greater of 60 cents per pound of taxed
chemical or an amount equal to the profit earned on the sale of the
chemical to the extent such profits exceed the profits earned on the
side of such chemical in 1987. The Administrator of the EPA deter-
mines the excess profit amount by comparing total revenues gener-
ated from the sale of taxed chemicals to an allowance for revenues
generated from like sales in 1987. An offset for Federal and State
income tax liability is permitted. Distributors of taxed chemicals
are granted an additional exemption of 60 cents per pound from
the excess profits tax.
Ozone-depleting factors
The Finance Committee provision is identical to the House bill.
The Environmental and Public Works Committee provision does
not provide for an ozone-depleting factor.
Exemptions and reduced rates of tax
The Finance Committee provision is identical to the House bill.
The Environment and Public Works Committee provision is the
same as the House bill with respect to exports and feedstock chemi-
cals.
Imports
The Finance Committee provision is identical to the House bill.
The Environment and Public Works Committee provision im-
poses the fee on importation of taxed chemicals, but not on deriva-
tive products.
Tnat fund
The Finance Committee provision does not establish a trust fund.
The Environment and Public Works Committee provision estab-
lishes within the Treasury an "Ozone Layer and Climate Protec-
tion Trust Fund." Fees collected are to be deposited in the trust
fund. The proceeds of the fund are to be invested in interest-bear-
ing obligations of the United States. Trust fund expenditure pur-
poses include implementation of the Montreal protocol, research
and development activities of the EPA, and to carry out the abate-
ment and control activities of the EPA.
Effective date
The Finance Committee provision is identical to the House bill.
The Environmental and Public Works Committee provision is ef-
fective July 1, 1989, for chlorofluorocarbons, and is effective Janu-
ary 1, 1992, for halons. The Administrator of the EPA may, by reg-
ulation, change the effective dates.
Paga 13 December 1989
-------
-------
\ttachment 7
"WASHINGTON REPORT" FEBRUARY 1990
UNEP Formulates CFC Options
The U.S. Environmental Protection Agency (EPA), in a briefing held in
Washington for the Agency's Stratospheric Ozone Protection Advisory
Committee, reviewed the proposed amendments to the Montreal Protocol
considered recently at the United Nations Environment Program (UNEP)
meeting in Geneva.
The purpose of the UNEP meeting was to discuss various options developed
by participating nations for additional restrictions on fully halogenated
chlorofluorocarbons (CFCs) and other ozone-depleting chemicals.
Participants attempted to refine and consolidate, where possible, existing
choices for review. A final round of negotiations will be held in London
before approval by signatory nations in June.
Currently, the UNEP Montreal Protocol, which took effect in July and with
which the United States is in full compliance places reductions on CFCs
11, 12, 113, 114 and 115 according to the following time table:
July 1989 - Cutback to 1986 production levels
July 1993 - Reduction to 80 percent of 1986 production
July 1998 - Reduction to 50 percent of 1986 production.
Halons 1211, 1301 and 2402 are to be frozen at 1986 production levels in
1992.
The Montreal Protocol also addresses other non-technical items including
special provisions related to international trade, production allotments
and special situations of the developing nations.
Additional CFC restrictions
Eileen Claussen, EPA's director of atmospheric programs, reported that a
broad consensus exists among the Geneva participants for a complete
phaseout of fully halogenated CFCs by the year 2000. Claussen emphasized
President Bush's earlier statement that the U.S. position for a phaseout
would depend on the availability of environmentally acceptable
alternatives based on the continuing reassessment of technology.
Various proposals were put forth by representatives of the attending
nations in Geneva related to additional interim restrictions on the
currently targeted CFCs with an understanding of a phaseout in the year
2000.
-------
The UNEP parties which attended the earlier meeting in Nairobi and Cana
proposed:
1994 or 1995: Reduction to 50 percent of 1986 production
1998: Reduction to 15 percent of 1986 production.
The European Community proposed:
1991 or 1992: Reduction to 50 percent of 1986 production
1995 or 1996: Reduction to 15 percent of 1986 production.
EPA reported that the Nordic nations with Austria, Switzerland, Austral
and New Zealand proposed:
1993: Reduction to 50 percent of 1986 production
1996: Reduction to 15 percent of 1986 production.
Japan did not support any interim reductions.
EPA indicated that the U.S. position on any interim adjustments on the
reduction schedule in effect will be made in Spring 1990 as more
technology assessment information becomes available.
Possible HCFC restrictions
Although HCFCs have relatively low ozone depletion factors, world conce
over controlling additional chlorine buildup in the upper atmosphere ha
drawn attention to even the smaller contributors to the issue. HCFC 22
has a depletion factor of 0.05 (as compared to a depletion factor for C
11 or 12 of 1.0), and the new potential alternative for CFC 11 is HCFC
which has an estimated depletion factor of 0.02. Three proposals were
placed on the table at the Geneva meeting.
As reported by EPA, the United States proposed a phaseout in new eguipn
by the year 2020 or up to 2040 and in existing equipment by the year 2(
or up to 2060. The Nordic nations proposed a phaseout by the year 201(
2020 except in essential uses (which they defined as foams, refrigerat:
and medical applications); it was unclear whether "refrigeration" incl\
air conditioning. The European Community proposed the reporting of dai
on HCFC production (outside of any Protocol provisions).
As possible restrictions on HCFCs are addressed in future UNEP negotia'
sessions, potential protocol actions may be tied to the specific ozone
depletion factor of the particular HCFCs in question. For example,
restrictions may be applied only to HCFCs whose depletion factors are
greater than 0.02.
-2-
-------
Halons
Also of interest to the ASHRAE community are halons, which have very large
depletion factors (up to 10.0). Several proposals for additional
restrictions on the targeted halons were presented. The U.S. position at
this time on halons is a phaseout by the year 2000 provided safe
substitutes are available (the phaseout may be possible by 1995 or 1996);
the U.S. supports no interim steps.
Canada proposed a complete phaseout (essential uses exempted) in the year
2000 with no interim reductions. The European Community proposal was
comprised of a 50 percent reduction from 1986 production levels in 1995 or
1996 with a phaseout in the year 2005. Japan proposed a 50 percent
cutback in the period of 1995 to 1997 with a phase out as soon as feasible
except for exemptions. The U.S.S.R proposed a 10 to 50 percent reduction
by the year 2000 with exemptions for essential uses (to be established by
each nation); EPA indicated that in order to be acceptable, exemptions
would have to be coupled to a particular list of applications.
Other chemicals
It is probable that other chemicals will be added to the Montreal
Protocol. Proposals (similar to those proposed for CFCs) were put forward
to include carbon tetrachloride and methyl chloroform. The United States,
along with the Soviet Union and Japan, proposed a freeze on carbon
tetrachloride (with feed stocks exempted) tied with a phaseout schedule
identical to that adopted for CFCs. The U.S. position on methyl
chloroform was a 25 to 100 percent cutback in production by the year 2000.
The base year for these chemicals will have to be determined.
U.S. Negotiating Strategy
Adjustments to the restrictions of targeted chemicals listed in the
Montreal Protocol requires a two-thirds approval of signatory nations
(representing at least two-thirds of the parties' production) and would be
binding on all parties to the Protocol. The addition of new targeted
chemicals (carbon tetrachloride, methyl chloroform and/or HCFCs) requires
an amendment process with a simple two thirds vote of parties in
attendance and voting.
The U.S. strategy is to package all provisions for newly added chemicals
into a single amendment. When adopted by the international body, an
amendment (which can address the addition of new chemicals or any other
topic) is subject to ratification by the individual countries. By putting
all provisions related to new chemicals into a. single comprehensive
amendment, the international body may be able to avoid numerous small
individual amendments - each of which could be applicable to different
nations. Claussen indicated that "It will be a very tough negotiation
process to achieve a packaged amendment."
-3-
-------
Series of Meetings Scheduled
The final decisions will take place when the full diplomatic conference
held June 20-29. However, there will be numerous meetings in the inter:
to- ''slim-down" the number of proposals to an acceptable number from whic
a compromise hopefully can be attained in June.
The UNEP process involves factors other than the technical considera-
tions. In working with nations with a wide spectrum of economies and
levels of industrialization, many considerations must be hammered out
particularly as related to developing nations. How will new technology 1
made available to developing nations? Should additional trade
considerations be implemented? Should funds be provided to assist
developing nations?
EPA Lead Agency
The EPA serves as the lead agency on formulating the United States
negotiating position. To support the meetings at the international lev*
the-Agency will continue with its assessments and analysis. The Advisor
Committee is an integral part of the process.
The EPA Advisory Committee was established in the Fall 1989 to provide t
Agency with "informed advice on policy and technical issues that relate
domestic and international aspects on the Montreal Protocol on Substance
that Deplete the Ozone Layer." The makeup of the 25-member advisory boc
is drawn from business and industry, educational and research
institutions, government bodies, non government and environmental group!
and international organizations.
-4-
-------
THE DESTRUCTION OF
HALONS IN THE NORDIC
COUNTRIES
Jan Bergstrom, Raine Harju och Eva Hyden
Environmental Consultants
(Miljokonsulterna
i Studsvik AB)
S-611 82 NYKfiPING
-------
SUMMARY
On behalf of the Nordic Council of Ministers' steering
committee for the halon project, Environmental Consultants at
Studsvik has studied the conditions for halon destruction in
the Nordic countries. This report investigates collection of
halons and the methods for the destruction of the halon bank
which can be put into operation within the next five years.
The halon bank is estimated at 3 000 tonnes. More than 80 %
of the halon bank consists of H 1301, i.e bromotrifluoromethane.
If the governments decide that halons must be actively
collected, this can be achieved without any technical diffi-
culties. For this to succeed, it must be possible to reach
the end-users of halogenated fire extinguishers with informa-
tion stating clearly that the fire-extinguishers must be
replaced by sending all stored halon to a specific collection
point. Collected halons can be stored pending destruction.
The cost of transporting and storing halons is insignificant
compared with the cost of destruction.
If the governments decide to initiate halon destruction in
the Nordic countries within the next five years, this would
clearly indicate the desire to set an example and a precedent.
The choice of the method of destruction would be based on
what is least hazardous to the environment. Therefore, the
cost of the destruction technique would not be the deciding
factor.
This report describes four techniques which can be put into
operation within a few years. In Denmark and Finland, halons
can be incinerated together with hazardous waste. It is
probably not possible to adopt a similar incineration
technique in Sweden since the amount of halogens which may be
supplied to the incinerator is restricted.
-------
It is our conclusion that the destruction of halons by
incineration together with combustible hazardous waste should
be avoided. Destruction techniques where aromatic compounds
occur should similarly be avoided. With such techniques, the
formation of persistent toxic organic compounds would not be
minimized. It is possible to compensate for this by adopting
more stringent requirements for flue gas cleaning and the
deposition of residual products.
There are two techniques which enable the destruction of
halons to be carried out without the formation of aromatics
such as dioxins arising from chlorine and bromine in the
process. These methods are incineration using fuel not
containing aromatics or destruction in a plasma reactor. In
both cases, the flue gases from the reactor are quenched in a
venturi cooler and the halogenated hydrocarbons are absorbed
in a multi-stage scrubber. The flue gases are then heated and
finally cleaned by a fabric filter. If the plant is sited
together with the hazardous waste incineration plant,
considerable advantages can be gained. The cost of halon
destruction is estimated at between SEK 25 and SEK 44 per
tonne.
If the capacity of the plant is adapted to the destruction of
both halons and CFCs, the destruction costs can be substan-
tially reduced without any major disadvantages.
-------
TABLE OF CONTENT
Introduction 1
1.1 Background 1
1.2 The project 3
Halons 4
2.1 General 4
2.2 The halon bank in the Nordic
countries 4
2.3 Physical properties 5
Handling before destruction 7
3.1 Management of the halon bank 7
3.2 Collection and storage 8
Principles of halon destruction 10
4.1 Halons as fire extinguishants 10
4.2 Destruction of halons 10
4.3 Combustion 12
4.3.1 Catalytic destruction 13
4.4 Molten iron 14
4.5 Plasma decomposition 14
4.6 Reduction 15
4.7 Supercritical water 16
Techniques 17
Existing plants 19
New plants 21
7.1 Capacity 21
7.2 Environmental requirements 22
7.3 Incineration 23
7.3.1 Design 25
7.3.2 Construction work 27
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Page
7.4 Molten iron 28
7.4.1 Tests performed 29
7.4.2 P-C1G for halon destruction 30
7.4.3 Pilot plant modification 32
7.5 Plasma technology 33
7.5.1 Design 33
8 Economic evaluation 36
8.1 Investment costs 36
8.2 Capital costs 37
8.3 Operating costs 38
8.4 Summary 39
9 Environmental impact 41
9 .1 Emissions to the air 42
9 .2 Emissions to water 44
9.3 Residual products 45
10 Conclusions 46
References 48
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1 Introduction
1.1 Background
Brominated fluorocarbons (halons) and chlorofluorocarbons
(CFCs) are the collective terms for a number of different
substances which contain chlorine, fluorine and bromine. The
basic substance is a hydrocarbon in which the hydrogen atoms
have been replaced. If halons and CFCs are released into the
atmosphere, they will partially decompose due to ultra-violet
radiation. The part of the substance that is transported to
the stratosphere is a significant contributing factor to the
depletion of the ozone layer.
An international agreement was reached under the auspices of
the United Nations in 1987, known as the Montreal Protocol,
concerning the successive reduction of the usage of halons
and CFCs. According to the agreement, the production and
consumption of halons shall be restricted to the 1986 level.
In the mid-eighties, the world production of CFCs amounted to
about 1 million tonnes per year.'The production of halons is
estimated at approximately 20 thousand tonnes per year.
Recent research has shown that despite the fact that the
amount of halons is insignificant, halons are a significant
contributor to the depletion of the ozone layer. Table 1
shows the estimated lifetime of the most common halons and
CFC compounds in the atmosphere and their ozone depleting
potential.
-------
Table 1
Ozone depleting potential of halona end crc«
Name
TrichloroJluorome thane
Dichlorodlfluorooe thane
Trichlorotrif luo roe thane
Dlchlorotetraf luo roe thane
Pentachlorofluoroe thane
Bromochlorordlf luoro-
me thane
Broaotrif luo rooe thane
Oibromotetraf luo rone thane
Carbon tetrachlorlde
Designation
CFC 11
CFC 12
CFC 113
CFC 114
CFC 115
H 1211
H 1301
H 2402
ccl
4
Chealcal for-
aula
ccl F
3
CC1 F
2 2
C Cl F
233
car
224
C C1F
2 5
CF ClBr
2
CF Br
3
CF BrCF Br
2 2
ccl
4
Lifeline In
ataocphere
year
58
96
103
247
548
18
72
23
51
Ozone dep-
leting
potential
0.9
0.9
0.8
0.4
4
10
7
1.2
In the comparison provided in the table, the amounts are the
same for each substance. The ozone depleting potential of CFC
11 is used as a basis. The negative effect of the halons on
the ozone layer is 4 to 10 times greater than that of the
CFCs.
The halons are mainly used as fire extinguishants. Their fire
fighting properties are exceptional. One major advantage is
that human beings can usually be present in areas where they
are being used.
The quantity of banked halon is at present many times greater
than the annual consumption. There are very important reasons
why this bank should not be released to the atmosphere.
Halon can be replaced as a fire extinguishant in most fire
fighting equipment. The main area of technical difficulty is
dealing with areas where personnel must be present when the
fire extinguishant has been released. An example of such
areas is control rooms in nuclear power plants, aeroplanes
and air traffic control centers.
-------
1.2 The project
In June 1989, Environmental Consultants at Studsvik was given
the task of evaluating the possibilities of halon destruction
in the Nordic countries by the steering committee for the
halon project of the Nordic Council of Ministers. The report
was to be presented no later than on November 15, 1989.
The objective of the study is to identify the technical and
economic conditions necessary for the environmentally safe
destruction of halons.
The report provides information on three main areas:
techniques for halon destruction.
evaluation of suitable siting for a destruction
plant.
general outline of the collection and storage of
halons.
-------
Halons
2.1
General
One of the oldest halon fire extinguishants is carbon tetra-
chloride, CC1.. If combustion of CC1. is incomplete, the very
toxic phosgene (COCl-) is formed. For this reason, carbon
tetrachloride is no longer used as a fire extinguishant.
A large number of halons has been developed for use as fire
extinguishants. Table 2 shows the most common.
Table 2
Halons
Name
Bromotrifluoromethane
Bromochlorodifluoro-
methane
Dibromodifluoromethane
Dibromotetrafluoro-
methane
Methyl bromide
Chlorobromomethane
Dibromotrifluoro-
methane
Halon
number
1301
1211
1202
2402
1001
1011
2302
Chemical
formula Car- Fluor-Chlor- Brorr.
bon
CF3Br 1
CF2ClBr 1
CF2Br2 1
CF2BrCF2Br 2
CHgBr 1
CH2ClBr 1
C2HF3Br2 2
ine
3
2
2
4
0
0
3
ine
0
1
0
0
0
1
0
ine
1
1
2
2
1
1
2
Today, halon 1301 and 1211 are mainly used. The halons 1011,
1202 and 2402 are also used to a lesser extent.
2.2
The halon bank in the Nordic countries
Halon is not produced in the Nordic countries. The halon bank
has developed through the importation of halons from other
countries. No exact data is available, but an estimate of the
-------
volume of the halon bank in the Nordic countries, carried out
by BTI (Brandtekniska ingenjorsbyran) is presented in Table
3, ref (1).
Table 3
Total banked halon
Denmark
Finland
Norway
Sweden
Total
Halon
600 -
350
600 -
930 -
2400 -
in the Nordic countries (tonnes)
1301
1000
1000
1430
3780
Halon 1211
80 - 100
330
60 - 100
70
540 - 600
Halon
10
-
3-5
-
13 -
2402
15
The halon bank includes both hand-held fire extinguishers and
permanent installations.
2.3 Physical properties
The physical properties of halons used are shown in Table 4.
Table 4
Physical properties
Chemical composition
Molecular weight
Boiling point (1 atm)
Density 20°C, fluid
Vapour press, at 20°C
Vapour press, at 70°C
Critical temperature
Critical pressure
°C
kg /dm3
bar
bar
°C
bar
Halon
3101
CF3Br
149
-58
1.6
14
42
67
41
Halon
1211
CF2ClBr
165
-4
1.8
2.5
9.0
154
42
Halon
2402
CF2BrCF2Br
260
+48
2.2
0.35
2.0
215
35
. I
-------
The table shows that halon 1211 has a higher boiling point
than 1301. Therefore it does not vaporize as rapidly and is
more suitable for use in hand-held fire extinguishers where
an extinguishant with a good stream range is desirable.
-------
3 Handling before destruction
3.1 Management of the halonbank
Halons are imported to the Nordic countries in large tanks.
These tanks are designed to withstand a pressure of 42 bars,
which is halon 1301's vapour pressure at 70°C.
The halons are taken from the tank and pressure vessels of a
suitable size are filled. The pressure vessel must meet the
stringent pressure vessel standards as regards material,
manufacturing and control.
For permanent installations, the discharge time of the
extinguishant should not exceed 10 seconds. In order to
guarantee this, the vessels are usually pressurized up to 25
or 42 bars. The pressure is selected depending on the time
required to empty the vessel. The propellant gas is nitrogen,
N~. Nitrogen is also used as the propellant in hand-held fire
extinguishers, where the pressure is usually 14 bars.
Halons are also stored in pressure vessels by the users of
the fire extinguishers. Halon containers with a weight of a
few kilograms up to to a maximum of 250 kg are kept at
permanent installations. The halon content of hand-held
extinguishers varies from about 1 to 10 kg.
The volume of the halon bank has not been exactly determined.
It is even more difficult to obtain precise information on
the number of halon containers in existence. In order to
arrive at some estimate, it can be mentioned that 4 730
hand-held fire extinguishers were sold in Finland in 1986.
The amount of halon 1211 contained in these extinguishers was
about 21 tonnes. Thus, each extinguisher contained on average
4 to 5 kg of halons. In Finland, halon 1211 is only used in
hand-held extinguishers. The bank of 1211 is estimated at 330
-------
tonnes. The number of hand-held fire extinguishers is thus
. i
estimated at between 60 000 and 75 000.
' i
When some of the major distributors of halons were contacted,
,1 it was found that they should be able to reach more than 90 %
of the end-users of halon through their customer registers.
Halon containers are required to undergo hydrostatic testing
: every fifth or tenth year. The testing is largely carried out
*' by the distributors. The hydrostatic testing requirement
< provides a natural opportunity for contact between the
,1 suppliers and end-users.
During hydrostatic testing, the halon containers are emptied.
There are established procedures for this. The extent of the
losses which occur in connection with the emptying of the
containers has so far been determined by the cost of halons,
, , not taking into account environmental considerations.
3.2 Collection and storage
: i
' If the governments decide that halons shall be actively
• collected and stored, this can be achieved without technical
. i difficulty.
For this to succeed, it must be possible to reach the end-
users of halogenated fire extinguishers with information
! stating clearly that the fire-extinguishers must be replaced,
1 which entails sending all stored halon to a specific collec-
tion point. The users must be sufficiently motivated to avoid
discharging the halons, otherwise there is a risk that too
many individual users will consider that discharging the
small quantities of halons that they have is insignificant.
The premises of halon distributors can function as collection
' points. The distributors must naturally be bound by contract
to provide this facility, and a fee for receiving and storing
the halons must be determined.
-------
The storage of halon containers requires storage space, but
in general, no other major difficulties are associated with
this task.
The only consequence of storing the halon bank for a long
period of time, is the cost of the buildings used for
storage, since it is anticipated that most of the containers
will not be put to alternative use. In any case, because of
the pressure vessel classification of the containers, they
cannot be used for CO- fire extinguishants.
The schedule for the collection of halogenated fire
extinguishants is mainly determined by the possibility of
obtaining a replacement for halons which conforms with the
safety requirements for fire extinguishing agents. This is
also the determining factor for estimating the volume of
storage space which must be set aside in each country or
region.
We estimate the annual cost for facilities for the storage of
2
halons to be SEK 150/m . With certain arrangements, it should
be possible to store halons in such storage facilities at an
annual cost of SEK 400/tonne.
A general estimate of the cost of transporting the collected
halons to the destruction facility cannot be made. However,
it is clear that the transportation and storage costs for
halons are negligible compared to the cost of halon destruc-
tion.
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10
4 Principles of halon destruction
4.1 Halons as fire extinguishants
The fire suppression capability of halons is mainly due to
the fact that halogen radicals are released at a relatively
low temperature, 400 - 500°C. Expressed in simple terms,
bromine steals the OH radical which is important for
combustion. Water is formed and bromine is again released as
a radical. The chain reaction continues and interferes with
combustion. If enough halons are used at the initial stages,
the fir(e will be extinguished. On the other hand, if a
moderate amount of halons is used on a blaze, this will only
result in the production of corrosive smoke.
The process is described in the following model. * is used to
indicate the radicals. Combustion occurs as follows:
2(H* + 0* - OH*) —~ 20H* —•• 0* + H20 + heat (1)
Halons interfere with the reaction as follows:
Heat + CF3Br — » CF3* + Br*
Br* + H* — •• HBr
HBr + OH* —* Br* + H20 (2)
With halogen in the combustion gas (2) water (H-0) is formed
by the hydroxyl radical. Without halogen, the hydroxyl
radical yields H_0 + heat and combustion continues.
4.2 Destruction of halons
Halon molecules can be decomposed by chemical processes or by
thermal processes, in principle, combustion. During combustion,
reaction (1) must be dominant. Enough energy must be supplied
-------
11
at the same time that an excess of hydrogen and oxygen is
maintained.
A summary of the binding energies of the halons in use today
is provided in Table 5. A comparison with methane, dichloro-
methane and carbon tetrachloride is made. The term binding
energy refers to the amount of energy needed to decompose the
molecule into atoms.
The required energy can be supplied in very different ways.
Table 5
Binding energies for substituted methane molecules
Halon
Compared substance
Binding
energy
kj/mol
1301
CF3Br
Br
F - C - F
I
F
1739
Methane (CH4)
H
I
H - C - H
H
1655
1211
Br
i
CF0ClBr F - C - F
£• i
Cl
1593
Dichloromethane (CH-Cl-)
H
Cl - C - Cl 1505
H
Carbon tetrachloride (CC1.)
Cl
Cl - C - Cl 1354
i
Cl
-------
12
4.3
Combustion
During combustion, halons can react with hot gas with enough
excess hydrogen to decompose the halon molecules and to form
halogenated hydrogen and CO-. The combustion process is
always controlled by the three t's, namely: temperature, time
and turbulence. If halons are permitted to remain in hot gas
for a long time and if the mixing is good, the temperature
necessary for decomposition is not particularly high. Figure
1 shows the decomposition of methane, carbon tetrachloride
and dichloromethane as a function of temperature. The
residence time is 2 seconds.
Weight percent wo
remaining
10
01
o methane
Q dichloromethane
x carbon tetrachloride
•00
Temperature ~C
Figure 1
Decompostion of methane, carbon tetrachloride and dichloro-
methane as a function of temperature
The data in Figure 1 were obtained from laboratory experiments,
Ref 2, and therefore cannot be applied to combustion in
actual plants.
Laboratory experiments also carried out with halons confirm
the data shown in Figure 1. The halons were passed through a
-------
13
quartz tube filled with quartz balls. The residence time in
the reactor was two seconds. The destruction is shown in
Figure 2.
100
400 500 600 700 800 900
Temperature *C
Figure 2
Thermal decompostion of halons
There is a sound basis for maintaining that halon destruction
by combustion in an excess of hydrogen is a technically
feasible method.
4.3.1 Catalytic destruction
The temperature during combustion may be reduced by using
suitable catalysts. Catalysts used in laboratory experiments
include platinum/titanium oxide and palladium/active carbon.
These experiments have shown that the fluorohydrocarbons
studied can decompose in a methane or steam atmosphere at
approximately 400 - 500°C. The temperature can probably be
further reduced as a result of testing other suitable
catalysts.
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14
4.4 Molten iron
The energy needed to decompose the molecules can be supplied
by molten metal. The molten metal is a conductor of heat, and
fluorine and bromine which are released can be directly bound
as salts. Molten metal containing sodium and iron has been
tested for this purpose.
MEFOS in Lulea, Sweden has a pressurized coal gasifier which
has also been test operated for chemical waste destruction.
Experiments with halon destruction in molten iron have also
been carried out in a smaller test furnace. The experiments
show that bromine and fluorine are released from the molten
iron in the form of dust-bound iron salts.
4.5 Plasma decompostion
The energy for the destruction of halons can also be supplied
by electricity, e.g in a plasma reactor. The amount of energy
supplied is so great that the molecules turn into plasma.
This plasma is formed in a continuous flow of an inert gas
such as argon or nitrogen, at atmospheric pressure. Plasma is
the physical state where the electrons of the molecules are
free from the nucleus. The physical states of matter are
illustrated in Figure 3.
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15
PLASMA
'/// LIQUID '///_
100
lO'OOO
J Mio.
10- 1000 lOO'OOO
TEMPERATURECK]
Figure 3
The physical states of matter
Laboratory experiments have been carried out by the National
Research Institute for Pollution and Resources (NRIPR), Ref
3, on the destruction of chlorofluorohydrocarbons in a plasma
reactor. These experiments show that a mixture of CC13F and
water in an argon atmosphere is almost fully converted to
CO,, HC1 and HF according to the formula:
CC13F + 2H20 » C02 + 3HC1 + HF
4.6
Reduction
Halogenated hydrocarbons can be converted into hydrocarbon
(carbon) and sodium salts through reduction with sodium
naphthalenide. The reaction occurs when halogenated hydro-
carbons are mixed with sodium naphthalenide in tetrahydro-
furan.
In the interests of safety, it is recommended that the
pulverization of sodium and the mixing of sodium with
napthalene to produce sodium napthalenide should be done on
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16
an industrial scale, skala. Sodium napthalenide must also be
handled very carefully to prevent contact with air or moisture.
The cost of the chemicals is also substantial. This method
has been used for the small scale destruction of PCB.
4.7 Supercritical water
Chemical reactions can occur very rapidly and completely in
supercritical water. Supercritical conditions are achieved by
raising the pressure and temperature so that the liquid
assumes properties which resemble gas and liquid at the same
time. The critical point of water is 374°C and 218 bar. The
pressure and temperature must therefore exceed these levels.
Halon destruction can probably be achieved by using this
technique. However, several years' work is necessary before
the technique can be evaluated and compared with the destruc-
tion techniques which can currently be carried out on a
commercial basis.
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17
5 Techniques
Several of the methods of destruction described in section 4
require several years of development work with an investment
of several millions before they can become technically
feasible plant designs. At present, it is only possible to
evaluate thermal destruction from a technical, economic and
environmental standpoint. If haIon destruction.is to be
initiated within a five-year period at a plant located in one
of the Nordic countries, one of the following alternatives
must be chosen:
utilization of existing incineration plants for
hazardous waste.
utilization of the coal gasification facility in
Lulea.
construction of a purpose-built incineration plant
for halogenated hydrocarbons.
construction a plasma plant modified for halogenated
hydrocarbons.
If it is decided to use the incineration plants for mixed
hazardous wastes, no separate investment will be required.
Several countries have planned to considerably expand the
destruction capacity of such plants. Our assessment of the
consequences of this course of action is provided in section
6.
The other techniques would require an in-depth study of
technical, economic and environmental considerations before a
decision on investment can be made. In principle, the tech-
niques are comparable, since they can be evaluated on the
basis of how they fulfil the need for destruction of the
halon bank in the Nordic countries alone. This comparison is
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18
provided in section 7. However, we assume that, in practice,
plant capacity will not only be suited to fulfil the need for
halon destruction, but also that of CFCs and other halogenated
hydrocarbons which can be gasified.
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19
6 Existing plants
There are currently three plants in the Nordic countries
which receive and incinerate hazardous waste originating from
industry and the public. The destruction of combustible waste
is carried out in the same way. Most of the waste is fed into
a rotary kiln where it is incinerated. Final oxidization of
the combustion gases is carried out in a secondary combustion
chamber (after burner). Heat is transferred from the flue
gases in a steam boiler and the flue gases are cleaned by a
method which results in a dry residual product.
The plants are located in Nyborg in Denmark, Rihimaki in
Finland and Kumla in Sverige. In Norway, there is as yet no
facility for this purpose. There are detailed plans to locate
a plant in Mo in Rana,and in Denmark a third furnace was
recently taken into operation. Consequently, there is some
capacity which has not yet been utilized. Finland and Sweden
need additional capacity as soon as possible to avoid storing
the hazardous waste which is collected in these countries.
Finland has decided to invest in a new furnace in Rihimaki.
In Sweden, no decision has been taken as regards the siting
or financing of a new processing facility.
The combined halon bank in the Nordic countries would occupy
a small share of the plants' nominal capacity. In spite of
this, the high concentrations of halogens in halons mean
that a significant part of the destruction capacity is
affected. Since the existing plants are all equipped with
steam boilers, the corrosion conditions can also result in a
limited capacity for the halon flow.
In Sweden, the granting of a licence for the incineration of
hazardous waste has involved certain conditions which, in
practice, mean that halons cannot be destroyed in a Swedish
facility. This is due to the bromine content of halons. Only
waste which allows an instantaneous halogen load during
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20
combustion of less than 100 g/s may be supplied to the
furnaces in Sweden. The halogen load is defined as
(Cl + lOxBr) g/s. This condition has been enforced in order
to limit the production of chlorine and bromine substituted
aromatics.
The incineration of halons in furnaces where mixed organic
waste is destroyed at the same time, will, in our opinion,
lead to the substantial formation of bromine aromatics, such
as bromodioxines, bromophenols and bromobenzenes. At present,
no plant is regulated as regards acceptable emission levels
of these pollutants. We have assumed that the granting of a
licence to destroy halons in the existing plants would
involve requirements on limiting emissions which would be
more stringent than the current levels. This is mainly due to
the fact that the bromine load would increase considerably
compared to when the licences were previously granted.
It is not possible for us to estimate the cost of performing
halon destruction in the existing plants. However, if no
additional requirements on emissions control are made, it is
evident that it will be less expensive to conduct halon
destruction in the existing plants than in new, separate
plants.
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21
7 New plants
It is possible to put into operation three different types
of plants for halon destruction in the Nordic countries
within a period of five years. It is uncertain when this can
be done, largely due to uncertainty as regards how soon the
decision on siting can be made.
However, if it is decided that the molten iron technique
should be used, the siting issue should be resolved. This
technique is not feasible without the substantial investment
represented by the existing coal gasifier in Lulea, Sweden.
As regards the other techniques we assume that they will be
located on the same site as an existing plant for handling
hazardous waste. Such a plant has the necessary infra-
structure which would limit the need for investment. Halon
destruction involves a limited period of time and limited
quantities of waste
We have also opted for siting halon destruction facilities
together with already existing plants to enable a comparison
of all three kinds of plants in our cost estimate.
7.1 Capacity
The capacity of the plant is based on the assumption that
3 000 tonnes of halon will be destroyed within a period of
five years. The plant will be operated periodically or will
be capable of a day shift operation of 220 days a year. The
destruction capacity obtained on the basis of these
assumptions is 340 kg/h of halon.
The material to be destroyed is a mixture of halons and
nitrogen. The average composition of the halons is estimated
as shown in Table 6.
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22
Table 6
Elemental composition of 3 000 tonnes of halon
weight %
Carbon 8
Fluorine 36
Chlorine 3
Bromine 53
7.2 Environmental requirements
The environmental impact of the plant will be an important
factor in the choice of the destruction technique, as will
economic and technical considerations. Regardless of the
design of the plant, the surroundings are affected by trans-
portation of materials personnel. This can affect siting but
not the choice of the process used.
In the design basis, the halon emissions from the plant are
assumed to be less than 1% of the quantity of incoming
halons. In order to reach this level, considerable effort
must be put into devising a system of handling halon
containers that prevents leakage during emptying. Stringent
safety arrangements are required. The total halon emission is
probably not affected by the destruction efficiency of the
processes, which should be higher than 99.99% for all the
cases.
In the design basis, it was assumed that all the techniques
would fulfil the requirements on emissions to the air, as
presented in Table 7.
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Table 7
Emission factors
Dust g/tonne halon 20
Hydrogen chloride g/tonne halon 20
Hydrogen fluoride g/tonne halon 20
Hydrogen bromide g/tonne halon 20
Total hydrocarbons g/tonne halon 200
TCDD-equivalents ug/tonne halon 1
Emissions to water are to a high degree affected by the
choice of technique, as well as by the amount and kind of
residual products which arise.
A reasonable, general requirement is that the technique
chosen results in the generation of a quantity of residual
products which is as small as possible, and a quantity of
substances hazardous to health and environment which is as
small as possible.
7.3 Incineration
Halons themselves do not contribute to the energy which is
needed for their destruction. Therefore, fuel is required.
The necessary excess hydrogen should also be provided along
with the fuel to guarantee the formation of HBr, HF and HC1.
The excess oxygen is controlled by the combustion air.
The carbon content of the halon mixture is low, only 8 %. If
a fuel without carbon is selected, i.e. hydrogen gas, the
risk of the formation of aromatic hydrocarbons is minimized.
However, hydrogen gas is expensive and is not a standard
fuel. A standard fuel, rich in hydrogen which is readily
obtainable is propane (LP gas).
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24
In order to ensure maximum safety to the environment, the
amount of excess hydrogen (H/(Fl+Cl+Br)) which is supplied
during incineration in practice, must be ^10. This is
probably a conservative estimate. In practice, the necessary
amount of excess hydrogen necessary in practice, may be
lower. Since this factor has a tangible effect on the fuel
consumption, it should be investigated experimentally, after
a decision to adopt incineration as a technique for destruc-
tion has been made. We do not have the resources available in
this study to investigate the issue more closely.
Fuel consumption and air requirements for the destruction of
340 kg/h halon with a large excess of hydrogen is shown in
Table 8.
Table 8
Incineration of halons with hydrogen gas or propane
Hydro-
gen gas
Propane
Fuel rating
MW
Excess hydrogen
(H/(F+Cl+Br))
mol/mol 10
10
Halons
Hydrogen gas
Propane
Air requirement
kg/h
kg/h
kg/h
Nm3/h
340
90
2435
340
475
5900
With propane as a fuel, the thermal output of the plant is
doubled to maintain the excess of hydrogen. However, the fuel
rating of 6 MW means that the plant design is easily manageable.
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7.3.1
Design
The plant design remains the same, regardless of the fuel
used. The reactor required is relatively small. The facility
is equipped with a propane station for the fuel supply. The
same applies for incineration using hydrogen. Propane can be
used as a cheaper form of fuel for startup, standby and
similar operating conditions. With a hydrogen gas consumption
of 90 kg/h it may be necessary to erect a separate factory
for the production of hydrogen gas if this fuel is used.
It is possible to avoid the relatively substantial costs that
this would involve if the siting is selected in connection
with a chemical industry producing a surplus of hydrogen gas.
A schematic diagram of the plant is provided in Figure 4.
Figure 4
Incineration plant
The fuel is burnt in the reactor, where the decomposition of
the halons is initiated. The halons remain in the secondary
combustion chamber (afterburner), for the necessary residence
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26
time and the mixture which is required for complete
combustion is achieved.
The necessary residence time in the reactor and the secondary
combustion chamber is estimated at four seconds. The reactor
and the secondary combustion chamber are both made of brick.
Once the gases have left the secondary combustion chamber,
they are cooled in a radiant-type cooler. The hot air
obtained is used in the plant for superheating the flue gases
before final cleaning. The flue gases from the recuperator
are quenched in a venturi cooler before the acidic gases are
removed by water in a multi-stage scrubber. The moisture can
be condensed and removed in the scrubber to limit the flue
gas flow rate. A multi-stage scrubber system for the removal
of the hydrogen halides from incineration is required, since
the quantities to be removed are considerable. The acid
effluent from the cleaning process is neutralized and filtered
before being taken to the recipient.
The flue gases from the scrubber are mixed with hot air to
attain suitable conditions in the fabric filter used for the
final stage of the flue gas cleaning.
The composition of the flue gases from incineration is shown
in Table 9 when hydrogen and propane are used as fuels.
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27
Table 9
Flue gas composition before scrubber
Flue gas
Vol %, dry gas
Hydrogen
Propane
N2
co2
°2
HC1
HF
HBr
3
Flue gas flow, run /h dry gas
H-0 vol %
2 3
Flue gas flow, nm /h
85.9
1.8
5.3
0.2
5.0
1.8
100.0
2900
24
3800
81.6
11.0
4.5
0.1
2.1
0.7
100.0
7200
11
8030
7.3.2
Construction work
It is assumed that the plant for the process described on the
previous page will be located on the same site as a similar
plant. The financial investment can thereby be limited, since
an infrastructure, in the form of buildings, personnel,
workshops and control systems will already exist and can be
used.
In our cost estimate, we have assumed that the flue gases can
be led to a flue gas cleaning facility in an existing plant,
thereby making separate stacks unneccessary. We also assume
that the effluent can be cleaned together with effluent from
the already existing plant.
We have not considered unfavorable site conditions and other
factors which affect cost when assessing the scope of the
construction work.
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28
The items in the cost estimate are shown in Table 10.
Table 10
Scope of the construction work
Halon handling plant
Construction of plant and connection to existing systems for
electricity and water and sewage
Liquid petroleum system
Hydrogen system (only for hydrogen-based technique)
Reactor
Secondary combustion chamber (afterburner)
Radiant-type cooler
Quench
Scrubber
Connection to existing water cleaning system
Connection to existing flue gas cleaning system
Power system
Control and monitoring system
Measurement instrumentation
7.4 Molten iron
Pressurized Coal Iron Gasification (P-CIG) is a process for
the gasification of coal which is injected into a slag
covered iron bath along with oxygen. The temperature of the
melt is approximately 1 450°C. The main functions of the melt
in the process are to:
to transfer heat to the coal particles
to act as a buffer to the coal to ensure an even gas
composition
to take up and transfer the sulphur in the coal to
the slag
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29
A schematic diagram of the gasifier is provided in Figure 5.
Liquid oiag
Molten iron
Gasification zone
Nozzle
Figure 5
Vertical steel converter type gasifier
The gasifier has a lining made of brick. The molten iron can
either be supplied from an external smelting furnace or be
obtained from melting scrap iron directly in the gasifier by
gas or oil-firing.
For several years, the Swedish National Board for Technical
Development (STU) has supported the development of the P-CIG
process. At present there is a pilot plant as well as a
demonstration plant for the technique at the the
metallurgical research station in Lulea, MEFOS. The pilot
plant has the capacity for to handle 50 tonnes of coal/day
while the larger demonstration plant has a capacity for 250
tonnes of coal/day. The pilot plants would have sufficient
capacity for halon destruction.
7.4.1 Tests performed
When heated, the halogens in halons form salts easily due to
their high electron negativity. In order to check this, STU
granted funds to Interproject Service AB, Bettna, to conduct
a test campaign on the destruction of halon in an iron bath.
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30
Experiments on the destruction of halon 1301 were carried out
during the summer of 1989 in a laboratory furnace at MEFOS.
The furnace had a capacity for 150 kg of molten iron and was
heated by induction. The halon was injected by a lance into
the molten iron.
Six series of tests were carried out in all, one of which was
a reference test. The measurements carried out in connection
with the tests show that bromine and fluorine are released
from the molten iron in the form of dust. A characteristic
dust formation occurs when the halon is injected into the
molten iron. In addition to bromine and fluorine, the dust
contains large quantities of iron, which indicates that the
halogens have formed iron salts. A certain amount of PAH,
Br-benzenes and Br-phenols are also released with the dust.
7.4.2 P-CIG for halon destruction
The thermal capacity of the pilot plant for coal gasification
corresponds to 15 MW. Its capacity is thereby greater than
that of the plant using a combustion technique. Figure 4 is a
schematic diagram of the pilot plant.
REACTOR
WITH
FEED
CO*
V
'O Q
Q O '
Figure 6
Schematic diagram of P-CIG
A A.
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31
The substance to be gasified is injected together with oxygen
through nozzles at the bottom of the reactor. Gasification is
carried out in the molten iron through the partial combustion
of coal which forms carbon monoxide. Hydrogen and iron
halides are formed at the same time. The feed material, e.g
halons, has a short residence time in the molten iron - less
than one second. Halon decomposes due to the good heat
transfer conditions and the high temperature in the molten
iron.
With the present plant design, the gas and dust from the
reactor pass through a slag separator in the gas line prior
to cooling and dust removal in a wet scrubber. The temperature
of the gas on entering the scrubber is approximately 1 200°C
and the total residence time of the gas and dust in the
system before reaching the scrubber is approximately 2-5
seconds.
Table 11 shows the calculated flow rates for the destruction
of halon 1301 using the P-CIG process.
Table 11
Flow rates for the destruction of halon 1301
Incoming
Halon 1301 (total) kg/h 1 000
of which
C 81
Br 537
F 383
3
Required 0, nm /h 78
Required Fe kg/h 563
Outgoing
FeBr2 kg/h 726
FeF- "- 759
3
Flue gases nm /h 407
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32
As a first step, the interested parties propose that a test
compaign be carried out in the pilot plant to verify the
calculations and results obtained from previous experiments.
The test operations will comprise two test campaigns each
involving operation of the plant for a week, destroying 10 to
20 tonnes of halons. The aim is to take comprehensive measure-
ments during the test period. If the test operations indicate
that the technical and environmental requirements have been
funfilled, the next step will be to modify the plant to
carry out halon destruction on a commercial basis.
7.4.3 Pilot plant modification
Interprojekt Service AB has expressed its willingness to
continue the development work with MEFOS and other interested
parties and modify the plant for halon destruction.
A cost estimate has been performed for the development work
and for certain specified plant modification work. The
estimate covers the replacement of the brickwork and the
addition of a ceramic liner to the reactor. The estimate also
includes the acquisition of additional instrumentation and
measurement systems as well as changes in the system for
handling the substances to be gasified. A new wet scrubber
system for the removal of dust has been budgeted for.
However, this does not include a fabric filter and sludge
treatment has not been specified in detail.
In the cost estimate we have taken into account certain
investments which are already known, including equipment for
handling halons, so that the emissions requirements can be
met.
The destruction of halon is estimated to be completed within
five years. It is planned that the plant will be operated
periodically, with three operating periods per year. During
each operating period, 200 tonnes of halons will be destroyed
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33
in 20 operating days. It is anticipated that the plant will
be operated in two shifts for ten hours a day.
7.5 Plasma technology
The development of plasma technology for the destruction of
hazardous waste is being carried out in many different
companies and organizations.-In Norway, Kvarner Engineering
and SINTEF are involved in joint work on plasma technology.
These companies are planning to put a prototype plant into
operation during autumn 1989. The plant will have an output
of 100 kW and will be used for research and development work.
It can also be used for tests on the destruction of certain
substances, for example, halons. In Sweden, SKF Plasma
Technologies AB is working with plasma technology for the
destruction of substances, including hazardous waste.
During the past year, at least two proposals have been put
forward for commercial plants using plasma technology for the
destruction of hazardous waste. Two small-scale plants have
been proposed by companies which are prepared to enter into
negotiations for a contract to construct these plants. One of
the systems is supplied by Nutrail Corporation, Mass, USA.
The system is called the SSP process. MGC Moser Glaser in
Basel, Switzerland markets a plasma technique, known as the
MGC process, which is similar in principle. We will describe
the MGC process since we have obtained details on this
particular technique.
7.5.1 Design
The MGC process for the destruction of solid and liquid
wastes is shown in the schematic diagram in Figure 7.
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34
trahich temoerarure r.^;1.:-
:'. a t e r i a 1
30 1 or 200 1 Normal
Hydraulic system.
So rev feeder
Direcc plasma burner
Centrifugal reactor
After burner/oxidation chamber
3 Quench
9 Control station
10 Energy supply
1 1 Gas supply
12 Cooling water supply
13-17 Flue gas scrubber-Flue gas
18 Analysis
T "~^ 'i
Figure 7
The MGC process
For halon destruction, the plant does not have to be equipped
with equipment for handling drums. However, this does not
seem to have a significant effect on the total cost of the
plant.
The plasma is generated by a direct burner, which allows a
long residence time for halons in the plasma. The reactor
consists of a centrifuge where the slag is collected. When
substances which do not form slag are destroyed, such as
halons, a matrix of silica (sand, glass etc) must be
provided, since the slag is the anode in the process.
Unlike combustion, the substances in this reactor are heated
without the addition of external oxygen. Argon or helium are
used as inert gases in the reactor. Any hydrogen necessary
during the destruction process, is supplied to the reactor as
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35
methane or water. Tests have been carried out using methane
in the reactor in the aim of increasing the lifetime of the
Cu electrode. Tests with halon destruction must be carried
out to investigate whether the anticipated reactions occur
and can be checked.
When the plasma leaves the reactor, it is cooled and the
gases are oxidized with oxygen gas (O_) in a reaction chamber.
The temperature in the chamber can be held at 2000°C. By
using oxygen directly, the volume of the flue gas is less
than that from ordinary combustion. However, it should be
necessary to supply air to cool the flue gases before they
reach the scrubber system. The flue gas cleaning system
handles the same flue gas components as those arising from
combustion. Therefore, the requirements for and the design of
the flue gas cleaning system are the same regardless of the
type of reactor used.
At present, we do not have the necessary information on
construction and design for a cost estimate.
MGC Mosel Glaser has stated that a plant with a capacity for
handling 7 000 tonnes/year of mixed hazardous waste would
cost MSEK 100. We have assumed that this waste would consist
of 50% organic material. With this design the plant would be
overdimensioned. We have therefore scaled down the costs to a
level that we consider applicable to a plant with a capacity
of 600 tonnes/year.
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8 Economic evaluation
The decision to invest in a particular plant cannot be based
entirely on the cost estimate. However, it can be used to
distinguish between the capital required and the funding
required due to other factors affecting the cost of the
destruction process.
8.1 Investment costs
When estimating the cost of the incineration and the plasma
techniques, it has been assumed that the plants will be
located on the same site as an existing plant in the Nordic
countries. The cost of determining the final site has not
been taken into account in the investment costs. With the
P-CIG alternative, it is assumed that the equipment at MEFOS
in Lulea will be used.
The costs are based on the price levels for autumn 1989.
Interest and other financing costs arising during the con-
struction period have not been taken into account since this
requires a knowledge of the form of financing to be adopted.
Information obtained in consultation with plant and component
vendors was used as a basis for the cost estimate. For the
P-CIG technique, estimates were obtained from Interproject
Service AB. MGC Mosel Glaser submitted certain estimates for
the costing of the plasma process. In addition to this, we
used our experience from other projects of a similar nature
as a basis for the cost estimates.
The scope of the construction work was presented in section
7. The investment costs, divided into main categories, are
presented in Table 12.
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37
Table 12
Investment costs, MSEK.
Combustion
Technique
Development
Licence ace. to ML, PEL*
Plant
Uncertainty 10%
Investment
Hydro-
gen gas
3
2
43
5
53
Propane
3
2
45
5
55
P-CIG
6
2
14
2
24.
Plasma
1
2
30
3
36
* Corresponding legislation in other Nordic countries
8.2
Capital costs
The capital costs for all the techniques are estimated on the
basis of an assumed amortization period of 5 years. The
capital costs are calculated for the total investment in each
case, including the development and licencing costs. With an
assumed interest rate of 15%, the fixed annual instalment
factor is a - 0.3.
The capital costs for the different techniques are shown in
Table 13.
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Table 13
Capital costs
Technique
investment, MSEK
Capital cost, MSEK
Combustion
Hydro- Propane
gen gas
53 55
15.8 16.4
P-CIG Plasma
24 36
7.2 10.8
8.3
Operating costs
This heading includes costs for personnel, fuel, handling of
residual products, maintenance and repair etc.
The personnel requirement for both the combustion and plasma
techniques is estimated to correspond to four man years. The
cost for one man year is estimated at SEK 230 000.
The P-CIG plant is operated periodically. Interproject
estimates that the cost for personnel including preparatory,
plant operation and post operation work amounts to MSEK
3.4/year.
The operating and maintenance costs for the combustion and
plasma techniques have been estimated at a flat rate corre-
sponding to 3 % of the investment. In addition to these
running costs, the combustion technique results in an annual
cost of MSEK 0.6 for the replacement of the brickwork in the
combustion chamber. The plasma technique involves a similar
amount for the replacement of the electrode. The fuel costs
(propane, hydrogen gas) and electricity have been calculated
according to the current price levels in Sweden.
Interprojekt has estimated the annual operating and
maintenance costs for the P-CIG process, at MSEK 8.8 MSEK.
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39
The cost of the necessary replacement of the brickwork in the
reactor etc is also included.
The operating costs for the different techniques are summarized
in Table 14.
Table 14
Total operating costs, MSEK
Hydrogen gas Propane P-CIG Plasma
9.5 5.0 12.8 4.1
The operating costs for propane incineration and plasma are
relatively low because of the proposed use of these
techniques in conjunction with the destruction of other kinds
of hazardous waste. The same applies to hydrogen, but the
fuel costs are higher. The operating costs from the P-CIG
process are high due to the periodic operation of the plant
with contracted personnel and resources.
8.4 Summary
Table 15 is a summary of the costs of the different
techniques. The table also includes the unit cost of halon
destruction.
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40
Table 15
Summary of costs
Combustion
Technique Hydro- Propane P-CIG Plasma
gen gas
Investment, MSEK 53 55 24 36
Annual destruction, tonnes 600 600 600 600
Costs:
capital, MSEK 15.8 16.4 7.2 10.8
operation, MSEK 9.5 5.0 12.8 4.1
Annual cost, MSEK 26.5 21.4 20.0 14.9
Destruction cost,
SEK/kg 44 36 33 25
In the summary, the highest cost is obtained from the use of
the combustion techniques. This may be due to the fact that
we are more familiar with the consequences of this technique.
The other processes do not exist in the form of plants
operating on a commercial basis.
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41
9 Environmental impact
The economic considerations should not be the only deciding
factor in the choice of technique and siting. The environ-
mental impact of the plant can affect the final decision to a
large extent.
Regardless of the technique used, the environent will be
affected through the transportation of the substances.
Similarly, the halon emissions are estimated to be 1 % of the
amount supplied to the facility.
Halon destruction entails a considerable specific energy
consumption in connection with collection, storage and final
destruction. This is largely the case, regardless of the
technique used. However, it can be noted that halon destruc-
tion in already existing plants is carried out without the
need for extra energy in any measurable quanity. The destruc-
tion of halon only results in a reduction of the capacity to
handle other products containing halogen. Because of the
capacity for the destruction of hazardous waste which will be
available in the Nordic countries during the nineties this
effect may be negligible. The halon bank is very small when
compared with the quantities of chemical waste products.
The decision to destroy halons is based on the substantial
ozone depleting potential of halons. In the light of this,
the energy consumption involved in the use of the different
techniques is hardly of interest. The different techniques
use very different energy carriers.
The destruction of halons using the P-CIG process, involves a
high consumption of energy from coal or electricity since for
each tonne of halon destroyed at least half a tonne of molten
iron is used. The total energy consumption resulting from the
use of the other techniques is lower and does not vary
greatly from technique to technique.
-------
42
We are limiting this description of the environmental impact
to a comparison of the new techniques and the factors which
are not dependent on siting conditions, but which are
different for each technique.
The destruction of halons in the existing plants is not taken
into account, since the effect of the additional halons
cannot be specifically measured. For this to be done, the
substance which is destroyed along with the halons in the
furnaces must be defined. Neither the flue gas emissions,
residual products nor any other environmental factor, such as
noise, need be measurably affected. At the same time, it is
obvious that if halon destruction is performed by increasing
the halogen load in the combustion process, more chlorine and
bromine aromatics will be produced in the plant.
9.1 Emissions to the air
When dimensioning the plant for the different techniques, we
have taken into account general requirements concerning
emissions to the air. However, the processes involve different
flue gas flow rates. For this reason, the total emissions
will be somewhat different.
However, all the techniques are well within the limits of the
emission requirements which can be anticipated in connection
with the licencing. Table 17 is a summary of the anticipated
annual emission.
-------
43
Table 17
Emissions to the air
Technique
Combustion
Hydro- Propane P-CIG Plasma
gen gas
Flue gas flow,
Halon flow,
Annual halon
destruction,
m3/h*
kg/h
tonne
2900
340
600
7200
340
600
400
1000
600
2900
340
600
Emission:
hydgrogen chloride, kg/yr
hydrogen fluoride, kg/yr
hydrogen bromide, kg/yr
5
5
5
12
12
12
0.2
0.2
0.2
5
5
5
Total hydrocarbons
50
120
50
TCDD equiv. ace. to Eadon
mg/yr
0.5
1.2
0.5
* m dry gas with 4 % 0-
This assessment of the quantities of substances emitted are
based on calculated equilibrium quantities and detection
limits when determining emissions from the plants.
Question marks are used in the table for the P-CIG technique
for the same reason that the conclusion was drawn that the
emissions of corresponding pollutants cannot be specified for
halon destruction in existing plants. It is not possible to
determine how any halogens released during the destruction
process substitute gasified organic substances originating
from the coal used in the process.
-------
44
There are good reasons for assuming that the other techniques
result in very small emissions of organic pollutants,
especially of the aromatic type, since no aromatic rings are
supplied with the fuel.
It should only be possible for these pollutants to occur as
impurities in the halons or to be formed in the process.
9.2 Emissions to water
With a destruction capacity of 340 kg/h of halons with the
composition shown in Table 6, an effluent is obtained from
combustion and plasma, containing halogens, as shown in Table
18.
Table 18
Halogen content in effluent
Effluent flow rate
F
Cl
Br
Total halogens
20
6
0.
9
15.
m3/h
g/i
5 g/1
g/i
5 g/1
This acidic effluent can be neutralized with sodium hydroxide
and sent to a recipient as dissolved salts. If it is neu-
tralized with lime, most of the fluoride is obtained as
sludge. Chloride and bromide are sent to the recipient as
dissolved salts. The choice of method is probably wholly
dependent upon the siting of the facility.
An effluent is obtained from the P-CIG process with a high
dust content, mainly of iron. It is possible that the quantity
of effluent sent to the recipient can be lower from this
process, while the amount of sludge handled is greater.
-------
45
The environmental protection analysis should result in the
implementation of safety systems enable detailed analyses to
be done before the effluent is released.
9.3 Residual products
Solid residual products in the form of sludge from effluent
cleaning mainly occur with the P-CIG process. The production
of sludge amounts to 6 t/h or 600 t/yr. The quoted amounts of
sludge mainly consist of iron dust. The sludge will contain
most of the halogens as iron salts. These salts can form
hydrogen bromide and hydrogen fluoride if moisture is present.
More or less the same quantity of sludge arises from combus-
tion if the fluoride is trapped with lime.
The sludge will probably be handled as hazardous waste and be
deposited at a controlled depository which is dry and leaktight.
-------
46
10 Conclusions
In the Nordic countries, there is a bank of about 3 000
tonnes of halons. This is a small share of the global amount
which depletes the ozone layer in the stratosphere. If the
Nordic countries find reasons for coming to a decision
regarding halon destruction before any international agree-
ment is reached on how this is to be done, this will be a
clear indication of the desire to set a precedent for the
rest of the world. Therefore, it is logical to conclude that
the choice of a method of destruction will not be based on
the cost of the technique but on what is least hazardous to
the environment.
The destruction of halons should therefore be performed so
that the conditions for the formation of persistent toxic
organic compounds is minimized. The halogen substituted
aromatic compounds are greatly enriched in the environment
and can lead to unforeseen problems in the future.
The destruction of halons by incineration together with
hazardous waste should therefore be avoided, as well as
processes involving the occurrence of large amounts of
aromatic compounds which can be substituted by halogens. In
each case, it is necessary that the requirements on flue gas
cleaning and deposition of the residual products be adjusted
in plants which are to be used for halon destruction.
There are two techniques which are preferable for the de-
struction of halons in the Nordic countries. One is incinera-
tion in a separate furnace and the other is destruction in a
plasma reactor. In both cases, the mixture of the flue gases
will be more or less the same regardless of how the energy
for the destruction process is supplied.
A decision as regards which of the two processes is optimal
from a technical and economic standpoint should be deferred
-------
47
until the point of investment. At the present, the descrip-
tion of the environmental impact of the plasma facility is
not acceptable since there is no operating experience for
such plants. However, this situation may improve within a
year. If the decision is to be made at present, combustion
according to the process description given in section 7 is
preferable. At present, it is the only alternative which can
be defined in operational, economic and environmental terms.
Combustion using hydrogen as fuel provides maximum safety.
However, use of this fuel involves a higher risk of opera-
tional interruptions than propane.
If it is decided to destroy halons separately in the plant
for environmental reasons, hydrogen should also be used as
fuel. If it is decided that halon should be incinerated
together with CFCs and other halogenated hydrocarbons,
propane is adequate as fuel. This applies in any event, if
CFCs mixed with oil are to be destroyed in the plant.
-------
48
References
1. Anvandning av halon 1301 och 1211 som slackmedel i
Norden.
Nordiska Ministerradet 1985:65
(Compiled by Brandtekniska Ingenjorsbyran AB)
2. DELLINGER, B, TORRES, J L, RUBEY, W A, HALL, D L,
GRAHAM, J L
Determination of the thermal decomposition properties
of 20 selected hazardous organic compounds.
University of Dayton, Research Institute, Environ-
mental Scinences Group.
3. KOVICHI, MIZUNO
Destruction of CFBs by thermal plasma reaction
method.
National Research Institute for Pollution and
Resources.
-------
Week Ending
January 5
January 12
MINISTRY OF ENVIRONMENT AND FORESTS
CFCS IN INDIA
Avani Vaish
Director, Ministry of Environment and Forestry
Phase I Work Plan
Tasks
1. Agreement on workplan between MOEF1 and SBB/TR/C&W2.
2. SBB briefs C&W on uses and manufacture of CFCs in India.
3. C&W prepares initial listing of technical options
relevant to India.
4. SBB finalizes C&W technical visit program.
5. Agreement on structure and content of Phase I/Interim
Report by SBB/TR/C&W.
6. TR prepares definition of "transition costs."
1. C&W program of technical visits starts.
2. TR investigates:
— market structures '
— economic background
— industry development
3. C&W expands/develops their statement of technical
options.
4. SBB completes data collection and analysis.
1MOEF is the Ministry of Environment and Forestry
2SBB, TR, and C&W are private consulting firms.
-------
-2-
Week Ending
Tasks
January 19 1. C&W completes program of technical visits.
2. SBB commences drafting Interim Report - Part A.
3. TR investigates industry structures.
4. C&W completes statement of technical options and
technical risks.
5. TR drafts Interim Report - Introduction.
6. Tr develops demand projections, with SBB support.
7. TR prepares sectoral analysis for reduced use of CFCs.
January 26 1. SBB completes drafting of Interim Report - Part A.
2. C&W makes technical presentation to MOEF and technical
experts on "the options for India."
3. C&W commence drafting Interim Report - Part B.
4. TR prepares CFC production reduction analysis (and
feedstocks).
5. TR prepares "scenarios for ???????"
6. TR commences drafting Interim Report - Part C.
7. SBB presents "CFC use in India" to MOEF.
February 2 1. SBB draft of Interim Report - Part A to MOEF for review
(and to TR and C&W).
2. TR presents "Targets and Scenarios" to MOEF.
3. C&W completes drafting of Interim Report - Part B.
4. Tr prepares cost implications of main scenarios.
5. TR continues drafting Interim Report - Part C.
-------
-3-
Week Ending
February 9
Tasks
February 16
1. TR completes drafting Interim Report - Part C.
2. Tr drafts "Executive Summary."
3. Production and internal review of draft report.
4. Draft report to MOEF for review.
1. MOEF reviews draft report.
2. Consultants meet MOEF to discuss comments/reactions/
suggested revisions.
3. Interim Report revised to take account of MOEF comments.
4. Interim Report - Final submitted to MOEF.
-------
jJrulumqnr
Volume 1 , No. 2 5c"C" ='z:^~ ^z-
-C 3o« ~2 3- ' 322 ~c~ars' ~~'ecr:~e :;• -35 23 2- January :S9C
Editorial
When we sent out the first number of
Protonique News, we were a little ap-
prehensive as to how it would be received.
It may be qualified- as a semi-success.
Those that we sent out directly to known
customers (about 500) were accompanied
by a reply card. Where our agents sent out
copies (about 1.000) to their customers.
we asked they did the same. We received
back 47. just'under the traditional 10% for
such a mailing. Of the ones we received.
three had favourable comments and no-
one made any unfavourable ones. All of
them had the square requesting a con-
tinuation of reception ticked. In a few
cases, we received photocopies of the
card, as the News was circulated amongst
several persons. About half the cards
received back requested literature on one
or more of our products. One of them has
even resulted in an important order.
Oh the whole, we find this good, but
what are we to think of the 90% who did
not send back the card? Does this mean
that these persons do not wish to receive
it. or does it mean the card got lost? Worse
still for us. who have gone to such pains
to produce a short newsletter which we
have tried to make as interesting as pos-
sible, does it mean that it was relegated to
the waste-paper-basket without even
having been read or that it arrived on the
desk of the wrong individual? A plea! If
you receive this and you think it concerns
a colleague, pass it on to him, please.
To try and get more feedback, we are in-
cluding this time a card in all the copies
(the circulation list is currently about
1600. including those sent through
agents). Please ensure we get back as
many as possibleO and especially if you
do not wish to continue receiving Protoni-
que NewsQ. Also, to help companies who
are not sure who is the right individual, we
have drawn up a blank circulation list to
help you pass it round. If you have a col-
league who would like his own copy, there
is space for his name on the accompany-
ing card©.
To end this self-imposed "bouquets and
brickbats" department, we have received
exactly one letter on this subject which we
have translated from French and
reproduced here. It makes us quite proud.
The person who wrote it has requested
that we do not publish his name, address
or Company and we respect this wish. D
Brian Ellis Honoured
by U.N.
The General Director of Protonique
S.A.. Brian Ellis, has been honoured to
receive a Citation of Excellence from the
United Nations Environment Programme
"in recognition of an outstanding con-
tribution to the protection of the Earth's
Ozone Laver". 0
Circulation list
Name
Date
Return to:
Ozone Layer Protection
Latest News
As most of you are probably aware, the Solvents Technical Options Com-
mittee reported to the United Nations Environment Programme last Summer.
In view of the Helsinki Declaration, at which the Parties to the Montreal
Protocol agreed that more severe measures were necessary, a meeting was held
in Nairobi starting last August at which the various Committee reports v^ere
accepted. The Parties to the Protocol are now studying the various possibility
of revision, which will take place in June 1990.
What can we expect from this first
revision? It is impossible to forecast the
decisions but. as far as solvents are con-
cerned, the situation is clear. The follow-
ing, under reserve, indicates the general
lines of thought behind any revision:
/the calendar may be modified. Instead
of a 50% reduction of CFCs by 1998. we
can expect at least a 90% reduction (pos-
sibly 100%) by 2000 and a 100% by
2005. It is not known yet whether or how
these reductions will be scaled.
/other CFCs may be included. CFC-112
may be brought into the Protocol.
/carbon tetrachloride may be included.
This is amongst the worst ozone
depleters (other than halons which some
class it with) and it may be a surprise to
know that about 70.000 tonnes are still
emitted each year, despite its known
carcinogenicity. A complete phase-out
of this substance as a solvent within the
Protocol as soon as possible is probable.
/1.1.1-tnchloroethane may be included.
This substance, also known as methyl
chloroform, is a moderate ozone
depleter but it is used in such vast quan-
tities that the total effect is nearly as
great as that of CFC-113. Due to a rela-
tively short lifetime, if it is phased out
rapidly, it would produce the most rapid
reduction in stratospheric chlorine
levels possible, within a rev*, decade^
Unfortunately, a phase-out uould be
more difficult than with the CFC -ol-
vents. It seems likely that this substance
may become severely restricted, but a
complete phase-out is unlikeh
/some new solvents mav be included.
Concern is expressed that some or the
continued on next paqe.
Contents
Editorial I
Brian Ellis Honoured 1
Ozone Layer Protection 1
Thought for the Day 2
Letter to the Editor 3
New Year's Thoughts 3
Telex " 3
The Ballad of the Zone
of Ozone 4
PnMonii^uc Se»s is j prv ate nr *'.cj.:;" j.-
ot'wturee to interested panics h .^ .»: • -r »a.;
SA reser%e-> the nght to reiUNt JC^TJ:." *.T-
being necessorv -VII matenji pi:ri^.-tr,: r : -
PS.V HMU. ill nghis reserved \o'tfs.-vr- -
tor opinions tfipressed ther(r:r D -:• --'
counines is through Proioni^uc ^»;.:"'v
-------
2
Protonique News Vol. 1. No. 2.
...i nuinuit'J trrifii prc\ niu.t puyi'
proposed substitute solvents, mostly
HCFCs ihydrochlorofluorocarbons).
have ozone depletion potentials (ODP)
which are still too high to prevent con-
tinued damage to the ozone layer, espe-
cially if they are massively adopted. It
has been proposed to introduce ceiling
values ot" ODP and substitution rate.
Proposed ceiling levels for the ODP
have been between 0.02 and 0.08 and for
the substitution rate between 20% and
50%. What does this mean? If. for ex-
ample, the Parties to the Protocol adopt
values of 0.05 and 35% respectively and
a nation had a total annual consumption in
1986 of. say 1.000.000 tonnes of all types
of CFCs. for all applications, it will be per-
mitted to use 35%, i.e. 350.000 tonnes, of
substitutes whose ODP does not exceed
0.05. It seems unlikely that much usage of
HCFC solvents can be envisaged and such
substances will have to be reserved for
very special applications where it can be
proved there is no other viable alternative.
In practice, it is foreseen that CFC-113
solvents will be phased out more rapidly
than is thought. In the industrialised
world, a snowball effect may occur. A
number of large consumers will make
strong efforts to reduce their consumption
as much as possible. This has started, with
a few names among many that can be
quoted: AT&T. Boeing, IBM. Northern
Telecom. Seagate. Seiko-Epson. Siemens
and at least a hundred others. Various na-
tions are introducing or proposing legisla-
tion more severe than is required by the
Protocol, notably Sweden with a phase-
out by 1991 and many who propose 85-
100% phase-downs by 1995. Taking these
cases alone, global demand will drop be-
tween 1990 and 1995 by more than 50%.
even if everybody else maintains status
quo. The price will increase by nearly
100% on the 1989 prices, under such a
scenario. This price increase will cause
others to stop using CFC-113 on
economic grounds, causing the price to
rise still further. Self-regulation will
create an almost complete de facto phase-
out of CFC-113 by as early as 1994-5.
This is a warning to electronics com-
panies who are adopting a "wait and see"
policy. They may be taken by surprise. If
they have not already started to examine
the five substitute methods (plus the sixth
one shown dotted in the figure), then they
may be forced to make a hasty and possib-
ly bad decision. Stan now, if you have not
already done so.
We. at Protonique, arc obviously
engaged in this matter as we can offer
equipment for three of the five viable sub-
stitute methods. This has not stopped us
Haiocaroon cleaning
Hydrocarbon
cleaning
Water
cleaning
HydrocarDorvsurfaclant cleaning Saponifier cleaning
Schematic of available substitutes for CFC-113
from establishing an impartial data base
and we are consultants for several or-
ganisations. The largest mandate we have
.received to now has been from the Swiss
Government to wnte a booklet entitled
"Replacement of CFC-113 in Industry" in
English. French and German. This is over
50 A4 pages of closely typeset material. It
will be available in early 1990. Although
written with the Swiss context in mind, it
is a useful guide for individuals and com-
panies in other countries. As over half the
Swiss consumption of CFC-113 is in
electronics, emphasis has been placed in
this sector with an equal accent on
methods where we have no commercial
axe to grind as those where we have. At
this time, it has not been decided by the
Swiss Authorities how this booklet will be
distributed outside of Switzerland, but if
anyone is interested in obtaining a copy.
return us the post card with the ap-
propriate box marked® and we shall in-
form you of the details within a few
weeks.
Countries "under development" present
one of the thorniest problems regarding
the Montreal Protocol. Some provisions
are included forexceptions for developing
countries and this has proved to be a stum-
bling block. At the Helsinki Conference.
some developing countries pointed out
that they needed aid for technological
transfer if they had to reduce their CFC
needs. Without going into the details this
was admitted in principle. This idea was
pursued at the Nairobi Conference
first revisionof the Protocol, in June. >
have to take the needs of these nan
into account, but how? The IS Em ir
mental Protection Agency are holdin
workshop in Washington in January
study such technological transfer v
representatives from sponsor
countries, technology experts and. ab
all. top representatives from so
developing countries such as Br^
Egypt. India. Kenya. Malaysia. Me\
China. Singapore and Venezuela
proposals are to study how. to do >
studies for each country. establish rru
of organisation, operation and coop
tion and examine the economical asp<
This will probably be one of the big
steps forward since the Montreal Proi
came into force, especially as run
states that at least two develoj:
countries are planning to construct <
producing plants. It must be bro
home to these countries that, even u
the existing Protocol, they are cou
economic disaster as the Parties i
form their major markets) will not in
products where ozone depleting sub
ces have entered into any manufacu
process. This could include such proi
as frozen foodstuffs, optical gc
automotive components and vehi
anything containing plastic foams, a:
as cleaned electronics assemblies
onus of proof that regulated subst.
have not been used must lie *w
producers.3
Thought for the Day:
Many have said that if the summer of 1989 is anything tojudze by. L >n «
the Greenhouse Effect! But if the summer of 1989 isjustasmall-scalefi >/v
of things to come...? 3
-------
January 1990
Proton/que News Vol. i. No.
Letter to the Editor
Dear Sir.
I am probably one of" the first users of a
Contammometer. My employers bought
one eleven years ago with a Myron Con-
ductivity Meter. At that time, all the in^
struments were manual and were difficult
to use. as was yours. In 1984. we decided
to replace it by a CM-2D with a Hewlett-
Packard computer. This has given, and
still gives, good service, with only one
major problem in nearly six years: we had
to replace the cell and amplifier after three
years. Other repairs have been small: re-
placement of the flexible hoses twice, re-
placement of the resins twice and a
standard software exchange. Last year, it
was decided to purchase a contamination
tester for another department and the
choice fell on the latest CM-4 turnkey sys-
tem. This w'as slightly dearer than X (Ed.:
the name of a competitive instrument was
put in here). but the greater flexibility and
the fact that it was a European instrument
swung the choice in your direction. I was
personally a little sceptical regarding
some of your claims. We received this in-
strument in late 1988 with three software
up-dates since. Not only can I say that
your claims were met. but that this instru-
ment is fantastic, especially for SMD cir-
cuits. In addition to this, the instruction
manual is exemplary: it is clear, well
presented and. above all. well indexed, so
that even someone of French mother-
tongue can follow it.
I am not in the habit of writing com-
plimentary letters and I would not have
written this one but that I received
Protomque .\ews on my desk this mom-
ing. This is the most informative and in-
teresting technical news sheet that I have
seen for a long time. But please allow me
to criticise it: on the back page you have
put in half a page of publicity: this is half
a page less of information! I enclose the
card asking that I be kept on your mail list.
Yours faithfully.
Name and address supplied
Editor's note: thank you for the compli-
ments—we are all blushing collectively
after reading this! We have perhaps
neglected communications in the past.
Our old instruction books, for example.
have not been perfect. Over the' past two
years or so. we have made conscious ef-
forts to improve them and we think we
have made advances in the right direction.
You are the first to have put your com-
ments on the new manual in writing, but
several customers have said that it is much
better than the old ones. Please be assured
that we also know of our other weaknesses
and we shall be making conscious efforts
to improve them, as well.D
New Year's Thoughts
As it is planned that this copy of
Prottmique VVwj be sent out in January.
it is perhaps not too late to take stock of
what has happened in 1989 and to foresee
what is likely to happen in 1990.
This past year has. for us. been a difficult
one for mainly internal reasons. Qualified
personnel is almost impossible to find in
Switzerland which has what is probably
now the lowest unemployment rate in the
world. The official figures, averaged over
the country, quote about 0.4%. Of course.
these do not take into account that there
are situations currently vacant of over 5%
of the total workforce, nearer I0<£ in and
near the major towns. In the Lausanne ag-
glomeration, where we are. there is a total
population of nearly quarter of a million.
The number actually officially un-
employed is just over one hundred, in
about thirty communes. An unofficial es-
timation places the number of temporary
and permanent jobs vacant in the region at
over 10.000. One of the local newspapers
has an average of five to six full pages per
day of advertisements for situations
vacant plus a weekly supplement of up to
48 pages! We were lucky to find a much-
needed secretary who started in Decem-
ber, but we are still badly understaffed on
both the technical and commercial sides.
All this has contributed to slowing down
our development, not helped by the extra
charge of environmental studies.
On the more cheerful, positive side.
1989 was an excellent year for us with a
very marked improvement in interest in
all our product range. Our turnover has
beaten all records. This is certainly be-
cause we have kept to the forefront of con-
tamination and cleaning technology. We
should like to thank you. our customers.
for this state of affairs by the confidence
you have expressed in us through your or-
ders.
Looking forward to 1990. we can confi-
dently state that this year will not be
without interest. We shall be introducing
some new products, two of them very
shortly. We shall lift a comer of the veil
of secrecy from the first one and we are
already in a position to talk about it. al-
though the product will not be launched
for a little while yet. It is the APL-5HS
unit. This is a module which will fit into a
standard APL-5 line for use with the new
hydrocarbon-surfactant solvents, such as
terpene mixtures and similar ones.
Laboratory tests have been very positive
and a full scale preproduction test is now
planned. The price? It may be necessary
to count up to 50<7r more than a standard
APL-5L line and running costs w ill neces-
sanl> be higher. The aclua: >.'-: ->: . ,c.::'-
mg circuit-, using this method. inciudi!'^
all running, amortisation' and product
costs, is estimated at about twice that o;
CFC-113 or ordinary 'Aater and
saponifier/water method.v but only two-
thirds that of alcohol cleaning, tor
throughputs ot'^up to 10 m",ri ot ordinary
circuits or 5 m~/h for SMD circuits. T;ck
the post card if you want more detaiNO
The other products in the pipeline are
not yet ready for announcement.
Finally, assuming it is not too late. ma\
we offer you our best w ishes for 1990' \V e
stopped sending out Greetings Card-, and
presents some eight years aao We send
the money thus saved to aid distressed
children, especially in famine areas This
does not mean that we do not otter our in-
terlocutors our best wishes. so:
"May 1990 bring every one of our
readers attthe best in '.Health.
'Prosperity and Happiness.
Telex
Important announcement
Please note that as from the end ot
March 1990. we shall no longer have
a telex machine. Please cancel our
telex number from your records.
This decision has been made be-
cause of the sharp decline in telex
communications. Over the last two
years, we have received 29 messages.
of which 16 were publicity, and we
have sent out 11. This averages out at
one real message received or sent per
month. As we pay the PTT a rental for
the line and machine of over
SFr 115.00 (S75) per month and as
virtually all our correspondents now
have fax (quicker and cheaper), we
feel that our decision is entirely jus-
tified for such a small volume of
traffic.
For those who wish to make >ure
that their records are up-to-date.
please note that we can be reached
through:
Telephone:+41 21-382334
Fax:+41 21-3824 11
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Protonique News Vol. 1. No. 2
The Ballad of the Zone of Ozone
To clean a printed circuit, oh
How life is so unfair.
It used to be so easy, till
We found the ozone layer!
But over the Antarctic land,
A hole did find its way,
Away up in the stratosphere
To end the Winter day.
The men of knowledge looked so hard
To find the very cause.
Molina, Rowland and some more
Suggested Nature's laws.
The laws were thought to be a cinch:
A can of aerosol,
Refrigerator, plastic foam
And nothing more, at all.
And then amongst the CFCs
One thought of one-one-three,
But that is what is used to clean,
And we're no longer free!
In nineteen-eighty-seven year,
The men of nations met
In Montreal: they said "no more".
And this to our regret.
Then some like Wally Rubin said,
"It does not matter much,
"Because I have a better flux
"Ex-thirty-two or such."
A light-hearted look at a serious subject
This kind of flux ;'s not to clean.
For all is safe and sure.
Contamination is not (here
And high is SIR.
But MIL and DEF did not agree.
Too simple was this view,
"You have to clean, no matter what",
With solvents, far too few.
So Michael Hayes in Florida
: Distilled some orange peel,
And EC-seven was the way,
Or so some people feel.
\ Bill Konyon, speaking for Du Pont,
An answer did release.
, He felt the future must rely
I OnhisHCFCs.
' And Colin Lea in NPL
i On his white charger rode.
; In "Circuit World" he wrote a lot
' Of papers a la mode.
• in EPA, Steve Andersen
• For UNEP started work.
• His committee did further go
' And stopped us with a jerk.
They said that things like one-one-one
' Trichbroethane were
Not the answer any more.
i To dean the upper air.
The Germans said that alcohol.
It was the only way.
But this is how they make the scrtpaoos
They drink up ev'ry day,
So, what is left to save the day7
Well, water does lust that.
To clean both rosin and OA.
It seems to be just pat.
And what about the ozone layer7
Let's not forget it's there.
If we act sharp and hit the gas.
We might just clean the air
But it will take some hundred years.
Before the stratosphere
Begins to get its ozone back.
And this will cost us dear
Now let us draw a moral from
This poem, full of wit: ,
That future cleaning does not land
Us truly in the mud'.
*(If they can find a better one,
are asked to improve on the last
but no prizes are offered for
one.)
The Montreal Protocol? No problem!
Clean your conventional and SM assemblies with water, the
only non-polluting solvent
The new Protonique
APL-5SMD line is in th
tradition which has mat
our aqueous cleaners
and dryers known
throughout the world <
the best!
Brief Specification*:
Typical practical throughput (SMD) 3-6m"h
Typical practical throughput (conventional) 5-20 m'/h
Typical Contaminometer™ CM-4 readings:
under SM devices <0.8ug/cm'eg. NaCI
general surface contamination <0.4ug/cm' eq. NaCI
Typical Insulohmeter™ IRMA-1 readings
under SM devices 1 hr after cleaning >10'6Cl/_
idem,at40°C. 95%RH >10'SQ'_
Typical Ol water consumption 4-8 I/m'
Typical electricity consumption 800 Wh/mJ
Typical saponifier injection loptionall lOO-SOOcm'm'
Typical rinse water isopropanol miection (optionall .. 200-400 cm1 m'
The above are indicative under average conditions, without obligation
Protonique S
P.O. Box 78
CH-1032 Romane!-sur-Laus
Telephone: +4121-3823:
Telex: 454144 PRTN CH
Telefax: +4121-382411
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