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

-------
                                     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.

-------
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.

-------
                              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.

-------
       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:

-------
       •     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

-------
 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.

-------
                   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.

-------
                          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

-------
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

-------
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)

-------
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:

-------
                               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

-------
                               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

-------
                              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

-------
                               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

-------
                              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

-------
                              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

-------
                              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

-------
                               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

-------
                                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

-------
                               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

-------
PRESENTATIONS

-------
PROPOSAL FOR A UNIFIED APPROACH
                Stephen O. Andersen




         Chief, Technology and Economics Branch




              Office of Air and Radiation




          U.S. Environmental Protection Agency

-------
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

-------
        National Experts
Excellent technical skills
Experience in adapting technology to
local conditions
Better able to improvise and fabricate

-------
  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

-------
   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

-------
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

-------
GLOBAL ENVIRONMENTAL PROBLEMS
          POLICY IN MEXICO
             Mr. Sergio Reyes-Lujan

             Undersecretary for Ecology

       Secretaria de Ecologia y Desarrollo Urbano

-------
(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

-------
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

-------
   I. INTRODUCTION






 
-------
 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

-------
 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.




 
-------
 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.

-------
          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.




 
-------
 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.









-------
 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

-------
 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

-------
(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

-------
THE  VIENNA   CONVENTION  AND   THE  MONTREAL   PROTOCOL
REPRESENT A  PATTERN  THAT  CAN BE  USED FOR  A  WORLDWIDE
CONVENTION ON GLOBAL CLIMATE CHANGE.
                      14

-------
s eouE
      GLOBAL ENUIRONMENTAL PROBLEMS
           POLICV IN MEXICO

-------
                    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

-------
                           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

-------
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

-------
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

-------
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

-------
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

-------
               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

-------
       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

-------
         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

-------
              Exhibit 2
1986 PRODUCTION OF HALONS AND CFCs
          Weighted By ODP
     CFCs
                            Halons

-------
                     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

-------
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.

-------
           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)

-------
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

-------
                                                                  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.

-------
                                                                        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

-------
                                                                  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

-------
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

-------
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.

-------
"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

-------
                                             -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

-------
                                            -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...)

-------
                                            -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)

-------
                              - 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

-------
                                           - 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.

-------
                                     -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?

-------
                                            -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?  	

-------
                                           - 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

-------
                                            - 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.

-------
                                             - 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 (	)

-------
                                            - 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.

-------
                                                      - 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 .

-------
                                            - 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

-------
                                                   -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

-------
 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

-------
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
                                                D-3

-------
This page is blank.
                                                D-4

-------
 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

-------
 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

-------
  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

-------
 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.
                                                 7-5

-------
This page is blank.
                                                  1-6

-------
 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

-------
  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

-------
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

-------
                                                        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

-------
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.

-------
                                    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.

-------
                                    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.

-------
                                    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

-------
                                    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.

-------
                                    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

-------
                                    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.

-------
                                    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

-------
                                    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.

-------
                                    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.

-------
                                    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.

-------
                                    23
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).

-------
                                    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.

-------
                                    25
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

-------
                                    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.

-------
                                    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.

-------
                                    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

-------
                                    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.

-------
                                      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.

-------
                                    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

-------
                                    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

-------
                                    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.

-------
                                        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

-------
                                    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.

-------
                                    36
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.

-------
                                    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.

-------
                                    38
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.

-------
                                    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.

-------
                                    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.

-------
                                    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

-------
                                    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

-------