EPA-600/2-91-056
September 1991
MANUAL FOR NON-CFC AEROSOL PACKAGING:
CONVERSION FROM CFC TO
HYDROCARBON PROPELLANTS
Final Report
by
K.M. Adams
K.E. Hi lining 1
T.P. Nelson
S.L. Wevi.ll
Radian Corporation
P.O. Box 201088
Austin, TX 78720-1088
EPA Contract No. 68-D0-0125
Work Assignment No. 8
EPA Project Officer
N. Dean Smith
Air ind Energy Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
-------
NOTICE
This document has been reviewed in accordance with
U.S. Environmental Protection Agency policy and
approved for publication. Mention of trade names
or commercial products does not constitute endorse-
ment or recommendation for use.
ii
-------
ABSTRACT
Because stratospheric ozone provides protection from biologically
damaging ultraviolet-B radiation, and because chlorofluorocarbons
(CFCs) have been strongly implicated in the thinning of the
Earth's stratospheric ozone layer, there is an urgent need to
eliminate production and use of the CFCs. In the United States,
CFCs were banned for use as propellants from nearly all aerosol
products as early as 1978. In place of the CFC propellants,
liquified hydrocarbons such as propane, n-butane, and isobutane
were found to be acceptable substitutes for the majority of
aerosol products. This report is intended to provide technical
assistance to aerosol product marketers and fillers in other
nations now faced with eliminating CFCs under the terms of the
Montreal Protocol. The report addresses the issues of hydrocarbon
propellant supply, product refonr.ulation, equipment conversion,
and safety concerns for both the manufacturing plants and the
aerosol products themselves.
i i i
-------
CONTENTS
Abstract iii
1. Introduction 1
Background 1
Conversion to Hydrocarbons 1
Organization of the Manual A
2. Availability of Hydrocarbon Propellants 5
Propellant Characteristics and Physical Properties ... 5
LPG and Propellant Sources 7
Purification Processes 17
Importing Propellants 22
3. Safety When Using Hydrocarbon Propellants 23
General Safety 23
Other Engineering Safety Measures 26
Other Safety Aspects 28
Labeling Requirements and Flajmnability Testing 29
4. Equipment Conversion of Hydrocarbon Filling Operations .... 33
Automated Filling Lines 33
Manual Filling Lines 42
5. Product Storage for Distribution and Sale 51
Classification of Aerosol Products 51
NFPA 30B: Code for the Manufacture and Storage of
Aerosol Products (1990) 53
6. Product Reformulation 69
Formulations 69
Generic Guidelines and Factors that Affect
Formulations 71
Can/Sprayer Choices 78
References 80
Appendix A - Industry Experts A-l
Appendix B - Sample Calculations B-l
Appendix C - Safety Checklist for Aerosol Plants Using Hydrocarbon
Propellants C-l
Appendix D - Reference Ordering Information D-l
Appendix E - Federal Register Methods for Flame Testing E-l
Appendix F - Hydrocarbon Guide F-l
Appendix G - Metric (SI) Conversion Factors G-l
Appendix H - Aerosol Formulations H-l
i v
-------
FIGURES
Number Page
1 World exports of refined LPG (1988) 13
2 Distillation train 14
3 Purification train 20
4 Automated aerosol filling line 34
5 Recommended hydrocarbon storage tank distances 37
6 Potential existing gassing room locations for automated
filling lines 39
7 Example of an open-air gassing area 41
8 Example of a manual filling line 45
9 Hydrocarbon storage for manual filling lines 47
10 "Decision tree" for determining aerosol product level number .... 54
V
-------
TABLES
Nnrahor Page
1 Physical Properties of CFC and Hydrocarbon Propellants 6
2 List of LPG and NGL Fractionation Plants Operating or Under
Construction in Non-Comunist Countries 8
3 Raw Plant Feed and Field Grade Analyses (Weight Percent) 11
4 U.S. Gas Processors Association LPG Specifications 12
5 Approximate Composition of Several Hydrocarbon Propellant Blends . . IS
6 Specifications for Aerosol Grade Hydrocarbon Propellants 16
7 Merits of Several LPG Treating Processes 19
B NFPA Codes Relevant to Aerosol Production, Storage, and
Distribution 24
9 Automatic Production Filling Line Equipment 35
10 Purchased Equipment Cost for Various Electrical Hardware
(General Purpose Vs. Explosion Proof) 43
11 Small Manual Production Filling Line Equipment List 46
12 Fume Hood Minimum Air Flow Requirements 50
13 Classification of Aerosol Products 52
14 Examples of Level 1 Aerosol Products 56
15 Examples of Level 2 Aerosol Products 57
16 Examples of Level 3 Aerosol Products 58
17 Arrangement and Protection of Palletized and Solid-Pile Level 2
Aerosol Storage 59
18 Arrangement and Protection of Palletized and Solid-Pile Level 3
Aerosol Storage 60
19 ESFR Arrangement and Protection of Level 2 Rack Storage 61
20 ESFR Arrangement and Protection of Level 3 Rack Storage 62
VI
-------
TABLES (Continued)
Niimhgr Page
21 ProtecCion of Rack Storage of Level 2 Aerosols with Standard
Spray Sprinklers 63
22 Protection of Rack Storage of Level 3 Aerosols with Standard
Spray Sprinklers 64
23 Dispersancy Characteristics of Various Propellants
(In order of Vapor Volune in mL/g) 72
vi i
-------
SECTION 1
INTRODUCTION
BACKGROUND
Recent concern about depletion of the stratospheric ozone layer has
focused on synthetic chemicals known as chlorofluorocarbons (CFCs). These
compounds have been used for many years in many products because of their
desirable properties: CFCs are nonflammable, relatively nontoxic, and
inexpensive. Historically, most CFCs have been used in refrigerants, sol-
vents, blowing agents, insulating gases, and aerosol propellants. Scientists
have concluded, however, that destruction of the ozone layer by CFCs will
allow too much harmful ultraviolet radiation to reach the Earth's surface,
with potentially catastrophic results. The most serious consequences include
a higher incidence of skin cancer and cataracts, suppression of the human
immune system, damage to plant and animal life, and global warming.
In response to these concerns, countries around the world have agreed to
phase out the production of CFCs by the year 2000. The Montreal Protocol,
drafted under the auspices of the United Nations Environment Programme (UNEP),
has been ratified as of October 1990 by 68 countries and the European Economic
Community (EEC) (1). Work is now underway to find substitutes and alterna-
tives to replace CFCs, as well as to decrease CFC emissions in those areas for
which substitutes are currently unavailable.
CONVERSION TO HYDROCARBONS
Many options exist for replacing the CFC-propelled aerosol package. This
manual does not try to discuss the strengths and weaknesses of the many
potential options. A brief list of these options, however, follows:
• Hydrocarbon propellants. Hydrocarbon propellants are primarily
mixtures (or pure components) of butane and propane, along with
1
-------
pentane and, to a much lesser extent, ethane. Advantages of
hydrocarbon propellants Include the fact that they can be treated
and blended to obtain the physical and chemical properties that
make them suitable aerosol propellants; most hydrocarbons are
essentially nontoxic, making them suitable for use in a variety of
personal care and household products; hydrocarbon propellants are
less expensive than CFCs, enabling manufacturers to produce
aerosols at a lover unit cost; and hydrocarbons are compatible
with properly selected container materials and formulations, thus
preserving shelf life and product stability. Disadvantages are
that hydrocarbon propellants are flammable and therefore require
special precautions by producers, distributors, and end-users; and
they are VOCs, and thus contribute to smog formation. In some
urban areas where smog formation is a health and environmental
problem, regulations have been proposed to reduce the amounts of
VOCs in consumer products. Since the banning of CFC aerosol
propellants, hydrocarbons have become the dominant aerosol propel-
lant in many developed and developing countries, and useful
experience is available that can minimize the conversion cost for
other countries.
Other liquified gas propellants, such as dimethyl ether (DME).
DME is widely used in European and Japanese products. The
advantages of DME include solvency and ease of reformulation to
water-based products. Disadvantages include its flammability:
filling lines and storage facilities must be designed to safely
use flammable gas. Also, DME is a volatile organic compound (VOC)
which is a smog precursor. Finally, DME is more expensive than
the aerosol-grade hydrocarbons.
Compressed gas propellants such as carbon dioxide, nitrous oxide,
and nitrogen. These account for approximately 5 to 10% of aerosol
fillings in the U.S. The advantages of compressed gas propellants
are low cost and insensitivity to low temperatures, which is
important for refrigerated whipped toppings and automotive
2
-------
products, such as engine scarcer spray and windshield de-icer,
used in cold veaCher. The primary disadvantages of these propel-
lanCs are the deterloraclon of spray pattern as the product is
used, the limited reservoir of propellant, and the need for
specially designed filling equipment (impact gassing, or satura-
tion tower).
Hydrochlorofluorocarbons (HCFCs) such as HCFC-22, HCFC-123, or
HCFC-142b. These compounds, some of which are nonflammable,
contribute substantially less to ozone depletion and do not
contribute to ground-level smog formation. These propellants are
being used in developed countries to a limited extent. Their main
limitation is h igh cost. HCFC-22 and HCFC-142b are already
available; however, some of these compounds are difficult to
synthesize and are only now beginning to enter commercial produc-
tion. In June 1990, the parties to the Montreal Protocol met in
London to discuss further restrictions on CFCs. The London
Amendments included a non-binding declaration that HCFCs should
only be used as temporary substitutes for fully halogenated CFCs,
and that all countries should voluntarily phase out HCFC produc-
tion between 2020 and 2040.
Hydrofluorocarbons (HFCs) such as HFC-152a and HFC-134a. These
compounds, some of which are nonflammable, do not contribute to
ozone depletion because they do not contain any chlorine and do
not contribute to ground-level smog formation. These propellants
are being used in developed countries to a limited extent.
Non-aerosol packaging such as mechanical finger pumps, trigger
sprayers, or other alternative packaging. Some of these products
compete side-by-side with aerosol products. In many instances,
this simple packaging is widely preferred by consumers because of
its ease of use, economy, and ecological advantage, regarding
destruction of stratospheric ozone.
3
-------
If manufacturers choose to continue to use aerosol dispensers instead of
non-aerosol alternatives, hydrocarbon propellants are the most feasible near-
term alternative to CFC aerosol propellants. This manual provides manufac-
turers of CFC aerosol products with the technical information that will enable
them to convert from CFC propellants to hydrocarbon propellants.
ORGANIZATION OF THE MANUAL
This manual is divided into six sections. Section 1 is the Introduction.
Section 2 discusses the availability of hydrocarbon propellants, and includes
subsections on their physical properties, raw material supply, processing
required to remove objectionable odors, and importing. Section 3 covers
safety issues, including a discussion of the applicable codes for the safe
storage of hydrocarbon gases. Section 4 presents a description of the
required equipment modifications and estimated costs for converting a filling
line to hydrocarbons. Section 5 briefly describes the requirements for safely
storing aerosol products in warehouses or distribution centers. Section 6
discusses the process of reformulating aerosols to use hydrocarbon propel-
lants. Finally, the appendices contain A) a list of aerosol industry experts,
B) sample calculations for LPG purification, C) a safety checklist for using
hydrocarbon propellants, D) reference ordering information, E) the U.S.
Federal Register methods for flame testing, F) a hydrocarbon guide, G) metric
conversion factors, and H) approximately 70 formulations of aerosol products
that predominantly use hydrocarbon propellants.
U
-------
SECTION 2
AVAILABILITY OF HYDROCARBON PROPELLANTS
PROPELLANT CHARACTERISTICS AND PHYSICAL PROPERTIES
A replacement aerosol propellant must have the properties chat allow an
aerosol package to function: 1) the propellant must provide the pressure to
expel the product from the container; 2) the propellant may serve as a solvent
to help keep the active ingredients in solution; and 3) the propellant must
vaporize after leaving the container, producing a spray or foam. Other
important properties of aerosol propellants are toxicity, stability, density,
and flammability (2). Table 1 compares the properties of the most common CFC
propellants (CFC-11 and CFC-12) and the hydrocarbon propellants (isobutane,
n-butane, and propane).
Either liquified gas or compressed gas propellants can provide pressure
to expel product from the container. Hydrocarbon and CFC aerosol propellants
are both liquified eases. Throughout the life of the aerosol product, they
generally provide a uniform internal pressure. This is possible because the
liquid propellant acts as a "reservoir" of gas to maintain the pressure in the
headspace even as the headspace volume increases. With a compressed gas
propellant, the pressure will drop as the product is used (2).
The solubility of the propellant is important, since it determines
whether the overall contents are uniformly blended ("homogeneous") or whether
the contents exist in separate phases ("heterogeneous"). The hydrocarbon
compounds are all nonpolar, which renders them insoluble with many polar
solvents (including water). However, in some cases, co-solvents such as
ethanol can be used to provide single-phase blends of hydrocarbons, alcohol,
and water (3). Some heterogeneous hydrocarbon-propelled aerosols require
shaking before use (to generate a temporary emulsion that becomes a spray or
foam on discharge). Other hydrocarbon-propelled aerosols are anhydrous
5
-------
TABLE 1. PHYSICAL PROPERTIES OF CFC AND HYDROCARBON PROPELLANTS
Name
Vapor
Molecular Pressure Specific
Formula Weight Q21°C (kPa) Gravity
Solublllty StabllIty
In Water (g/L per Tear)
(Kauri- Toxicity (v/steel 30®C,
Butanol) (TLV) 101.3 kPa)
FlanmabLlLty
(explosive range)
CFC-11
CC1,F 137.4
89
1.476 60
1000
10
Nonf laninable
CFC-12
CCl.F, 120.9
586
1.311 18
1000
0.8
Nonf laamable
Propane CjH, 44.1
855
0.5077 15.2
1000
Flamable
(2.18 - 9.5 vol I)
Iiobutane C«H 1Q 58.1
317
0.5631 17.5 800 (est.)
Flammable
(1.86 - 8.5 vol Z)
0.5844 19.5
600
Flamnabl*
(1.86 - 8.5 vol Z)
Source:
(2.3)
-------
(containing no water) and may be homogeneous. Finally, surface-active agents
can be added to provide stability to the blend (2).
The toxicity of propellants may be compared by using the threshold limit
value (TLV, a trademark of the American Conference of Governmental Industrial
Hygier.ists--ACGIH) . The TLV is the maximum level that a person working 8
hours a day, 40 hours a week throughout a normal working career can be exposed
to a given compound without incurring adverse health effects. Table 1 shows
occupational exposure guidelines for CFC-11, CFC-12, and hydrocarbon propel-
lants; they are roughly comparable. A TLV* of 1000 ppm is the highest value
listed by ACGIH (lowest toxicity).
The corrosion properties of propellants may be compared by testing their
hydrolytic stability. These tests measure the rate of hydrolysis (decomposi-
tion) in the presence of a steel test coupon in water (grams hydrolyzed per
liter of water per year). As seen in Table 1, the two CFCs are less stable
than the pure hydrocarbons. Contaminants in "field-grade" hydrocarbons,
however (e.g., water, and sulfur compounds), may have a major effect on
corrosion. Hydrocarbon propellant purification will be discussed in a later
subsection.
No discussion of the properties of hydrocarbons would be complete
without considering flammabilltv. The flammability of an aerosol spray is a
combined function of the composition of the product inside the container and
of the design of the valve (4). Frequently, other major ingredients of the
formula (e.g., alcohols or petroleum distillates) are also flammable (3). A
more detailed discussion of aerosol safety appears in Section 3.
LPG AND PROPELLANT SOURCES
Hydrocarbon propellants are derived from liquified petroleum gases
(LPG). LPG comes from the ground as a constituent of wet natural gas or crude
oil or as a by-product of petroleum refining (5). Table 2 lists the LPG or
natural gas liquids (NGL) plants currently operating or under construction in
non-communist countries outside of the U.S. as of 1989 (6,7,8). In areas
where LPG may be in short supply, processes are available to hydrocrack
7
-------
TABLE 2. LIST OF LPG AND NGL FRACTIONATION PLANTS OPERATING OR UNDER CONSTRUCTION
IN NON-COMMUNIST COUNTRIES
Future LPG Plants
Current LPG Plants (Planned or Under
Construction)
Country
Raw NGL or
Current
LPG/NGL
Future
LP-Gas Mix
Fractionation
Total
Recovery
Fractionation
Total
Algeria
2
0
2
0
0
0
Argentina
0
5
5
2
0
2
Australla
1
3
4
0
0
0
Austria
1
1
0
0
0
Bahrain
0
1
1
1
0
1
Bolivia
1
1
2
0
0
0
Brazil
10
10
0
0
0
Brunei
0
1
1
0
0
0
Canada
117
47*
164
1
1
2
Chile
0
2
2
0
0
0
Columbia
3
2
5
1
0
1
Ecuador
2
0
2
1
0
1
Egypt
6
0
6
3
0
3
France
0
1
1
0
0
0
Greece
1
0
1
0
0
0
Hungary
3
2
5
0
0
0
India
15
0
15
4
0
4
Indonesia
5
2
7
2
0
2
Iran
0
0
0
2
0
2
Italy
1
0
1
0
0
0
Kuwa1t
0
3*
3
0
0
0
Libya
3
0
3
1
0
1
Malaysia
0
2
2
0
0
0
Mexico
10 C?.
0
0
0
0
0
(Continued)
-------
TABLE 2. (Continued)
Future LPG Plants
Current LPG Plants (Planned or Under
Construction)
Country
Raw NGL or
LP-Gas Mix
Fractionation
Current
Total
LPG/NGL
Recovery
Fractionation
Future
Total
New Zealand
1
1
2
0
0
0
Norway
1
1
2
0
0
0
Oman
3
1*
4
0
0
0
Pakistan
1
0
1
0
0
0
Peru
0
1
1
0
2
2
Qatar
0
2
2
1
0
1
Saudi Arabia
1
3
1
0
0
0
Sharjah
0
1
1
0
0
0
Taiwan
1
2
3
0
0
0
Thailand
2
0
2
1
0
1
United Kingdom
1
2
2
1
0
1
Venezuela
9
5*
14
0
0
0
* Numbers include transfers from other plants.
Source: Reference (6,7,8).
-------
heavier naphthas to propane and butane [e.g., the LPG Unibon® process licensed
by UOP (Des Plaines, IL)]. LPG usually refers to a mixture of propane and
butane, although other hydrocarbons may also be present (ethane at the light
end and pentanes at the heavy end). Table 3 shows the plant feed and "Field
Grade" analyses for one Canadian gas plant (3). Table 4 presents the U.S. Gas
Processors Association specifications for the LPG products: commercial
propane, butane, and butane-propane mixtures (9). LPG is generally in high
demand because of its use as a feedstock for petrochemical plants or refiner-
ies. The feedstock use of LPG is divided between a portion sent to cracking
furnaces to produce ethylene (some of which ultimately ends up as polyethylene
plastic) and a portion further distilled to separate propane from butanes (the
butanes are later isomerized to isobutane which is reacted to make a high-
octane alkylate gasoline blending component). One of the popular technologies
for the isomerization of n-butane to isobutane is the Butamer* process
[licensed by UOP (10)]. LPG is also sold as a fuel for heating (industrial,
commercial, and residential), and for direct motor fuel in special applica-
tions (5). Figure 1 is a chart showing world exports of LPG in. 1988.
The amount of LPG used for aerosol propellants is very small (less than
0.1 percent in the U.S. in 1981) (3). Aerosol grade hydrocarbon propellants
are prepared by first distilling the LPG to separate the various species.
Distillation separates the components of a solution using repeated vaporiza-
tion and condensation (13). The degree of separation is essentially limited
by the amount of heat energy that must be supplied. Figure 2 is a schematic
diagram of a distillation system to separate propane and butane (depropanizer)
followed by separation of the isobutane from normal butane (Cfc splitter).
Hydrocarbon propellant blends of varying vapor pressure are formulated as
shown in Table 5 (14), and the specifications for aerosol grade hydrocarbons
from several U.S. vendors are listed in Table 6 (3). The distillation of
hydrocarbon propellant is normally carried out at a specially designed plant
that serves the regional aerosol industry. These plants are generally quite
sophisticated and would be too large for any single aerosol filler.
Some aerosol products may use the so-called "natural blend" LPG instead
of distilled hydrocarbons. According to one source, natural blend LPG,
obtained by a coarse distillation of natural gas liquids (de-ethanized and
-------
TABLE 3. RAW PLANT
FEED AND
FIELD GRADE ANALYSES (WEIGHT
PERCENT)
Ingredients
Plant
Feed
Field Grade
Propane
Field Grade
Isobutane
Field Grade
Normal
Butane
Methane
0.05
0.1
0.01
0.01
Ethane
1.7
2.9
0.03
0.02
Propane
50.3
94.9
2.4
0.4
Isobutane
9.8
2.0
96.2
1.9
n-Butane
17.3
0.1
1.3
96.0
Isopentane
5.0
0
0.05
1.9
n-Pentane
4,6
0
0.03
0.2
Hexanes, etc.
11.3
0
0
0
Unsaturated Hydrocarbons
0.03
0
0
0
Sulfur Compounds
trace
trace
trace
trace
Water
trace
trace
trace
trace
Typical month, at Dome Petroleum Ltd. Sarnia, Canada.
Source: Reference (3)
11
-------
TABLE 4. U.S. GAS PROCESSORS ASSOCIATION LPG SPECIFICATIONS
Product Characteristics
Cocnraerc i el
Propane
CoBoarcial
Butane
CCxuAfl r C 1 S 1
8"P Mi*tursa
Composition
Vapor Freaaura at 38*C, kPa max.
Volatile Residuar
max. temperature at 95J evaporation
butane and heavier, liquid volume pttcmt ¦
pantana and heavier, liquid voltaae parent
Residual matter:
residue on evaporation of 100 ml, n
-------
Rest of world
12.
Netherlands 2.1%
United Kingdom 2
Indonesia 2.1%
Venezuela 2.6%
Mexico
3.3%
United States
4.6%
Kuwait
6.8%
Saudi Arabia
36.2%
Algeria
10.3%
Other Middle East*
16.2%
% of Total World Exports
* Includes United Arab Emirates, Bahrain, Qatar, Iran, Iraq
Figure 1. World exports of refined LPG (1988)
Source: Reference (12)
13
-------
C4 SPLITTER
COLUMN Condenser
DEPROPAN1ZER
COLUMN
Pressure
Overheads
Accumulator
Overheads
Accumulator
Reflux
Pump
Propane
LPG
Mixed
Feed
Reflux
Pump
ReboUer
Pump
Bottoms Pump
Figure 2. Distillation train.
-------
TABLE 5. APPROXIMATE COMPOSITION OF SEVERAL HYDROCARBON PROPELLANT BLENDS
Composition
Propellant Name9
Pressure at 21#C (kPa)
Compound
Ueight %
A-31
315
Isobutane
100
A-AO
377
Propane
10
Isobutane
90
A-46
418
Propane
16
Isobutane
84
BIP-55
480
Propane
32
Isobutane
27
n-Butane
39
Pentane
3
A-60
515
Propane
32
Isobutane
66
n-Butane
2
A- 70
584
Propane
43
Isobutane
57
A- 85
689
Propane
63
Isobutane
37
A-108
648
Propane
100
""A" type designations are trademark of Phillips Petroleum Company.
Source: Adapted from Reference (14).
15
-------
TABLE 6.
SPECIFICATIONS FOR
AEROSOL
GRADE HYDROCARBON
PROPELLANTS
Aeropres
Diversi fied
Phi 11 ids
Property
Propane
Isobutane n-But arte
Propane
Isobutane
n-Butane
Propane Isobutane
n-Butane
Purity-Ut. X
(mini nun)
95
95
95
Purity-Nol. X
(mininun)
95
95 95
98 95
97
Pressure (kPa)
21.1-C (70°F)
38°C (100°F)
54°C (130°F)
859
315 218
846
1287
1873
315
508
770
218
356
563
846 315
218
Initial Boiling
Point (*C)
-43
-12.7
-2.2
Dry Point CC)
-41
-9.4
0.5
Flash Point (°C)
-104
-83
-74
Specific Gravity
of Liquid
(15°C)
0.508
0.563
0.584
Moisture (ppn)
(max i nun)
25
25 25
<5
<5
<5
Sulfur (ppn)
(maxinun)
5
5 5
<1
<1
<1
5 5
5
Unsaturates (ppn)
(maxinun)
10
10 10
Residue (0/100 ml)
(maxinun)
0.0005
0.0005 0.0005
0
0
0
0.0005 0.0005
0.0005
Total Saturated
Compounds (wX)
>99.9
>99.9
>99.9
>99.9 >99.9
>99.9
Acidity of Residue
Neut.
Neut. Neut.
Neut. Neut.
Neut.
Odor (Panel)
Pass
Pass Pass
Pass
Pass
Pass
Pass Pass
Pass
Source: Reference (3).
-------
partially depropanized), may typically have a composition of approximately 60%
n-butane, 20% isobutane, and 20% propane (14). Its primary advantage is that
it is less expensive because there is less processing of the hydrocarbon. The
natural blend propellant is suitable in products where odor is not as important
(where the concentrate itself is quite odorous as in some degreasers or spray
paints) or where the spray characteristics are not critical (such as wet sprays
in some residual insecticides). A disadvantage of natural blend hydrocarbon
propellant is that the quality varies resulting in inconsistent pressure.
Because the natural blend is produced by a coarse distillation, the amount of
propane, butane, and pentanes may differ from one lot to the next, and this
will affect the spray pattern of the finished product. For example, low
pressure, due to there being too little propane component, could theoretically
be adjusted by the filler at the point of manufacture. However, this would
require either a separate gassing step to adjust the pressure or propellant
blending facilities.
Natural blend hydrocarbon propellants are likely to contain larger
quantities of impurities (such as water, sulfurous compounds, olefins, or
reactive particulates). For example, the water content in commercial propane
is typically 350 parts per million weight (ppmw) or less (equivalent to a dew
point of -26°C) (15). This is much higher than the water content of aerosol
grade hydrocarbon propellant, which Table 6 shows to be between 5 ppmw and 25
ppmw (equivalent to dew points of -54 to -66°C). The presence of water can be
tolerated in water-based products, but not in products intended to be an-
hydrous. The removal of these impurities is discussed in the following
section.
PURIFICATION PROCESSES
Some types of aerosol products require a purer hydrocarbon propellant
than other types. The most demanding aerosol products are aerosol perfumes and
fragrances. Other products which require a highly refined hydrocarbon propel-
lant include personal care products, food products, medicinal or pharmaceutical
products, some household products, certain paints and coating sprays, and
certain automotive and industrial sprays.
17
-------
Before the propane and butanes are suitable for these aerosol propellant
applications, they must be purified further to remove odorous and reactive
compounds such as unsaturated hydrocarbons (for example, 1-butylene or propyl-
ene), as well as sulfur compounds and water (3). The processes used Include:
• Dehydration (for removing moisture);
¦ Acid gas removal (for removing sulfur compounds); and
• Sulfuric acid treatment or desiccant treatment (to remove unsatu-
rated compounds).
Purification of the hydrocarbon propellant is proprietary, since each producer
may havfe unique processing techniques. The processes selected depend on the
level of contamination and on the scale of processing. Table 7 presents the
relative merits of various processes employed in large-scale LPG purification
(9). Contacts with industry experts and limited published data suggest that
the most common type of hydrocarbon propellant purification is the solid
adsorbent process. The remaining processes listed in Table 7 are certainly
applicable to the refinery, petrochemical, and gas processing industries, but
it is unclear to what extent they are appropriate for hydrocarbon propellant
purification. The following discussion will therefore focus on the use of
various adsorbents for LPG purification. A schematic of an on-site propellant
purification process installed at a large (15-million-unit-per-year) aerosol
production plant in Egypt (16) is shown in Figure 3.
The solid adsorbent process can involve the use of such materials as
silica gel, activated aluminas, or molecular sieve adsorbents for water or
sulfur compounds (dehydration and acid gas removal). Unsaturated compounds can
be removed using activated carbon or molecular sieves. The process shown in
Figure 3 is a nonregenerable system, and could be appropriate for a large
filling plant with a hydrocarbon propellant supply of variable quality. The
disadvantage of this type of plant, however, is that the adsorbent must be
periodically replaced. Once the adsorbent becomes saturated, the impurities
will no longer be removed, and contaminated propellant will enter the system.
18
-------
TABLE 7. MERITS OF SEVERAL LPG TREATING PROCESSES
1. Molecular Steves Treating
A. Can handle large or small streams with equal facility.
B. Reduces total sulfur content by removing hydrogen sulfide,
mercaptans, or other organic sulfur in the same adsorber vessel.
C. Will produce copper-strip, doctor sweet productab.
D. Will dry in the same step without additional equipment.
E. Requires that plant fuel supply be made slightly sour by use of
this stream to strip sulfur compounds from the molecular sieve.
(Only applies if regenerated on site.)
2 . Regenerative Caustic (10% NaOH in Packed Column')
A. Handles a large volume of hydrocarbon.
B. Primarily for removing methyl and ethyl mercaptans.
C. Capable of producing a "doctor sweet" product*.
D. Reduces the total sulfur content of treated product.
3. Solid Potassium Hydroxide Treatment
A, Low installation and operating costs.
B. Acts as a desiccant as well as removing the sulfur compounds.
U. Merox* Treating'
A. Can handle large or small streams with equal facility.
B. Eliminates problem of disposing of spent phenolic caustic.
C. Product is sweet when it leaves unit; no holding period is
required.
D. Adds problem of sulfur compounds from regenerated air leaving the
regenerator.
""Copper-strip" refers to ASTM Test Method D1838 to test for corrosion by LPG.
b"Doctor sweet" refers to a low-sulfur content, as measured by the Doctor Test
for sulfur using sodium plumbite.
cMerox® is a trademark of UOP (Des Plaines, IL).
Source: Reference (9).
19
-------
ho
O
©—
Transfer
Pump
< r
From Crude
From Crude
LPG
Storage
Adsorber 1
770 b
Silica Gel
Adsorber 2
660b
Activated Carbon
Adsorber 3
770 b
Zeolite
Molecular Sieve
Type 13X
To Deodorized
LPG Storage
Figure 3. Purification train (16).
-------
If the "breakthrough" point is not detected promptly, the quality of the
aerosol propellant would be jeopardized.
Appendix B contains example calculations for a dehydration/desulfuriza-
tion system using two nonregenerable beds for the purification of LPG. The
example case is for a large-size automated filling plant producing 10 million
cans per year. These calculations include several "worst-case" assumptions
that may not hold true in many cases (i.e., saturated water content and greater
than 90 ppmv H2S content), but they nevertheless suggest that annual costs for
adsorbent change-out could range as high as $50,000 per year (or $0,016 per kg
of LPG processed). This calculation assumes that the spent adsorbent has no
residual value and does not include the amortization of fixed equipment (such
as pumps, surge vessels, and adsorber vessels).
An alternative to on-site purification is to use a central purification
facility in conjunction with the distillation system described previously. The
central purification facility can operate with multiple adsorbent beds that can
be alternated between purification (on-line) and regeneration (off-line). This
type of system is large enough to serve for several large aerosol filling
plants. Together with a source of LPG and a distillation system, the purifica-
tion system completes the basic elements needed for a regional hydrocarbon
propellant supply.
The science of purifying hydrocarbon compounds using solid adsorbents has
been studied extensively. Purification of hydrocarbon propellants is one
specific application of this technology. Regenerable solid adsorption facili-
ties for hydrocarbon purification are commonly used in natural gas processing
plants (cryogenic type) to avoid the formation of solid hydrates. Similar
processes are often found in the pretreatment of hydrocarbon streams to avoid
catalyst poisoning in many petrochemical processes. Additional technical
information on purifying hydrocarbons with adsorbents is available from
adsorbent suppliers such as those listed in Appendix A.
21
-------
IMPORTING PROPELLENTS
Countries importing purified hydrocarbon propellant instead of producing
it from native LPG supplies can transport the hydrocarbon propellants by land
or by sea. To transport overland, the country must have a highway or railroad
system capable of handling a large tractor-trailer rig or railcar load of
propellant and the source of supply must be close enough to ship overland
directly (such as from the U.S. to Mexico). The costs of the two methods are
similar.
To ship hydrocarbon propellant by ocean, the importing country has two
options: International Organization of Standardization (ISO) Containers and
Tank Trailers. ISO containers are available in sizes up to 22,700 liters
(6,000 gallons) (water capacity); older versions were limited to roughly 17,000
liters (4,500 gallons) (water capacity). The actual shipment volume is limited
to 80% of the water capacity. These containers are fitted into specially
braced steel frames, and are rigged so that they can be stacked on a container-
ized cargo ship. Because they can be stacked Just the same as a standard 20-
foot container, they are charged a lower rate. Unloading ISO containers at the
port of entry requires "Ocean Service." A port with ocean service has large
dock cranes to transfer containers on and off the dock and ship. The ISO
container contents can either be transferred by pumping from the container into
a road tanker at the port, or the container can be transported on a low-boy
chassis trailer.
Tank trailers have a capacity of up to 37,850 liters (10,000 gallons)
(water capacity), or an effective product capacity of about 30,280 liters
(8,000 gallons). Since the tank trailer cannot be stacked and therefore takes
up more deck space, it is charged a higher rate for shipment. The tank trailer
can be driven on and off of a special cargo ship known in the trade as a "Roll-
on/Roll-off" ship. These vessels are often used for transporting automobiles,
and special ramped dock facilities are required.
Appendix A provides a list of suppliers who will export hydrocarbon
propellents.
22
-------
SECTION 3
SAFETY WHEN USING HYDROCARBON PROPELLANTS
GENERAL SAFETY
Hydrocarbon gases are used primarily as fuels. Because of their flamma-
bility, they must be handled with great care. This section focuses on the
properties of hydrocarbons that relate to potential explosion and fire hazards
and on the engineering of safe aerosol-filling operations.
In the U.S., the National Fire Protection Association (NFPA) has issued
standards for manufacturing and storing aerosol products (NFPA Code 30B,
Reference 17) and for storing and handling LPG (NFPA Code 58, Reference 18).
In addition to these codes, which relate directly to the safety of aerosol
products, there are references to many other relevant NFPA codes. Table 8
lists all the NFPA standards relevant to the handling of hydrocarbon propel-
lents (17). The NFPA Codes do not apply to aerosol products that contain a
nonflammable base product and a nonflammable propellant (for example, aerosol
whipped cream contains a water-based base product and the propellant is
nitrous oxide, which is a nonflammable). The "base product" is synonymous
with "concentrate," which consists of the active ingredients and the solvents.
NFPA Code 30B covers manufacturing, warehouse storage (both in-plant and
distribution), and the storage and display of aerosols in stores selling
aerosol products. The first topic (manufacturing) is discussed in this
section; safety issues relating to warehouse storage, sales display, and
backstock storage are covered in Section 5.
A primary focus of NFPA 30B in the manufacturing area is to ensure the
safety of propellant storage areas ("Tank Farms") and propellant gassing rooms
("Gas Houses"). Appendix C contains a safety checklist for aerosol fillers
using hydrocarbons. Safety measures include the following:
23
-------
TABLE 8. NFPA CODES RELEVANT TO AEROSOL PRODUCTION, STORAGE, AND DISTRIBUTION
2.
Primary Codes :
NFPA 3QB-190O
NTPA 56-1089
HTPA 70-1990
Manufacture md Storage of Aaroaol Producta
Standard for the Storage and Handling of Liquaflad Petroleum Gases
National Electrical Coda (Esp. Articles S00 and SOI)
Additional Fire Protection Codes:
NFPA 10-1990
NFPA 11-19BB
NFPA 1U-1988
HTPA 12-1989
NFPA 12A-19B9
NFPA 1ZB-1990
HFPA 13-19B9
NFPA 14-1990
NFPA 16-1986
NFPA 16A-1988
NFPA 17-1990
NFPA 20-1990
NFPA 22-1987
NFPA 2*-1987
NFPA 30-1990
NFPA 31-1987
NFPA *5-1986
NFPA 54-1988
NFPA 69-1986
NFPA 72-1990
NFPA 72E-1S90
NFPA 80-19S0
NFPA 90A-1989
HFPA 101-1988
NFPA 231-1990
NFPA 231C-19B6
HFPA 505-1987
NFPA 1221-198B
Standard for Portable Plre Extinguiehers
Standard for Low Expansion Foam and Combined Agent Systems
Standard for M*dlt» and Sigh Expanaion Foaa Systems
Standard cm Carbon Dioxide Extinguishing Systems
Standard on Balon 1301 Flra Extinguishing Systems
Standard on Balon 1211 Fire Extinguishing Systems
Standard for the Installation at Sprinkler Systems
Standard for the Installation of Standplpe and Boss Systems
Standard on Deluge Foaa-Uatar Sprinkler and Foam-Water Spray Systems
Recoanended Practice for tha Installation of Closed-Bead Foam-Hater
Sprinkler Systems
Standard for Dry Chemical Extinguishing Systems
Standard for the Installation of Centrifugal Fire Pumps
Standard for Hater Tanks for Private Fire Protection
Standard for the Installation of Private Flra Service Haina and Their
Appurtenancee
riamneble and Combustible Liquids Code
Standerd for the Installation of Oil Burning Equipment
Standard on Fire Protection for Laboratories Using Chemicals
National Fuel Gas Code
Standard on Explosion Prevention Systems
Standard for the Instellatlon, Maintenance, and Use of Protective Signaling
Systems
Standard on Automatic Fire Detectors
Standard for Fire Doors and Windows
Standard far the Installation of Air Conditioning and Ventilating Systems
Life Safety Code
Standerd for General Storage
Standerd for Rack Storage of Haterlels
Fire Sefety Standard for Powered Industrial Trucks Including Type Desig-
netione, Arena of Uee, Maintenance, and Operation
Standard for tha Inatalletion, Maintenance, and Use of Public Fire Service
CosDunlcatlon System
2k
-------
Locating manufacturing buildings and flammable propellent storage
tanks at a safe distance [7.6 m (25 feet) or more] from the
property fenceline and from other areas of the plant that could
become sources of ignition or shrapnel.
Providing for a blast wall between flammable propellant charging
rooms and other areas.
Providing a well-ventilated gas house that gives positive ventila-
tion (at both normal and "emergency" rates).
Routing all discharge vents from vacuum pumps, propellant pumps,
and building ventilation systems no less than 3 m (10 feet) above
the roof to ensure adequate dispersion.
Complying with the 1990 U.S. National Electrical Code (NEC) for
hazardous atmospheres, which requires that equipment be isolated
so that these potential ignition sources are enclosed in "explo-
sion proof" housings. The NEC Code specifies that approved
fixtures be used on electric motors, switches, lamps, and other
electrical equipment. The minimum ratings for the gas house and
pump room where flammable hydrocarbon propellants are used are
Class I, Division 1, Group D. The standard for the flammable
propellant DME is slightly more stringent Group C. This usually
means that, while much of the equipment can be approved for either
propellant, electric motors must be upgraded for DME. Appendix D
contains information for ordering the 1990 NEC code.
Installing blow-out walls or ceiling ("deflagration venting") to
allow a controlled release of pressure if an explosion occurs. If
venting is not possible or if personnel will be present when
filling is underway, a specially engineered "explosion suppres-
sion" system is required. This type of system often employs
pressurized halon, which is also an ozone-depleting substance.
Its production will be phased out under the Montreal Protocol by
25
-------
the year 2000, except for "essential uses" that are yet to be
defined.
* Providing automatic sensing systems to measure flammable gas
concentrations in the gas house, sound alarms, and activate the
"emergency" ventilation system and interlocks to cut off the
propellant supply from the tank farm.
Again, this is only a partial list of the Code requirements. Other important
areas cover such topics as fire sprinkler systems, standpipes, fire hoses, and
fire extinguishers. The interested reader is referred to the complete NFPA
Code 30B for a comprehensive list of requirements.
A fully enclosed gas house with two-speed ventilation and an explosion
suppression system may not be necessary in warm climates, where an "open-air
filling" area may be possible (19). The open-air filling technique has
several advantages, such as the reduced capital expenditure for installing or
retrofitting an aerosol-filling plant.
Explosion-proof laboratory hoods with adequate face velocity (along with
other equipment modifications) may be an appropriate alternative for small,
labor-intensive aerosol fillers. These options are discussed in Section 4.
OTHER ENGINEERING SAFETY MEASURES
In addition to the general safety considerations for hydrocarbon storage
and building construction, other engineering safety measures apply to the
hydrocarbon container valves and accessories, piping, and safety relief
devices. The Chemical Specialties Manufacturers Association (CSMA) handbook,
Hydrocarbon. Dimethyl Ether, and other Prooellants: Considerations for
Effective Handling in the Aerosol Plant Laboratory (20) discusses the engi-
neering safety measures for these areas. Appendix D contains information on
how to order the CSMA handbook. In general, engineering safety considerations
for container valves and containers include the following:
26
-------
• All valves, fittings, and accessories connected directly to the
hydrocarbon storage container, including primary shut-off valves,
should have a minimum-rated working pressure of 1824 kPa (250
psig). Materials should be compatible with LPG and should not be
cast iron,
• All connections to the container, except for safety relief
devices, should have shut-off valves. These valves should be
located as close to the container as practical.
• Fixed storage tanks should employ excess-flow valves. These
valves will automatically close if the liquid or vapor flow rate
exceeds a preset rate. All connections from the excess flow valve
should have a rated capacity greater than the excess-flow valve.
General engineering safety considerations for piping include the
following:
• Pipe, tubing, and fittings should be able to handle a working
pressure of a least 1824 kPa (250 psig). Schedule 80 pipe should
be used if the pipe is to be threaded, back welded, or buried.
Schedule 40 pipe can be used if joints are to be welded or welded
and flanged.
• The valve seat, gaskets, packing, diaphragms, etc., should be made
of material that is compatible with the hydrocarbon propellant to
be used.
• After assembly, the piping system should be pressure tested at no
less than 1824 kPa (250 psig) to check for leaks.
• Flexible connections or expansion loops should be used in long
piping runs to minimize expansion, contraction, vibration, and
settling.
27
-------
• The entire piping system, Including flanges and valves, should be
electrically grounded.
In addition to excess-flow shut-off valves, hydrocarbon storage tanks
and piping systems should use other safety relief devices, designed to open at
a set pressure to protect the vessel against rupturing under high pressures as
a result of fire or other increases in temperature. The safety relief devices
are either spring-release devices or rupture discs. In either case, relief
devices should be installed on all unobstructed venting. Shut-off valves
should not be installed between the storage tank and the relief device.
OTHER SAFETY ASPECTS
In addition to safety issues related to the use of flammable propellants
in the gas house and tank farm, other potential hazardous areas must be
examined. Many aerosol filling plants use a water bath ("hot tank") to heat
the filled aerosol containers in order to raise the pressure and verify
container strength or check for leaks. Occasionally, full aerosol containers
rupture during this test; therefore, adequate ventilation near the water bath
must be available.
Another issue is the possible prohibition of shipments of deodorized
("unstenched") LPG or hydrocarbon gases from producer to end-users. This is a
potential regulatory impediment that could require aerosol fillers to install
on-site deodorizing facilities--at a cost possibly prohibitive to small
.undercapitalized operations. In the U.S., shipments of LPG are governed by
the Department of Transportation (DOT), which requires that all LPG must be
odorized, unless odorization would be harmful to the further processing of the
LPG (21). Since odorization would be harmful in the case of most hydrocarbon
propellants, unstenched LPG shipments are permitted by DOT.
28
-------
LABELING REQUIREMENTS AND FLAMMABILITY TESTING
Manufacturers normally place warnings on labels of aerosol products to
ensure that the product is used safely and for the intended purpose. Among
the most important labeling statements are the words FLAMMABLE and EXTREMELY
FLAMMABLE. In the U.S., the Consumer Product Safety Commission (CPSC)
requires that these warnings are printed on "household product" aerosols, and
the U.S. Environmental Protection Agency (USEPA) requires warnings on insecti-
cide product labels. Products under the Jurisdiction of the U.S. Food and
Drug Administration (FDA) include hair spray and personal deodorants.
Labeling and Precautionary Statements
"Flammable" precautions normally do not discourage purchases of useful
products except on baby products, foods, and some pharmaceuticals. In one
controlled test, a run of insecticides labeled CAUTION: FLAMMABLE sold more
rapidly than their unmarked counterparts. Products marked EXTREMELY FLAMMABLE
are common among aerosol products (such as automotive aerosols). Well over
half of all aerosols in the U.S. are now marked FLAMMABLE or EXTREMELY
FLAMMABLE. Over 90% contain flammable propellants, and more than two-thirds
contain flammable or combustible concentrates (22).
Some flammable aerosol products are dangerous if misused. Overheating
is perhaps the most frequent hazard of flammable aerosol products. The second
major consumer risk can occur when cans are dropped, causing the valve to
malfunction. In some cases, it may be appropriate to describe the severe
consequences of not following critical precautions (23). For example, an
insecticide product known as a Total-Release Insect Fogger (TRIF) includes the
instruction to shut off stove and other appliance pilot lights before use.
Serious explosions have occurred in homes as a result of consumers who did not
shut off pilot lights or who used more than one can per room. Another
potentially dangerous product is an aerosol tire inflator intended to tem-
porarily repair and inflate a punctured automobile tire. If flammable tire
inflator products are repeatedly used without deflating and reinflating the
tire with air, the HC gas could be concentrated to the explosive range, which
29
-------
could pose an extreme fire hazard when the tire is dismounted from the rim
(24).
The standard phrase "Keep Away from Fire or Sparks" is commonly used
with flammable aerosols. Examples of other standard precautionary statements
include:
• "Always Use with Adequate Ventilation;"
• "Heavy Localized Concentrations of Flammable Vapors May Be Hazar-
dous ; " and
• "Do Not Puncture or Incinerate."
Fillers and marketers should ensure that the directions for use are
legally complete.
Testing for F1ammahl1^ry
In the U.S., two tests are used to determine when FLAMMABLE or EXTREMELY
FLAMMABLE labels are required: 1) the Modified Flash Point Test, and 2) the
Flame Projection/Flashback Test. Appendix E contains a copy of the Federal
Register official methods (26 FR 191; August 12, 1961).
The Modified Flash Point Test for determining the lowest temperature at
which application of the test flame causes the vapor at the surface of the
liquid to ignite but not continue to burn (flash). The flash point test used
by the CPSC and applied to hydrocarbon-propelled aerosol products has several
problems. One is that virtually any aerosol product using a hydrocarbon
propellant will be classified as EXTREMELY FLAMMABLE by this test, even if the
product contained 99% water and 1% isobutane (3). The EPA version of the
Flash Point Test, on the other hand, applies only to the concentrate. As a
result, many products tested by the EPA version (concentrate tested) are
classified as FLAMMABLE, while the CPSC version classifies the product as
EXTREMELY FLAMMABLE. Another limitation of the flash point test is that many
30
-------
products cannot be meaningfully tested. This is because the Modified Flash
Point test involves chilling the aerosol contents to -32*C (-25*F), and slowly
warming at the rate of 0.8 to l.A*C per minute. Products containing signifi-
cant amounts of water cannot be tested in this way because they freeze solid.
Likewise, products that separate into liquid phases, become partially solid or
viscous, or develop a gel structure cannot be tested; in addition, foams and
pastes cannot be tested.
The Flame Projection/Flashback test uses two methods to test the flamma-
bility of aerosol products. The Flame Projection test defines the maximum
length of the flame at full valve opening. An aerosol will fail the flame
projection test if the flame projects more than 457 mm (18 inches) beyond the
source at full valve opening. The aerosol will fail the Flashback test if the
flame extends back to the aerosol dispenser at any degree of valve opening.
The formilator can make several modifications to a product so that it will
pass the flame projection test including:
• Reduce the delivery rate;
• Reduce the particle size;
• Add nonflammable ingredients to the concentrate [such as water or
chlorinated solvents like 1,1,1-Trichloroethane (which, however,
will be phased out by the year 2005 under the Montreal Protocol)];
and
• Replace some of the flammable propellant with nonflammable propel-
lant such as HCFC-22 (22).
One of the most difficult aspects of performing the flashback test is
that flashback may be particularly pronounced when the valve is throttled back
to very low delivery rates--this despite the fact that aerosol valves are not
designed to be throttled down.
31
-------
Finally, flashpoint and flame projection have essentially no relation-
ship to each other. Materials with low flashpoints and nonflammable propel-
lants can be made to show dramatic flame projection (22). Despite these
problems, these tests are still the key methods used for labeling aerosol
products in the U.S.
32
-------
SECTION l*
EQUIPMENT CONVERSION OF HYDROCARBON FILLING OPERATIONS
Propellant filling operations are classified in three sizes: 1) large
operations producing over 2.5 million units per year (automated); 2) medium
filling operations producing 0.5 to 2.5 million units per year (manual and/or
automated); and 3) small filling operations producing fewer than 0.5 million
units per year (manual filling lines).
AUTOMATED FILLING LINES
The large aerosol filling operation typically uses an automated produc-
tion line that can produce 14,000 to 28,000 units per shift, which equals
approximately 35 to 70 units per minute. On a basis of 35 units per minute,
three 8-hour shifts per day, and a 7-day work week, this type of plant could
produce nearly 15 million units per year. Additional operations, such as
labeling and packing, may be automated or manual.
Figure 4 illustrates an automated filling line. Table 9 lists the major
equipment and production areas, including the base product and blending areas,
the propellant supply, and test baths. Table 9 also itemizes possible line
modifications. The equipment can be either air-operated or electrical. Each
container is mechanically conveyed from one step to the next.
The equipment that must be modified to convert from CFC aerosols
includes the propellant supply, the gassing area, and possibly the main
production facility, depending on the location of the gassing area. Modifica-
tions to each of these areas are discussed below.
Propellant Storage
Automated filling lines typically use bulk storage of the hydrocarbon
propellant. The size of the bulk tank installation depends on the following:
33
-------
Gassing Area
(Explosion Proof)
Check
Under-t he-Cap Weigher Z'
Rotary
| Filler/Cnmper/Gasser
Machine
Valve
Sorter
and vacuum
Inserter
Conveyor
Drive
Hot Water Test Batti
Cleaner
Can De-Palletlier
-Main Production Facility Wall
a)Rotary Under-the-Cap Filler/Crimper/Gasser
Gassing Area
(Explosion Proof)
Check
Weigher
Conveyor
Drive
Through-the-Valve
Automatic FYopellant
Charger
Crimper VaJve
Inserter
±1
Hot Water Test Bath
Sorter
Can De-Pallettzer
Concentrate
Filler
Main Production Facility Wat
b) Rotary Through-the-Valve Gasser
Figure 4. Automated aerosol filling line.
34 {
-------
TABLE 9. AUTOMATIC PRODUCTION FILLING LINE EQUIPMENT
Area
Item
Cost ($1000)
Modification
Base Product and Blending
Areas
1.
Base product raw material
storage tanks and transfer
pumps
0-20
Reformulation of base product may be
required
2.
Scale/load cell for blending
tank
0-15
Only If base product is reformulated
3.
Base product filling supply and
transfer pump
0-5
If electric pump, switching to
explosion-proof motor may be needed
PropeLlant Supply Area
1.
Propellant storage tank
0-200
Cleaning, testing, and moving of tank
may be needed
2.
Propellant booster pump to
gasser
0-0.5
Converting to explosion-proof motor
3.
Pressure regulating valve,
valve bypass
o
o
Gassing Area
1.
Product filler
0-1
Fittings and gaskets may need to be
replaced depending on base product
reformulation
2.
Propellant charger
0-1
Fittings and gaskets may need to be
replaced depending on base product
reformulation
3.
Crimper
0-1
Fittings and gaskets may need to be
replaced depending on base product
reformulation
4.
Vacuum pump
0-0.5
Converting to explosion-proof motor
Support Area
1.
Packing table
0-0.25
Converting to explosion-proof motor
Optional
1.
Hot tank (test bath)
0.5-10
Rood ventilation may be required
2.
Container dryer
0.25-0.5
Converting to explosion-proof motor
-------
• Maximum daily propellant use;
• Number of different propellant grades required;
• Size of tanker delivery and ease of access;
• Time to process and receive tanker deliveries; and
• Location of tanks relative to adjacent buildings.
Installation of new tanks should follow the specific guidelines
presented in NFFA 58 "Standard for the Storage and Handling of Liquified
Petroleum Gases" (18). Additional specific and general guidelines for
hydrocarbon propellant storage, use, and safety are discussed in NFPA 30B
"Code for the Manufacture and Storage of Aerosol Products" (17), the British
Aerosol Manufacturers' Association (BAMA) "A Guide to Safety in Aerosol
Manufacture," and the Aerofill "Hydrocarbon Guide." The Aerofill document is
reproduced in Appendix F. Ordering information for the NFPA codes and BAMA
Guide appears in Appendix D.
One of the most Important guidelines is Intended to ensure that the
distance between the tanks and charging pumps and the production and gassing
areas meets specifications. Figure 5 shows the minimum recommended distances
for two different storage tank sizes. NFPA 30B recommends a minimum distance
of 8 meters (25 feet) from the nearest production facility for tanks under 7.6
m3 (17). For tanks over 7.6 m3, a distance of 15 meters is recommended (18).
For propellant charging pumps, the minimum recommended distance is 7.6 meters
from an adjacent wall, from all other vails and buildings, and from the
nearest source of ignition, such as nonexplosion-proof electrical equipment or
motor vehicles.
If existing fixed storage tanks are reused, they must be thoroughly
cleaned (sandblasted) and hydrostacically tested at 2 times their maximum
working pressure to ensure they can safely store the hydrocarbon propellant.
The following example illustrates the evaluation of a fixed storage tank that
could be converted from CFC to hydrocarbon propellant. Assume the tank was
originally designed to contain a typical blend of 60 vt % CFC-12 and 40 wt %
CFC-11. The vapor pressure of this blend would be 532 kPa gauge at 38"C
(77.2 psig at 100'F), The American Society of Mechanical Engineers (ASME)
36
-------
-J
8 meters
15 meters
Up to
7600 liters
Hydrocarbon
Storage Tanks
7600 to 114000
I iter8
Gassing
Area
Main Production Facility
Figure 5. Recommended hydrocarbon storage tank distances.
-------
code applies to any container over 654 L of liquid capacity and requires a
minimum design pressure of 963 kPa. This tank could be approved for reuse
with isobutane (501 kPa at 38"C) or n-butane (356 kPa at 37.8°C), but not with
pure propane (1307 kPa at 38*C) or blends containing mostly propane. A
typical hydrocarbon blend A-&6 (containing Ideally 15 wt % propane and 85 vt %
isobutane) has a pressure of about 659-660 kPa at 3B*C and would be only
marginally acceptable in such a tank.
In addition, fixed storage tanks should be a minimum distance of 8 m (25
feet) from the gassing area; this may require moving existing tanks, lines,
and pumps. Lines and pumps must be cleaned or replaced with material designed
for flammable hydrocarbon liquids.
Gassing and Production Areas
In addition to the storage area, modifications may be needed for the
gassing and production area9. The gassing room should be constructed outside
the main production area, as shown in Figure 4. Figure 6 depicts four
different interior gassing room locations (20). If the gassing area is
located within a large area, as shown in the top two schematics of Figure 6,
modifications can be made to the gassing room only. However, if the gassing
room is contained within a small main production facility, as shown in the
bottom two schematics of Figure 6, modifications to both the gassing room and
the main production facility must be made. These changes would Include
Increased ventilation, combustible gas detectors, electrical devices (motors,
switches, and lights) enclosed in "explosion-proof" housings (as described
earlier for Class I,' Division 1, Group D atmospheres), and possibly an
Improved explosion suppression system. In addition, the walls and roof of the
gassing room should be made blast proof. A gassing room located in the center
of the main production facility (as shown in the lower right schematic of
Figure 6) is not recommended because only celling explosion relief is possible
in this design.
3B
-------
Main Production
Facility
Filling
Lines
L/
^Door
Gassing
Room
1.6
rrieter*
7
Door
Door
External Walls of Gassing
Room i. 50% of Wall Areas
Main Production
Facility
Filling
Lines Gassing
N^Room
rxi
VI I N7T
Door Door ¦
1.5 meter3
External Walls of Gassing
Room < 50% of Wall Areas
Main Production
Facility (Division 1)
Door
/\
l
L
Gassing
Room
Filling
^ Lines
XT
Door
Main Production
Facility (Division 1)
Door
Gassing
toom \
Filling
Door Lines
Only ceiling explosion relief
is possible in this design.
Figure 6. Potential existing gassing room locations for
automated filling lines.
39
-------
For ventilation, all buildings should have an air flow rate of 0.3
m3/mln per m2 of floor area provided (17). The gassing room may need more
ventilation, which can be calculated as follows:
CM (lOO-LED (V) (R)
(DL) (LEL)
where CM is the required ventilation flow/rate (m3 per minute) , LEL is the
lower explosive limit of the propellant (%), V is the vapor volume produced by
1 liter of liquid propellant (a3), R is an estimate of the propellant lost
during filling plus an additional 20% for occasional leaks (liters), and DL is
the LEL design level (usually not more than 10% of the LEL). The estimated
propellant lost during filling, R, can be calculated from:
R - (1 Liter/1000 cm3) x (loss per can, cm3)
x (cans per minute) x (1.2)
The typical loss per can for one filler line is 3.0 cm3/can, and 4.0 cm3/can
for a two-filler line.
If a facility is not able to make the modifications suggested above, an
open-air gassing room may be used. This type of gassing room, depicted in
Figure 7, has been used successfully in Mexico for a number of years (19).
The main feature of the open-air gas house is the use of natural ventilation
to keep any escaped hydrocarbon vapors below flammable or explosive limits.
The gassing apparatus is located outside of the main production facility, with
a solid roof, and wire mesh walls on three sides, and a solid wall between the
gassing area and the main production facility. Design considerations for an
open-air gassing area include;
• Odor (is the hydrocarbon propellant stenched or unstenched);
• The LEL and relative flammability of the hydrocarbon propellant to
be used;
The typical wind speed and direction; and
40
-------
Rotary Indexing
Machine
Conveyor
Drive
Hot Water Teat Bath
Valve Sorter
and Inaerter
Can De-Pallatlzer
~ Main Production Facility Wall
Wind Direction
Open-Air Gassing Facility (Plan View)
Main Production Facility
Open-Air Qaaalng Area
Open-Air Gassing Facility (Side View)
Figure 7. Example of an open-air gassing area.
41
-------
• Land availability and location of nearby buildings, parking lots,
or electrical equipment.
This type of system has the advantage of not requiring mechanical
ventilation (however, high-speed filling lines may need some additional
ventilation with explosion-proof fans), or a blast-proof gassing room.
Table 9 contains the estimated cost range of suggested gassing and
production area modifications. These costs, however, do not Include addition-
al ventilation that would be required, nor do they include blast-proofing the
gas house. Conversion costs would be less for air-operated equipment than for
electrically operated equipment. The costs of various explosion-proof
electrical hardware are listed in Table 10. The approximate cost of a halon
explosion suppression system for a large gassing area (3.5 m x 5.0 m) would be
approximately $30,000 U.S. Dollars [based on three times (3x) the cost of a
fire protection system from the Richardson Cost Manual (25) and conversations
with system vendors.] System vendors caution that explosion suppression
system costs cannot be estimated without site-specific details.
The Mexico Case Study, for example, estimated that the cost to convert
an automated filling line (producing 8 million units per year) from CFCs to
LPG was $566,000 for capital investment (machinery and filling lines) and
$793,000 for auxiliary equipment (gas detectors, fire extinguishing systems,
and alarms), resulting in a conversion cost of $1.36 million U.S. dollars.
However, the estimated propellant savings from using less expensive hydrocar-
bons in place of CFCs would be $1.69 million U.S. per year. Therefore, the
cost savings from converting to hydrocarbons would more than offset the
initial capital investment (26).
MANUAL FILLING LINES
Small- to medium-sized aerosol-filling operations typically use a manual
production line capable of producing 6,000 to 8,000 units per shift with two
persons (limited to filling, gassing, and crimping only), which would equate
to approximately 15 units per minute. On the basis of one 8-hour shift per
42
-------
TABLE 10. PURCHASED EQUIPMENT COST FOR VARIOUS ELECTRICAL HARDWARE
(GENERAL PURPOSE VS. EXPLOSION PROOF)
ItOGl
~•script ion
Rating
Cost
Junction Box**
Load Centers
Circuit Breakers
2*"x2A"x6-3/8"
30"x24"x6-5/8"
2*"*2*"x6"
30"x2Vx8"
100 Amp, 10 circuit
225 Amp, circuit
125 Amp, 10 circuit
223 Amp, 24 circuit
IS Amp - 60 Amp
15 Amp - 60 Amp
NZMA 1 (Non-Hazardous) 9118
HEMA 1 (Non-Hazardous) S146
NEMa 12 (Hazardous 3133
Environment)
HEMA 12 (Hazardous 3180
Environment)
NEMA 1 (General 3290
Purpose)
NB4A 1 (General S«91
Purpose)
HQ4A 3 (Hazardous Area) Si,931
KD1A 3 (Hazardous Area) S3,*23
NfMA 1 (General Pur- S208
pose)
Lxploaion Proof 5*82
Motor Starters
Non-Reversing, Size 0
243V 8 3HP, 480/600V 8 5HP
Non-Raversir.g Combination Size 0
240V g 3HP, 480/600V 8 5HP
Non-Reversing, Size 0
240V S 3HP, 480/600V | 5BP
Non-Reversing Combination Size 0
24 0V g 3EP, 480/600V g 5BP
General Purpose
General Purpose
NEMA 7 or ND4A 9
(Explosion Proof)
NIMA 7 or NEMA 9
(Explosion Proof)
3139
S452
3663
S942
Electric Motors
(Single Phase)
Rigid Mount
Horispower Enclosure
0.5
Protected Drip Proof
Totally Enclosed Fan Cooled
Explosion Proof
Class I, Group D
S232
S256
$4 16
1.0
Protected Drip Proof
Totally Enclosed Fan Cooled
Explosion Proof
Class I, Group D
S4 56
S4S0
Si,000
2.0
Protected Drip Proof
Totelly Enclosed Fan Cooled
Explosion Proof
Class I, Group D
S*88
S508
S66*
(Polyphase)
HEMA C End Mount
1.5
Protected Drip Proof
Totally Enclosed Fan Cooled
Explosion Proof
Class I, Group D
S362
S407
3667
Source: Reference 25.
43
-------
day and a 5-day work week, such a plant could conceivably produce nearly 2
million units per year. Other operations, such as labeling containers with
paper labels or packing, would either slow the rate or require additional
labor.
A manual aerosol-filling line is illustrated in Figure 8. The equipment
is typically air operated and manually actuated through a lever or button.
Each container must be transferred manually from one step to the next.
Table 11 lists the equipment and its estimated cost in U.S. dollars (1990
basis) for a manual filling line. Modifications to the hydrocarbon storage
area and the gassing areas for the smallest manual filling operations are
discussed below. Cold filling is not appropriate with hydrocarbon propellants
and should be replaced by pressure filling. A single-station pressure filling
machine may cost up to $30,000.
Hydrocarbon Storage Area
As depicted in Figure 9, the hydrocarbon storage used for the small,
manual filling lines are typically several 53-kg cylinders manifolded together
or a 385-kg container. Cylinders not in use should be stored in the open air
or in well-ventilated areas. No more than six cylinders should be stored
together with a minimum distance of 3 meters between the storage and a
boundary, building, or fixed ignition source (such as pumps, electrical
motors, or vehicles). All cylinders should be stored upright with protective
valve caps in place and securely chained. Full and empty cylinders should be
identified and segregated.
In-use cylinders should be manifolded together using changeover valves
and nonreturn valves. As with the in-storage cylinders, in-use cylinders
should be upright and securely chained. Piping from the cylinder or manifold
should be done with hydrocarbon-compatible materials. The piping route to the
gassing area should avoid steam pipes and other sources of ignition or heat.
Individual piping should be used for each grade of hydrocarbon propellant
used.
UU
-------
Product Crimper Propellant
Filler Charger
Aerosol Can Test Bath
(Optional)
Figure 8. Example of a manual filling line.
-------
TABLE 11. SMALL MANUAL PRODUCTION FILLING LINE EQUIPMENT LIST
Ar««
Item
Cost ($)
Modification
Base Product and Blending
Areas
1. Bese product transfer pump
0
Manual pump assumed for base product
transfer
Propellent Supply Area
1. Propellent cylinder storage
area
$1,500
Fencing, chain, cover for outside
cylinder storage
2. Propellent booster pump to
gasser
$500
Conversion to explosion-proof motor
Crimper
1. Addition of vacuum pump
$1,700
Explosion-proof vacuum puap (cold filling
not used)
Cesser
1. Propellent charger
$700
Fittings, gaskets, valves replaced with
propellent compatible materials
2. Fume hood
$3,000
Fume hood (explosion-proof with rear
exhaust duct)
Test Beth
1. Fume hood
$2,600
Fume hood (explosion-proof with rear
exhaust duct)
Subtotal Capital
$10,000
Installation Costs (20X)
$2,000
Total Capital for Modifications
$12,000
-------
/
1220 mm
380 mm
Hydrocarbon Cylinder
Contents 53 Kg
2110 mm
840 mm
Hydrocarbon Container
Contents 385 Kg
Figure 9. Hydrocarbon storage for manual filling lines.
kl
-------
Piping should be of seamless carbon steel as specified in ASTM Specifi-
cation A-53 Grade B [equivalent to American National Standards Institute
(ANSI) Designation B36.1], with a minimum tensile strength of 414 MPa (60,000
psi). The pipe should be a minimum of Schedule 80 if threaded fittings are
used or if the pipe is to be back-welded or buried. No less than Schedule 40
pipe should be used if the fittings are to be welded or welded and flanged
(20). Gaskets and packing must also be compatible with hydrocarbons.
Examples of some materials are tetrafluoroethylene (TFE), Kel-F, and metal-
encapsulated asbestos substitutes. All applicable codes for piping and
gasket/sealing materials should be consulted before commissioning any new
hydrocarbon piping system.
If existing CFC cylinders are reused, they must be thoroughly cleaned
(sandblasted) and hydrostatically tested at 2 times their maximum working
pressure to ensure that they can safely store the hydrocarbon propellant. In
addition, lines and pumps must be cleaned or replaced with material designed
for flammable hydrocarbon liquids.
Additional discussions and more specific guidelines for storing and
using hydrocarbon propellants appear in Appendix F and in References 17
through 20.
Gassing Area
In addition to the propellant supply, equipment modifications for manual
lines also must be made to the gassing area. Many small filling operations are
located in crowded urban areas, and the use of an open-air gassing area would
not be possible. One way to significantly reduce the hazards associated with
hydrocarbon propellants would be to locate the gassing and crimping operations
within a laboratory fume hood. These types of hoods have been successfully
used for laboratory-scale, manual filling operations that closely correspond
to cottage-size production facilities.
Although fume hoods can vary in size, they are typically 76 cm deep, 100
cm high, and from 122 to 240 cm wide. A fume hood for use with hydrocarbon
48
-------
propellants has a vertical sash, an aic face velocity of at least 30 to 45
meters per minute, and air exhaust vents located at the bottom rear of the
hood. Having the air exhaust at the bottom rear of the hood is very impor-
tant, since hydrocarbon propellants are more dense than air and will collect
at the bottom of the hood. Table 12 gives additional minimum air flow re-
quirements for different hood sizes.
The exhaust from the fume hood should be connected to a flue or pipe
duct that uses an explosion-proof fan motor. The end of the duct or piping
should exit directly through the roof of a one-story building or to an
adjacent outside wall if the filling room is located in a multi-story
building. The location of any ignition sources that may be near the exhaust
duct should be considered. The fume hood, fan-motor, and any equipment used
within the fume hood (such as lighting) should be Class I, Division 1, Group D
explosion-proof equipment. Table 10 shows the costs for various explosion
proof equipment. The costs for the laboratory hood are for a 122-cm-(48-in.)
wide benchtop; a walk-in hood of the same width would be approximately twice
as expensive. Explosion suppression system vendors should be consulted for
details on installing these systems in laboratory hoods (see Appendix A).
Table 11 presents the costs for converting a manual filling line. This
size of filling line is assumed to produce 0.5 million units per year. The
total capital cost for conversion to hydrocarbon propellants is estimated to be
at least $12,000 U.S. Modifications to equipment would include purchase of
explosion-proof motors, starters, and solenoid valves; installation of explo-
sion-proof fume hoods for the gassing equipment and test baths; and construction
of a covered, fenced hydrocarbon storage area. This initial capital investment
would be more than recovered by the material cost savings of using hydrocarbon
propellants in place of CFC propellants. This cost savings would be nearly
$67,700 per year. The costs for CFC propellant would be $75,000 per year
(assuming a 340-gram aerosol can, 30% by weight of CFC propellant, and a CFC
cost of $2.21 U.S. per kg), compared to a hydrocarbon propellant cost of $7,300
U.S. per year (using isobutane at $0.44 U.S. per kg).
49
-------
TABLE 12. FUME HOOD MINIMUM AIR FLOW REQUIREMENTS
Minimum Air Flow (m3/minute)
Hood Width for Face Velocities of
(meters) 30 m/s 46 m/s
1.2 23 34
1.5 28 42
1.8 34 51
2.4 45 68
Source: Reference (27).
50
-------
SECTION 5
PRODUCT STORAGE FOR DISTRIBUTION AND SALE
This manual not only provides manufacturers of aerosol products with
information that will enable then to convert from CFC to hydrocarbon propel-
lants, but also contains information on proper product storage, including
warehouse, backstock, and sales display storage. Since hydrocarbon propel-
lants are flammable (containing butane, propane, or a mixture of these two,
and, less frequently, pentane or ethane), producers, distributors, and end
users must take extra care to handle them safely. This section discusses
issues relating to the storage of flammable products such as 1) the classifi-
cation of aerosol products into three levels according to their perceived
flammability hazard, 2) the 1990 NFPA 30B Code for the Manufacture and Storage
of Aerosol Products, and 3) what the Code says about the storage and display
of the three levels of hydrocarbon aerosols.
In the United States, four organizations develop the fire and building
codes: The National Fire Protection Association (NFPA), the International
Conference of Building Officials (ICBO) with the Western Fire Chiefs Associa-
tion, the Southern Standard Building Code International (SSBCI), and the
Building Officials and Code Administrators (BOCA). The last three are
regional building and fire code organizations that generally produce codes
that closely follow the criteria set by the NFPA. Codes developed by the
regional organizations generally become adopted into state, county, and city
laws and regulations.
CLASSIFICATION OF AEROSOL PRODUCTS
The NFPA 30B Code for the Manufacture and Storage of Aerosol Products
classifies these products in three categories. Table 13 shows how aerosol
products are classified according to their percentage of flammable base
material and flammable propellant. Materials that mix with water, such as
ethanol, isopropanol, propylene glycol, glycerin, sorbitol, acetone, methyl
51
-------
TABLE 13. CLASSIFICATION OF AEROSOL PRODUCTS (17)
If Percentage of
And
Flammable Material in
Percentage of Flammable
Then
Base Product Is:
Propellant 19:
Level Is:
£25%
o%«
1
£25%
<50%
1
525%
250% but <80%
<85% and water-miscible
o%«
1
>25% and water-miscible
<50%
2
>25% and water-miscible
250%
3
>25% but <55% and water-
immiscible
0%
2
>25% but £55% and water-
immiscible
<50%
2
>25% but 255% and water-
immiscible
250%
3
>55% and water-immiscible
0% to 100%
3
any %
260%
3
'i.e., propellant Is nonflammable.
NOTE 1: The base product Is defined as the contents, excluding the
propellant. A base product component 1s considered flammable if its
flash point is below 260'C (500*F). The percentage of flammable
material in the base product is calculated as follows:
% Flammable Weight of Flammable Base Components
Material (Ut. of Contents - Ut. of Propellant)
x 100
NOTE 2: The percentage of flammable propellant is its proportion of the total
contents, by weight. Any nonflammable portion of a propellent blend
is not included in the calculation. The percentage la calculated as
follows:
% Flammable Weight of Flammable Base Componenta
Material ~ Weight of Contents
x 100
52
-------
ethyl ketone, methyl acetate, and most surfactants, for example, would
dissolve In the water from sprinklers and fire hoses during a fire and be
rendered nonflammable. Vater Immiscible materials, on the other hand, such as
toluene and aliphatic petroleum distillates, would not dissolve and could
spread as a burning top layer as water was directed at a fire.
Figure 10 Is a "decision tree" showing how to determine the level number
of an aerosol product (17). In Level 1 products, the base product contains up
to 25% by weight of materials with flash points of 260°C (500*F) or less. In
Level 2 products, the base product contains either 1) more than 25% by weight
of water mlsclble materials with flash points of 260*C (500°F) or less, or
2) more than 25% but less than 55% of water Immiscible materials with flash
points of 260*C (500*F) or less. In Level 3 products, the base product
contains more than 55% of vater mlsclble materials with flash points of 260"C
(500°F) or less, or the flammable propellant equals or exceeds 80% of the net
container weight.
NFPA 30B: CODE FOR THE MANUFACTURE AND STORAGE OF AEROSOL PRODUCTS (1990)
In the late 1970s and early 1980s, actual fire Incidents and full-scale
fire testing made It apparent that flammable aerosol products presented a
severe fire challenge. In response, the aerosol Industry initiated further
full-scale fire testing, and NFPA's Technical Committee on Aerosol Products
began working on fire protection guidance for both manufacturing and storage
facilities. NFPA 30B became effective on August 17, 1990. This section
summarizes Chapters 4 and 5 of Code 30B, which describe NFPA's basic require-
ments for storing and displaying aerosol products.
Storage In Warehouses and Storage Areas
In the U.S., all cartons of aerosol products produced after January 1,
1992 must show the classification of the aerosol products within somewhere on
the carton. Level 1 aerosol products are equivalent to a Class III commodity,
i.e., to paper, cardboard, and wood products (28). These "water-based"
53
-------
No
Is the percentage of flanmable
material in tha baaa product
greater than 251?
Laval
1 No
Is tha propellant
flam able?
No
Yea
Yes
la tha percentage I
of flasmable \
material in the '
baaa product !
graatar than 521? !
Laval
1
No
Laval
2 No
Is parcantaga of
propellant to con-
tainer content by
weight greater
than or equal to
501?
Yes
Is percentage of
propellent to con-
tainer content by
weight greater
than or equal to
801?
Yes
-•vei
2
Ho
Is propellant
flasmable?
Yes
Level
2
No
Is percentage of
propellant to con-
tainer content by
weight greater
than or equal to
501?
Yes
i Is f laoxnable
jmatenal in baser
|product water !
!soluble? !
No
Level
3
Yes
i
|Is the propellant :
|£lamnable? ' No
Yes
Levei
2
Lave i
3
Yes
Level
3
lis percentage of
Ipropellant to con-
tainer content by
Iweight greater
i than or equal to
! 501?
No
LeveL
2
Yta
.aval
3
Figure 10. "Decision tree" for determining aerosol product level number
(Adapted from Ref. 17).
54
-------
aerosol products, examples of which appear In Table 14, do not require special
fire protection measures.. Level 2 aerosol products In containers whose net
weight of flammable contents is less than 1 ounce may be stored as Group A
plastics, as defined by NFPA 231. Tables 15 and 16 list examples of Level 2
and Level 3 aerosol products, respectively.
Tables 17 through 22 show how Level 2 and Level 3 aerosols being stored
on pallets, in solid piles, or on racks should be arranged and protected from
fire. The tables give details about sprinkler spacing, the necessary duration
of sprinkler performance, and maximum ceiling and pile heights when ordinary
or Early Suppression Fast Response (ESFR) sprinklers are used. In general,
the pile height can increase when ESFR or large drop sprinklers are used;
sprinkler duration varies from one to two hours.
Up to 454 kg (1000 lbs) net weight of Level 2 and up to 227 kg (500 lbs)
of Level 3 aerosol products [or up to 454 kg (1000 lbs) of Level 2 and Level 3
aerosols combined] can be stored in places other than warehouses, i.e., in
business, educational, industrial, and institutional environments.
Up to 5450 kg (12,000 lbs) of combined Level 2 and Level 3 aerosol
products can be stored in general purpose warehouses in solid piles or on
pallets if: 1) the sprinkler system over the aerosol area and 6 m (20 ft)
beyond conforms to the standards shown In Tables 17 and 18; and 2) any
flammable and combustible liquids stored in the same warehouse are separated
from the aerosol products by at least 8 m (25 ft).
According to NFPA Code 30B, up to 10,900 kg (24,000 lbs) of Level 2 and
Level 3 aerosol products combined may be stored in racks in a general purpose
warehouse protected by an automatic sprinkler system If: 1) the sprinkler
system for the aerosol storage area and 6 m (20 ft) beyond meets the standards
shown in Tables 19 through 22; and 2) the aerosol products are separated from
any flammable and combustible liquids by at least 8 m (25 ft).
55
-------
TABLE 14. EXAMPLES OF LEVEL 1 AEROSOL PRODUCTS (29)
Air Fresheners - Water-baaed
Insecticides - Water-based
Herbicides - Water-based
Shave Creams
Starches & Fabric Finishes
Many Furniture Polishes - Water-based
Kitchen & Bathroom Cleaners
Oven Cleaners (both caustic and noncaustic formulas)
Mousse Products
Engine Cleaners - Water-based
Whitewall Tire Cleaners
Fabric Dewrinklers
Anti-static Sprays - Water-based
Some Cookvare Release Sprays - Water-based
Rug & Upholstery Shampoos
Whipped Creams
Pet Shampoos & Conditioners
56
-------
TABLE IS. EXAMPLES OF LEVEL 2 AEROSOL PRODUCTS (30)
A. Alcoholic or Hydro-alcoholic typea
Hair Sprays--Anhydrous
Hair Sprays--To 9% water, in solution
Hair Sprays-- Dimethyl Ether type--to 20% water in solution
Hair Sprays--Two-phase type--to 30% water
Disinfectant/deodorants --C02 type
Disinfectant/deodorants--Hydrocarbon type
Personal Deodorants
Air Fresheners--Anhydrous
Air Fresheners--To 6% water in solution
Perfumes and Colognes
Windshield De-icers
Some Breath Fresheners
Deo-colognes
Certain Mousse Products (Rare)
De-wrinklers--for Fabrics
Certain Topical Medicinals
b. Petroleum Distillate Emulsions
Furniture Polishes
Furniture Cleaners
Laundry Prewash Spot Removers
Engine Cleaners (Exterior)--Water-based
Certain Paints and Coatings--Water-based
Certain Insecticides--Water-based
Certain Herbicides--Water-based
Certain Leather or Vinyl Dressings
c. Alcohol and Water Immiscible Oil Types
Ethanol-based Insect Repellents--C02 or Hydrocarbon
Isopropanol-based Insect Repellents--C02
Certain Lubricants
Certain Mousse products, e.g., Mineral Oil Types
Certain Hair Glossing Sprays
d. Miscellaneous
Diethyl—Ether Engine Starting Fluid--C02 or CO^A-60 Types
Diacetone Alcohol Carburetor Cleaners--C02 Types
Methanol Gel for Pot, Urn, or Food Tray Warmer Refills
Methyl Acetate-based Graffiti Removers
57
-------
TABLE 16. EXAMPLES OF LEVEL 3 AEROSOL PRODUCTS (31)
Most Spray Paints
Most Automotive Products (such as choke and carburetor products)
Most Aerosol Antlpersplrants
Some Dry Powder Drug Products
Some Pesticides (such as some total release Insect foggers
and wasp/hornet sprays)
Some Lubricants
Some Solvent-based Herbicides
58
-------
TABLE 17. ARRANGEMENT AND PROTECTION OF PALLETIZED AND
SOLID-PILE LEVEL 2 AEROSOL STORAGE* (17)
Max. Ceiling Ht (m)
9.1
9.1
7.6
7.6
Maximum Pile Ht (m)
1.5
4.6
5.5
6.1
Sprinkler
1.27 cm.
ESFR
Large drop
1.63 en
ESFR
Temp. Rating"
High
Ordinary
Ordinary
Ordinary
Sprinkler Spacing (m2)
9. 3 max.
7.4-9.3
7.4-9.3
7.4-9.3
Sprinkler Demand
3.6 L/min/m2
over 232 m2
12 sprinklers
at 446 kPa
15 sprinklers
at 446 kPa
12 sprinklers
at 446 kPa
Duration (hr)
2
1
2
1
'All fire tests on which this table is based were conducted with standard spray, large drop, or
ESFR sprinklers. This does not Include large drop sprinklers equipped with quick response
links. The Response Time Index (RTI) of standard spray and large drop sprinklers shall not be
less than 100 (meter/sec)1/2 [181 (ft/sec)1/2] .
bUhen use of higher temperature-rated sprinklers is necessary, such as near unit heaters, refer
to NFPA 13, Standard for the Installation of Sprinkler Systems.
-------
TABLE 18. ARRANGEMENT AND PROTECTION OF PALLETIZED AND
SOLID-PILE LEVEL 3 AEROSOL STORAGE" (17)
Max. Celling Ht (m)
Maximum Pile Ht (m)
Sprinkler
Temp. Rating"
Sprinkler Spacing (m2)
Sprinkler Demand
9.1
9.1
7.6
7.6
1.5
4.6
4.6
3
1.27 cm
ESFR
ESFR
Large drop
1.63 cm
High
Ordinary
Ordinary
Ordinary
9.3 max.
7.4-9.3
7.4-9.3
7.4-9.3
2 L/mlnute/m2
over 232 m2
12 sprinklers
at 618 kPa
12 sprinklers
at 446 kPa
15 sprinklers
at 618 kPa
Duration (hr)
"All fire tests on which this table Is based were conducted with standard spray, large drop, or
ESFR sprinklers. This does not Include large drop sprinklers equipped with quick response
links. The Response Time Index (RTI) of standard spray and large drop sprinklers shall not be
less than 100 (meter/sec)1/2 [181 (ft/sec)1/2].
bUhen use of higher temperature-rated sprinklers Is necessary, such as near unit heaters, refer
to NFPA 13, Standard for the Installation of Sprinkler Systems.
-------
TABLE 19. ESFR ARRANGEMENT AND PROTECTION OF LEVEL 2 RACK STORAGE* (17)
Max. Celling Ht (n)
Maximum Storage Ht (m)
Temp. Rating*
Sprinkler Spacing (o2)
Sprinkler Demand
Hose Stream Demand (L/minute)
Duration (hr)
9.1
4.6
Ordinary
7.4-9.3
12 sprinklers at
446 kFa
946
1
7.6
6.1
Ordinary
7.4-9.3
12 sprinklers at
446 kPa
946
1
'Single and double row racks only.
bVhen use of higher temperature-rated sprinklers is necessary, such as near
unit heaters, refer to NFPA 13, Standard for Installation of Sprinkler
Systems.
61
-------
TABLE 20. ESFR ARRANGEMENT AND PROTECTION OF LEVEL 3 RACK STORACE* (17)
Max. Celling Ht (m)
Maximum Storage He (m)
Temp. Rating*1
Sprinkler Spacing (a2)
Sprinkler Demand
Hose Stream Demand (L/minute)
Duration (hr)
9.1
4.6
Ordinary
7.4-9.3
12 sprinklers at
618 kPa
946
1
7.6
4.6
Ordinary
7.4-9.3
12 sprinklers at
446 kPa
946
1
'Single and double row racks only.
bWhen use of higher temperature-rated sprinklers is necessary, such as near
unit heaters, refer to NFPA 13, Standard for Installation of Sprinkler
Systems.
62
-------
TABLE 21. PROTECTION OF RACK STORAGE OF LEVEL 2 AEROSOLS WITH STANDARD SPRAY SPRINKLERS (17)
Duration:
Clearances: In-Rack Sprinklers
Ceiling Sprinkler In-Rack Sprinkler Storage to Ceiling Sprinkler and Hose
Arrangement Arrangement Sprinklers Demand Demand Stream
K1*C (286*F) rated;
9.3 nr max. spacing
1.27 ca orifice
<74*C (165°F) rated;
sprinklers 2.4 n apart
awx.
One line at each tier ex-
cept top.
Locate In longitudinal
flue spaces double-row
racks.
4.6 a
Need barrier with
sprinklers beneath if
clearance exceeds 15
ft. (See note.)
3.6 1/ninute/m^
over 232 nr
30 psi per sprinkler
niniaun.
Based on operation of
hydraulically Most re-
mote:
(1)8 sprinklers If
one level.
(2) 6 sprinklers each
of 2 levels if only 2
levels.
(3) 6 sprinklers on
top 3 levels if 3 or
more levels.
2 hr
MOTE- Provide aroroved rack storage sprinklers with built-in water shields. Locate longitudinal flue in-rack sprinklers at least
0.6 a (2 ft) from rack Rights. Provide at least 150 wm (6 in.) between sprinkler deflectors and top of storage in tier.
-------
TABLE 22. PROTECTION OF RACK STORAGE OF LEVEL 3 AEROSOLS WITH STANDARD SPRAY SPRINKLERS (17)
Celling Sprinkler
Arranf (Milt
la-Rack Sprinkler
Arranf want
Claarancaa:
Storage to
Sprlnklara
Calling
Demand
la-Rack
Sprloklar
Daaand
DuratIon:
Sprlnklara
and Boaa
Straaa
Ul'C <2B6*F) ratad
17/32 In. orlflca 9.3
a* aaa. (pacing.
«74*C <163*F) ratadi
aprlnklara 2.4 ¦ apart
au.
Inatall In longitudinal
flue and on faca of aach
tlar.
1.3 a or la**
3.6 L/alnute/o*
ovar 212 m1
Hora than 1.3 ¦ to 4.6
7.2 L/alnute/o*
ovar 139 n* to
232 a*
Interpolate for
claarancaa ba-
tman 1.3a and
4.6 a
On
P-
Hora than 4.6 a
7.2 L/alnutmlmf
ovar 232 a* plua
a barrlar abova
top tlar with
faca aprlnklara
balow.
113 L/alnuta par 2 hr
aprlnklar alnlaua.
Baaad on operation of
hydraullcally no it ra-
aotai
(1) S aprlnklara If
ona laval.
(2) 6 aprlnklara aach
of 2 levala If only 2
lavala.
(3) 6 aprlnklara oo
top 3 lavala If 3 or
aora lavala.
113 L/alnuta par 2 hr
aprlnklar alnlaua.
Baaad on operation of
hydraullcally Boat re-
aotei
(1) B aprlnklara If
ona laval.
(2) 6 aprlnklara aach
of 2 lavala If only 2
lavala.
(3) 6 aprlnklara on
top 3 lavala If 3 or
aora lavala.
113 L/alnuta par 2 hr
aprlnklar alnlaua.
Baaad on operation of
hydraullcally aoat re-
aotei
(1) B aprlnklara If
ona level.
(2) 6 aprlnklara aach
of 2 lavala If only 2
lavala.
(3) 6 aprlnklara on
top 3 lavala If 3 or
aora lavala.
(Continued)
-------
TABLE 22. (Continued)
Celling Sprinkler
In-Rack Sprinkler
Clearances:
Celling
In-Rack
Duration:
Arrangement
Arrangement
Storage to
Demand
Sprinkler
Sprinklers
Sprinklers
Demand
and Hose
Stream
*76°C (165°P) ratedi
Up to 4.6m
7.2 L/mlnute over
113 L/mlnute per
2 hr
sprinklers 2.4 m (8 ft)
232 m'
sprinkler minimum.
apart max. One line at
Based on operation of
each except top. Locate
hydraullcally most
In longitudinal flue.
remote;
(1) 8 sprinklers If
one level.
(2) 6 sprinklers each
of 2 levels if only 2
levels.
(3) 6 sprinklers on
top 3 levels If 3 or
more levels.
NOTE: Provide approved rack storage sprinklers with built-in water shields. Locate longitudinal flue ln-rack sprinklers at least
0.6 m (2 ft) from rack uprights. Provide at least 150 rem (6 In.) between sprinkler deflectors and top of storage In tier.
More th*n 4.6 m 7.2 L/mlnute over 113 L/mlnute per 2 hr
232 m* plus a sprinkler minimum,
barrier above top Based on operation of
tier with face hydraullcally most
sprinklers below remote:
(1) 8 sprinklers If
one level.
(2) 6 sprinklers each
of 2 levels If fcnly 2
levels.
(3) 6 sprinklers on
top 3 levels If 3 or
i i _
-------
Segregated storage of Level 2 and Level 3 aerosol products is permitted
under the Code if the warehouse is protected throughout by an automatic
sprinkler system designed according to NFPA 231. To prevent aerosol products
from rocketing and spreading a fire, Level 2 and Level 3 products must be
segregated from the rest of the warehouse by interior walls, chain link
fencing, or a separation area. The chain link fencing must extend from the
floor to the roof deck or ceiling.
The Code permits quantities of Level 2 and Level 3 aerosol products in
excess of the amounts discussed above only in warehouses dedicated to the
storage of aerosol products, and fire protection must be for the highest level
of aerosol product present. The Code leaves to the jurisdiction of individual
area and regions whether aerosol warehouses may be unprotected by sprinkler
systems when located at least 30 m (100 ft) from exposed buildings or adjoin-
ing property, if those buildings or property are themselves protected.
Otherwise, the minimum distance is 60 m (200 ft). Other hazardous materials,
such as flammable liquids, may also be stored in unlimited quantities within
such a building.
Level 2 and Level 3 aerosol products stored in a warehouse meant for
storing liquids must be within a segregated area separated from the rest of
the warehouse by either interior walls or chain link fencing, and the area
must be protected by a sprinkler system such as described in Tables 17 through
22. Fire doors or gates leading into the segregated storage area should be
self-closing or activated by water flow or by the fire detection system to
close automatically.
Up to 454 kg (1000 lbs) of Level 2 or 227 kg (500 lbs) of Level 3
aerosol products, or 1000 lbs of combined Level 2 and Level 3 products, may be
stored separately inside flammable liquid storage rooms of 47 m2 (500 ft2) or
less if the rooms meet the NFPA 30 Flammable and Combustible Liquids Code. If
the room is larger than 47 m2 (500 ft2) up to 1135 kg (2500 lbs) of Level 2 or
454 kg (1000 lbs) of Level 3 aerosol products, or 1135 kg of Level 2 and Level
3 combined, may be stored in this way. If the room is protected by sprinkler
66
-------
systems such as those described In Tables 17 through 22, up to 2270 kg
(5000 lbs) of Level 2 and Level 3 aerosol products may be stored.
Level 2 and Level 3 aerosol products stored outdoors should be located
as far as possible from buildings and other important structures. At least
15 m (50 ft) separation should be maintained between these aerosol products
and other combustible yard storage. Temporary storage trailers must also be
located at least 15 m from other unprotected outdoor storage or from the
property line.
Sales Display Areas
The display of Level 1 aerosol products is not regulated by NFPA 30B.
Level 2 and Level 3 products, however, should be removed from combustible
cartons in sales display areas unless: 1) the area is protected by sprinkler
systems such as those described in Tables 17 through 22; or 2) the cartons are
display-cut --i.e., only the bottom 50 mm (2 inches) of the side panels
remains. In addition, the quantities displayed in unprotected areas should
not exceed the following:
The aerosol products should be stacked not more than 1.8 m (6 ft) high from
the base to the top of the display unless they are placed on fixed shelving.
Backstock Storage Area
When backstock areas are separated from the sales display areas by
construction that has at least a one-hour fire resistance, Level 2 and Level 3
aerosol products must be stored as described in the previous subsection
entitled Storage in Warehouses and Storage Areas. If backstock areas are not
Floor
Maximum Net Weight
Per Floor, kg fib)
Basement
Ground
Upper
Not Permitted
1135 (2500)
227 (500)
67
-------
separated from Che sales display areas by one-hour fire resistant construc-
tion, Level 2 and Level 3 aerosol products must be counted in the total
allowed in a sales display area, as described in the previous subsection
entitled Sales Display Areas. Additional quantities of Level 2 and Level 3
aerosol products, however, may be stored in backstock areas in flammable
liquids storage cabinets or flammable liquids storage rooms.
68
-------
SECTION 6
PRODUCT REFORMULATION "
FORMULATIONS
Aerosol products can be divided into the categories used in the U.S.
Chemical Specialties Manufacturers' Association (CSKA) Pressurized Products
Survey (32):
1. Insect Sprays
A. Space Insecticides (flying Insect spray, house and garden
spray)
B. Residual Insecticides (Insect repellents, noth proofers, ant
and roach killer)
2. Paints and Finishes
A. Paints, Primers, and Varnishes
B. Other related products (strippers, graffiti removers,
decorative "snow")
3. Household Products
A. Room Deodorants and Disinfectants
B. Cleaners (glass, oven, rug, fabric, wall, and tile)
C. Laundry Products (starch, fabric finish, prevash)
D. Vaxes and Polishes
E. Other Household Products (shoe polishes, dyes, leather
dressings, anti-static sprays)
4. Personal Products
A. Shaving Lather
B. Hair Spray
C. All Other Hair Products (mousse, lusterlzers)
69
-------
D. Medicinals and Pharmaceuticals (vaporizers, fungicides,
antiseptics, contraceptives)
E. Colognes, Perfumes, and After Shave
F. Personal Deodorants, Antiperspirants, Powders and Deodorant
Colognes
G. Other Personal Products (suntan preparations, lotions,
breath fresheners, depilatories)
5. Animal Products
(Includes veterinary and pet products such as shampoos, insec-
ticides, repellents)
6. Automotive, Industrial & Miscellaneous Household Lubes
A. Refrigerants
B. Windshield and Lock Spray De-icers
C. Cleaners (automotive upholstery, leather or vinyl dressing,
tire cleaners)
D. Engine Degreasers
E. Lubricants and Silicones (penetrating oils, demoisturizers,
rust proofing, mold releases)
F. Spray Undercoating
C. Tire Inflators and Sealants
H. Carburetor and Choke Cleaners
I. Brake Cleaner
J. Engine Starting Fluid
K. Other Automotive and Industrial Products (adhesives)
7. Food Products
(Includes all types such as pan sprays, cheese food, cake decora-
tions)
8. Miscellaneous Products
(Other products not listed above)
70
-------
Example formulations of several of these products are presented in
Appendix H.
GENERIC GUIDELINES AND FACTORS THAT AFFECT FORMULATION'S
This section discusses some characteristics of hydrocarbon propellants
as they relate to formulations and performance.
Hydrocarbons require changes in formulations and values to evaporate at
the proper rate and yield the preferred spray. For example, the "transfer
efficiency" of an antiperspirant spray with straight isobutane propellant was
about 55%, versus over 80% when propelled by CFCs, In some cases, less
volatile hydrocarbons such as n-butane or isopentane may provide the same
effect as CFCs.
For certain products such as paints, lacquers, and industrial products,
less expensive liquified petroleum gases (LPG) (nay be used. In these specific
applications, the stronger odor of LPG is not a problem.
The most difficult problems of reformulating aerosol products with
hydrocarbons have been solved. For example, in the U.S., problems with
perfume formulations were solved by: 1) developing concentrates that were
more compatible with the hydrocarbon propellants; 2) adding up to 18% water to
help separate insoluble components; and 3) purifying the hydrocarbon propel-
lants to remove the objectionable olefinic species by use of molecular sieves
(3).
Dispersancy, one major attribute of aerosol propellants, is the effi-
ciency with which a propellant can produce a fine spray or an acceptable foam.
This is illustrated in Table 23.
The dispersancy of blends can be readily calculated. For example,
Propellant A-46 (20 mol% propane and 80 mol% isobutane) has a dispersancy of
[549 x 0.2 + 415 x 0.8] - 442 mL/g at 21.1'C.
71
-------
TABLE 23. DISPERSANCY CHARACTERISTICS OF VARIOUS PROPELLANTS
(In order of Vapor Volume in mL/g)
Propellant
Vapor Volume
(mL vapor/g liquid at
21.1° C)
Vapor Volume
(mL vapor/mL liquid at
21.ro
Nitrogen
862
N/A
Carbon Dioxide
549
N/A
Nitrous Oxide
549
N/A
Propane
549
280
Dimethyl Ether
523
345
Isobutane
415
234
n-Butane
415
239
HFC-152a
365
333
HCFC-22
279
337
CFC-115
256
(not avai
HCFC-142b
240
269
HFC-134a
236
283
HCFC-141b
206
253
CFC-12
200
265
CFC-125
198
227
CFC-11
176
261
HCFC-124
176
242
HCFC-123
158
232
CFC-114
141
207
FC-C318
119
179
NOTE: These propellants boil at >21.2*C (Range: 23° to 33*C).
N/A - Not Applicable
72
-------
A shave cream or mousse made using either 8% CFC-12/114, 4% A-46, or 2%
nitrous oxide will all show the same properties of foaa density and overrun.
(However, the nitrous oxide formula will have a very high pressure, which can
be expected to decrease significantly with use.)
In the years before the CFC aerosol ban of 1978 in the U.S., hair sprays
were commonly formulated with 45% CFC-12/11 (55:45) or 40% Propellant A (10%
isobutane, 45% CFC-12, and 45% CFC-11). They are now formulated with 20 to
26% isobutane, sometimes with a snail amount of propane added. These examples
show the importance of dispersive effect on propellant volume.
The dispersive effect is not linear but i9 modified by vapor-pressure,
solubility factors, and even by the pressure itself. It normally can be used
as a general guideline to determine equivalencies when changing from one
propellant choice to another.
After a concentrate has been tentatively developed, the correct type and
amount of propellant must be added, and an aerosol valve must be used that
will develop the desired spray pattern or foam puff. One of the most impor-
tant characteristics that the formulator looks for is particle size distribu-
tion, which can be of paramount importance. If the droplet size is too
coarse, it can be decreased by one of the following techniques:
• Increase the percentage of propellant;
• Increase propellant pressure and/or dispersancy;
• Use a vapor-tap valve or a larger vapor-tap orifice;
• Use a mechanical break-up button;
• Add a low-boiling (volatile, easy breakup) solvent; and
• Reduce the quantity of polymers, thickeners, resins, adhesives,
and water.
73
-------
Approximately 40-50% of the world's 8 billion aerosol products use
vapor-tap valves. Such valves have an orifice extending through the side or
bottom wall of the valve body and into the head space area. Vhen the orifice
of a vapor-tap valve is enlarged to decrease particle size, a price is paid.
The negative effects are listed below:
• A broader particle size distribution will generally result.
• A gradual coarsening of the spray may occur during use.
• The internal pressure will decrease, as air and the more volatile
propellant ingredients preferentially escape through the vapor-tap
orifice.
• The delivery rate will always be lower than without a vapor-tap,
and will decrease during use, because of pressure reduction.
The potential problems with vapor-tap valves can be minimized by the
following techniques:
• Use the smallest vapor-tap hole that will suffice (a 0.25 mm size
may be a good starting point).
• Use a fairly large amount of propellant that disperses well
(reservoir effect).
• Use a pure propellant; otherwise, the more volatile ingredient
will be preferentially discharged, causing a pressure drop.
• Use reasonably large liquid orifices.
• Emphasize any or all of the above in taller cans, since (near
emptiness) a liquid column of 150 • 250 mm will have to be main-
tained in the dip tube just to bring the product into the valve
Ik
-------
chamber. A greater dynamic pressure potential is needed, compared
with shorter.can 9izes.
As a rule, thin or driving spray9, or sprays with high delivery rates,
will be perceived by consumers as "wet" or "cold," although they may be
anhydrous. Vet sprays are usually disliked, except for the coating of
inanimate surfaces (such aa a paint spray or bug killer); they are most
disliked for cosmetic items designed to be sprayed on the skin, such as
underarm antiperspirants or deodorants. The aerosol antiperspirant provides
an Interesting challenge because large valve orifices must be used to prevent
possible valve clogging by the 7 to 12% aluminum chlorohydrate powder normally
present. Here, the vapor-tap valve, used with a mechanical break-up button,
provides a fine-particled spray. The propellant content is in the 68-82%
range to give good breakup and to provide an adequate reservoir for the vapor -
tap.
Flamm/ibilitV
To devise a good aerosol product, a formulator must try to minimize the
risks of flamicability and possible explosivity. It is a tribute to the
excellence of the aerosol packaging form that extremely flammable products can
be safely dispensed, if the user follows the label directions, and if the
formulator is able to make allowances for reasonably foreseeable consumer
misuse. Flammability is a potential problem when large amounts of product are
discharged at one time, as in some hair spray applications, painting, water-
proofing, and in the total release insect fogger (TRIF) products. Flammabili-
ty has also been a problem when containers are dropped on the valve stem,
causing it to bend or crack in such a way that the valve jams, releasing a
continuous spray.
Pressure
Most U.S. aerosols are formulated to a pressure as low as is consistent
with good operational performance across the anticipated temperature range of
75
-------
their use. For example, hair sprays are expected to work well between 13s -
37°C, and reasonably well just outside these limits.
Pressure limits for containers vary only modestly among countries. In
the U.S., the so-called ordinary or non-specification can is permitted to hold
product with pressures up to 1,067 kPa abs. (9.85 bar - gauge) at 54.4®C. It
will not rupture below 1,546 kPa abs. (14.8 bar - gauge). Special cans with
14% and 28% higher pressure ratings are also available at an extra cost. They
only hold about 9% of the market. Aerosols of less than 118 mL capacity are
not regulated for pressure limits in the U.S. Most aerosol containers will
begin to deform at about 65'C and will rupture at 75*C or higher, depending on
can and product.
Materials Compatibility
The formulator's job is not complete when an acceptable product and
packaging system has been developed. Test packing is always needed to
establish data on weight loss rates, can and valve compatibility, organoleptic
stability, etc. Hundreds of sad stories could be written about new products
that were inadequately tested, and then could not be manufactured, eroded the
can, demulsified, changed color or odor, were subject to microbial prolifera-
tion, grew inorganic crystals, or eventually threw down resinous precipitates
in the container, swelled valves shut or partly shut, blistered can linings,
became latent leakers, etc. No fewer than 36 cans per variable should be test
packed and checked-- some at about 25°C and some at 40°C; some upright and some
inverted.
Tinplate cans do not corrode unless at least 0.008% of free water is
present. Above about 0.250%, greater concentrations of water will have no
additional effect on the rate of corrosion, if any. Water has little effect
on aluminum cans. In fact, Its virtual absence can sometimes allow anhydrous
alcohol (C2H50H) to attack aluminum cans to produce aluminum ethoxide
[(C2HsO)3Al] and hydrogen (H2) gas. Water is implicated in the well-known
ability of 1,1,1-trichloroethane to sometimes attack plain and lined aluminum
cans, but the mechanism is still unclear. Finally, water can facilitate
76
-------
development of high pH values in hair depilatory formulas and certain others,
leading to aluminate (A102") ion formation, plus hydrogen (H2) gas. Since
aluminum is amphoteric, it should only be used with formulas having a pH of
less than 12.0 at 25°C, and then only when reliably lined.
If a generalized, non-pitting corrosion pattern is seen, it is best to
use a lined or double-lined can. Detinning is generally a good sign, showing
that the tin (not the iron) is anodic. If pitting is detected, the formula
should be changed. Several options are described below:
• Remove the offending or causative ingredient if possible, such as
sodium lauryl sulfate, especially if chloride ion is present.
• Add corrosion inhibitors, such as sodium nitrite, sodium benzoate,
morpholine, or sodium silicates. (Do not use nitrites in conjunc-
tion with primary or secondary amines, or N-nitrosamines will very
slowly form in situ. Many of these are carcinogenic.) From 0.05%
to 0.20% inhibitor is generally sufficient.
• Increase the pH to between 7.6 and 8.8, if possible, by adding
triethanolamine or ammonia (NHt0H Solution).
• Remove or minimize ionizing materials, i.e., those that permit
electroconductivity and thus promote galvanic corrosion reactions.
• Minimize chloride ion (especially). It is a very active corrosion
promotor, even for underfilm corrosion. It is critical to mini-
mize chloride ion when materials such as sodium lauryl sulfate
(which contains it in some grades) or lauryl polyoxyethylene
sulfates are present.
• Sometimes specific corrosion inhibitors are required. Sodium
lauryl sarkosinate and sodium coco-B-aninopropionate surfactants
are useful for sodium lauryl sulfate. Coco-diethanolamide is good
for non-ionic surfactants. Virco-Pet 20 (composition proprietary,
77
-------
except chat it is an organic phosphate), is good for dimethyl
ether and water compositions.
• For some formulas, traces of moisture can be removed by using such
scavengers as propylene oxide or epichlorohydrin. (Very limited
evidence suggests that both may be mutagenic.) These chemicals
are never recommended for cosmetics.
Many formulations that are intensely corrosive to steel cans may be
conveniently packaged in lined aluminum containers. Examples are mousse
products and saline solutions. The latter contain 0.9% sodium chloride (NaCl)
in water under nitrogen pressure.
CAN/SPRAYER CHOICES
Successful marketing of a new or reformulated product depends on the
stability and performance of the complete package system. Typically, this
involves selecting formulations that have been tested for periods of a year or
more, Potential problems that can be avoided include: corrosion of the
container, instability of emulsions, changes in color or odor, microbial
growth, crystallization or precipitation of insoluble compounds within the
container, swelling of valves, or blistering of can linings (14), Failing to
select the right reformulation of a product can be disastrous.
Converting from a CFC-propelled formulation to hydrocarbon-propelled
formulation does not generally lead to problems with tinplate can corrosion.
However, it is possible that a reformulated hydrocarbon-propelled product
might require the addition of water, which could cause can corrosion.
On the other hand, there are instances when conversion away from CFCs to
hydrocarbon propellents reduces the potential for corrosion. CFC-11 is known
to readily hydrolyze to form corrosive HC1; this is possible in otherwise
anhydrous formulations because of the use of 190-proof alcohol (95% alcohol
and five percent water).
78
-------
Aluminum containers are somewhat more prone to corrosion than tlnplate
containers, because aluminum Is a very active metal and has unique corrosion
properties. Therefore, many chlorinated solvents or propellants should not be
used In unlined aluminum cans. Chloride Ion Is a strong corrosion promoter,
especially In acidic solutions (3).
Both tlnplate and aluminum containers can be protected from corrosive
formulations by using sprayed can linings. Tlnplate cans are available in the
U.S. with nine different coatings. Three-piece tlnplate cans have a side-seam
stripe, whereas aluminum cans are impact-extruded and seamless. The integrity
of the lining in these "monobloc" aluminum containers is far superior to that
of most tinplate containers, since there Is no subsequent bending or welding.
Two examples of common coatings are Epoxy-Phenolic and Organasol.
Aerosol valve manufacturers state that valve selection is highly
product-specific, and that no generalizations can be made about the effect of
propellant conversion on the optimum aerosol valve.
79
-------
-------
REFERENCES
1. Atmosphere, Volume III, No. 2. Friends of the Earth, October 1990.
2. Sanders, P. A. Handbook of Aerosol Technology (2nd Ed.). Van Nostrand
Reinhold Co., New York, NY, 1979.
3. Johnsen, M. A. The Aerosol Handbook (2nd Ed.). Wayne Dorland Co.,
Mendham, NJ, 1982.
4. Meuresch, H. Considerations at the Change-Over to New Aerosol Systems.
Aerosol Age, June 1982, pp. 26-32.
5. Shreve, R. N., and J. A. Brink. Chemical Process Industries (4th Ed.)
McGraw-Hill Book Co., New York, NY, 1977.
6. Gas Processing Report. Oil and Gas Journal, July 10, 1989. pp. 45-80.
7. HPI Construction Boxscore. Hydrocarbon Processing, October 1990.
8. Sudhaker, B., and B.K.B, Rao. India's Energy Options: The Latest
Review. Hydrocarbon Processing, April 1990, pp. 116C-116H.
9. Gas Processors Suppliers Association. Engineering Data Book (9th Ed.).
Gas Processors Association, 1972.
10. "1988 Gas Processing Handbook," Hydrocarbon Processing, April 1988. p.
55.
11. Standard Specifications for Liquified Petroleum (LP) Gases. American
Society of Testing and Materials (ASTM). ASTM D1835-89 (May 1989).
12. International Energy Annual, 1989. Energy Information Administration,
U.S. Department of Energy DOE/EIA-0219 (89). February 1991.
80
-------
-------
13. Treybal, R. E. Mass Transfer Operations (3rd Ed.). McGraw-Hill Book
Co., New York, NY, 1980.
14. Nelson, T.P., and S.L. Wevill. Aerosol Industry Success in Reducing CFC
Propellant Usage. EPA-600/2-89-062 (NTIS PB90-143447). U. S.
Environmental Protection Agency, Research Triangle Park, NC, November
1989.
15. American Gas Association. Gas Engineers Handbook (Fuel Gas Engineering
Practices). First Edition, Fifth Printing. Industrial Press, Inc., New
York, NY, 1977.
16. Costs to Egypt of Protecting the Stratospheric Ozone Layer (1st Ed.).
Egyptian Environment Affairs Agency/U. S. Environmental Protection
Agency, June 1990.
17. National Fire Protection Association, NFPA 30B Manufacture and Storage
of Aerosol Products. NFPA, Quincy, MA, August 1990.
18. National Fire Protection Association, NFPA 58 Standard for Storage and
Handling of Liquified Petroleum Gases. NFPA, Quincy, MA, 1989.
19. Nardini, G. Open Air Filling of Hydrocarbon Propellants. Presented at:
1990 International Conference on CFC and Halon Alternatives, Baltimore,
MD, November 1990.
20. Chemical Specialties Manufacturers Association. Hydrocarbon, Dimethyl
Ether, and Other Propellants: Considerations for Effective Handling in
the Aerosol Plant and Laboratory. Order TP-7/TP-7A (1984 Edition).
CSMA, Washington, D.C.
21. Code of Federal Regulations, 49 CFR 173.315 61, p. 652, 10-1-91.
22. Johnsen, M.A. Comparison of Flammability Tests and Intrinsic Consumer-
Related Aerosol Flammability. Aerosol Age, October 1988, pp. 34-38.
81
-------
23. Johnsen, M.A. Consumer-Related Aspects of Aerosol Flammability an
Explosivity. Aerosol Age, Decenber 1988, pp. 36-42.
24. Johnsen, M.A. Consumer-Related Aspects of Aerosol Flammability.
Aerosol Age, November 1988, pp. 46-52.
25. Richardson Cost Manual. Account 15-105 (Halon Chemical Type Fire
Protection System). 1990 Edition.
26. Mexico's Strategy on Ozone Layer Protection: A Case Study on the Costs
of Implementing the Montreal Protocol (1st Edition). Secretaria de
Desarrollo Urbano y Ecologia/Camara Nacional de la Industria de la
Transformacion/U.S. Environmental Protection Agency. June 1990.
27. Johnsen, M.A. Aerosol Quality Assurance and Product Development
Laboratory Operations. Aerosol Age, May 1988, pp. 42-48.
28. According to NFPA Code 231, Standard for General Storage, and NFPA Code
231C, Standard for Rack Storage of General Materials
29. Johnsen, M.A. Fire Protection of Aerosols During Storage and Display.
Aerosol Age, March 1989.
30. Johnsen, M.A. Fire Protection of Aerosols During Storage and Display.
Aerosol Age, May 1989.
31. Telephone conversation with Douglas Fratz, Chemical Specialties
Manufacturers Association, Washington, D.C.
32. Chemical Specialties Manufacturers Association. Aerosol Pressurized
Products Survey United States 1989. Order SR-2. CSMA, Washington, D.C.
82
-------
APPENDIX A
INDUSTRY EXPERTS
A- 1
-------
INDUSTRY EXPERTS
General
Area
C»p any
Kama
Contact Hum
and Title
Address
Fhona
1. Bydroearbon
Propellent
Suppliara
Aaroprea
Dr. Harry McCain
Technical Dlractor
132* N. Bearne
Sulta 200
Shraveport, LA 71107
USA
318-221-6282
Calor Gaa Ltd.
K.A. Brtnboaccc
Ganeral Mac ajar -
national Salaa
Appleton Park
Slough, SI3 9JG
England
<0733) 40000
(0733) *8121
Dlvaralfiad CPC
International,
Ine.
Mr. Bala Bathan
Santa Fa Industrial
Dlatrlct
Durkaa Road
Charmahon, IL 60*10
USA
813-423-3993
813-*23-3627
Induatrlal
Hydrocarbona
~~
173 W. Bonlta Ave.
San Dlmaa. CA 91773
USA
714-399-6386
2, Contalnar
arid Valva
Suppliers
Advanced HonobLoc Mr. Scott Schneider
Precieion Valva Mr. Willia® Gregg
Corp. Vlca Prealdent, R&D
Valvulaa da Pracl- Gano Nardiol
¦ ion, S. A. HarkatIn* Dlractor
Saaqulat Valva Co. Ha. Carlaan Kxlader
(Dlv. of Plttway Vlca Praaldant, R&D
Corp.)
Hermitage. PA, 161*8
USA
U.S. Can
Mr. Paul Brubeeky
700 Nepperham Ave
P.O. Box 309
Tonkara, NY 10702
USA
Aiafran 313
CoL. Granjas Mexico
Hailco, D.F. CP 08*00
Mailco
1160 N. Sllvar Laia
Rd.
Cary, IL 60013
USA
BOO Coonarca Drive
Oak Brook, IL 60321
USA
412-981-4*20 *12-342-1116
91*-969-6300 91*-96B-1985
634-99-16 63*-19-39
6i*-99-37
708-639-212* 708-639-1179
708-888-5673 708-886-3680
Equipment Aaroflll Ltd.
Monufac- (FilLlng Equlp-
turara mant)
Coatar Technology
Spaclall SpA
(Filling
Equipment)
The Kartrldg Fak
Co. (Filling
Equljment)
Tareo (Filling
Equljmant)
Flka Corporation
(Ezploaion Sup-
praaalon)
Mr. R. L. Ruaaall
Haehanlcal Projecta
Hanagar
Mr. Glancaxlo
Becchetta
Mr. Barb Page
Mr. Dava Cull
Mr. Bruce McLaLland
EPC Product Managar
33-33 Clayton Road
Bayea
Mlddlaaaz LFB3LRU
England
Via Fablo Fllzl 27
2012* Milan
Italy
807 H. Kiobarly Road
P.O. Box 38*8
Davenport, 1A 32806
USA
*98 Lunt Ava.
Schaumburg, IL 60193
USA
70* S. 10th Straat
Blue Sprlnga, HO
6*013
USA
081-e*8-»501 061-361-3308
392 669 8*76*
319-391-1100 319-391-*931
70B-B9*-e628 708-69*-BB*6
816-229-3*03 6L6-228-B277
(Continued)
A- 2
-------
INDUSTRY EXPERTS (Continued)
General
Arts
Coopany
Nidi
Contact Han
and Title
Address
Phone
Fax
3.
Equlpmnt
Manufactur-
ers (Cent.)
Fennel Safety
Systems, Inc.
(Explosion Sup-
pieaalon)
Kiddle Gravinar
Ltd. (Explosion
Suppression)
Mr. Henry Oaxiia
System Design Mgr.
700 Hickerson Rd. 308**81-5800
Marlborough, MA 01752
USA
50B-*B5-3113
Polya Road
Colnbrook
Slough, Berkshire
SL30HB
**7 536832*5 **753685126
England
LaRoche Chemicals,
Dr. John H. Novak,
Airline Bwy.
50*-356-8*23
S0*-3S8-2820
Inc. (Activated
Product Mgr.
P.O. Box 1031
Aluminas for LPG
Baton Rouge, LA 70821
Purification)
USA
Alcoa Separations
Mr. Hugh B. Walker,
333 North Belt
713-9BB-B05D
713-999-5*03
Technology, Inc.
Regional Sties Mgr.
Suite 650
(Subsidiary of
Houston, TX 77060
AlCOA) (Activated
USA
Aluminas and Acti*
vatad Carbons for
LPG Purification)
Dtviion Chemical
Mr. George W. Alafeld
P.O. Box 2117
301-659-9292
301-659-9213
Division (W.R.
Technical Sales Rep.
Baltinore, MD 21203-
Grace & Co.) (Sil-
2117
ica Gals and Mo-
USA
laculer Slaves for
LFG Purification)
UOP Molilv Adeor-
Mr. Michael E. Clerk
13105 Northwest Fwy.
713-7**-28*0
713-7**-2802
bents (Molecular
Technical Sales Rep.
Suite 600
Slave Adsorbents
Houston, TX 770*0
for LPG Purifica-
USA
tion)
*. Consultants Montfort A. John-
Montfort A. Johneen
26 Sheral Driva
Z17-*4Z-1*00
217-**2-1*00
tan & Assoc., ltd,
Aerosol Consultant
Danville, IL 61832-
X228
135*
USA
Richard C. Knollys
Richard C. Knollyt
Greys
0491 873094
4*73*8*5865
Aerosol Conaultant
Manor Road
c/o CMB
Goring on Thanes
Aerosols
Reading,
Barkshirs: RG8 9ED
England
5. Plant
Spray Qulmlca C.A.
Jose Pont Pons
La Victoria
58**213753 58**210521
Operators
General Manager
Venezuela
Toyo Aerosol In-
Katsuo Imazekl
Saiwai Building
81-3-502-1292 81-3-508-8685
dustry Co. Ltd.
1-3-1 Uchiaaiwaicho
Chiyoda-ku, Tokyo 100
Japan
A- 3
(Continued)
-------
INDUSTRY EXPERTS (Continued)
General
Area
Coop any
Kama
Contact Ran
and Titla
Address
Phone
Fax
6.
Government
Official*
Egyptian Environ-
mental Affaica
Agency
Dr. El-Mohamady Eld
Chalrasi of EZAA
Miniatry of Light Mr. Zbaogxl Bunag
Indust. Dept. of Cbaiman, Aerosol
Intl. Cooparatlon Technical Subcom-
mittee
Hlnlatry of tha
Chemical Induatry
U.S. EPA
Office of Air &
Radiation
Global Change
Division
U.S. EPA
Air and Energy
Engineering Re-
aaarch Laboratory
Stratoapharic
Ozone Protection
Branch
Vital? Fullkov
Stephen 0.
Ph.D.
Andaraan.
N. Dean Smith, Ph.D.
Arab Republic of
Egypt
Cabinet of Miniitera
11-A Haaaan Sabry St.
Zamalak, Cairo
Egypt
22b Pu Wai Da Jia
Beijing, 100833
Chine
Kirov St. 20
101851 Moscow
USSR
Hall Stop ANR-**5
*01 H Street, S.W.
Washington, D.C.
20*60
USA
Air and Energy Engi-
neering Research Lab-
oratory
MD-62B
Research Triangle
Park, NC 27711
USA
20-2-341-1323 20-2-3*2-0768
86-1-867-9*0
927-7363
222717 LIMDI
CM (telex)
*11009 BIUR SU
(tales)
202-*75-9*03 202-382-7883
919-5*1-2708 919-5*1-7885
A-4
-------
APPENDIX B
SAMPLE CALCULATIONS
B-l
-------
SAMPLE CALCULATIONS FOR LPG PURIFICATION
BASIS:
1) Assume a lu|i-ili> automated aaroaol filling plant producing approximately 10 million cana
par year
2) Aaauma each unit contain! approximately SOX by volume HC propallant
3) Assume an average unit aica of 12 fluid ounces
Aaauma production schedule of 250 daya per yaar with 6 hour par day ibifti
A. PRODUCTION RATI: UOxlO6 unlte/yr)/(250 day/yr)- 40,000 units/day
or (*0,000 units/day)/(9 hour/day shift)- 5,000 units/hr
B. LPG CONSUMPTION RATI: (30 volZ propallant)*(12 fl. ot)*(5,000 unit«/br)/(128 ox./gallon)
- 141 gel/hr LPG
(Round up to 150 gal/hr) - (150 gal/hr)*(8 hr/day)*(21 day/mo)
- 23,200 gal/mo LPG
(150 gal/hr)*(4.695 lb/gal) - 705 lb/hr
Given that a large tanker load may have a capacity of 10,000 gallona but may only ba filled
to 90 or 90 percent of full, thii hypothetical plant would racalva a ahipoant approximately
once each weak.
C. DEHYDRATION
Take water content in hydrocarbon aa 0.01E Lb HjO/100 lb HC at 100*F for iaobutana (from
Figure 3 "Solubility of Water in Hydrocarbon!" In ALCOA Bulletin "Dehydrating Liquid* with
Alcoa Activated Aluslnae" Form No. F35-14481)
Use valua of 2 wtX I^O capacity for silica gal when drying to 0'F Dew Point (froa Figure 5
"Silica Gel Bad Temperature et Various Watar Loadings" in Daviaon Silica Gala Brochure
IC-15-1087)
Assume operation at 100*F: (705 lb/hr)*(0.018 lb B2O/IOO lb BC)
- 0.127 lb HjO/hr
Required Amount of Silica Gel for 0*F D«w Point:
Aaauma Silica Gal replacement every 3 months: (3 mo.)*(21 deyi/mo.)*(8 hr/day) ¦ 504 hra
between regeneration/replacement
Required Silica Gal - (504 hr>*(0.127 lb/hr)/(2 lb H20 per 100 lb Silica Gal) - 3,200 Lb of
Silica Gal
Approximate bed dinars Ions: Aiiiae denalty of 35 lb/ft'
Bad Volume: (3,200 lb)/(35 lb/ft3)- 91.4 ft3
(This could ba acccemodated with a bad of 4 ft. diameter and 7 ft. deep)
Approximate Coet of Silice Gal Charge: Assume unit cost of S3.00 per pound (per U.S. supplier at
1,200 pound minimum shipment) - (3,200 Lb)*(S3.00/lb) ¦ S9.600 par charge every 3 months.
(Continued)
B-2
-------
SAMPLE CALCULATIONS (Continued)
D. DESULTUXI1ATI OH
Take sulfur content in hydrocarbon as 10 grains H2S/100 ft3 BC (equals ISO ppov) (sulfur
content la highly variable depending on local LPG aupply and odorization: for example, tha
U.S. standard for coomarciaL propane and butana la IS grain* par 100 ft , while tha
odoritstion limit using athyl marcaptan la approximately 2 grains par 100 ft3).
Convert to parts-per-ailllon (weight): 10 graina - 0.0014286 Lb and (100 ft3
isobutana)/(6.529 ft /Lb at Std. Cond.) " IS.316 lb
B2S (ppDM)- (0.0014286 Lb H2S)/(15.316 lb gaa)*(106) - 93.3 ppow B2S
Uaa valua of 3 wtl H2S capacity for Type 13X Molecular Sieve whan treating at 77"F (Iron
Isotbera Data Shaat No. 207 "Bydrogan Sulfide Adsorption on 13X Pellets" In Union Carbide
Molecular Sieves Hateriala Data Sheeta XT-19)
All IBM operation at 77'F: (705 lb/hr)*(93.3 lb B2S/106 b BC)- 0.0658 Lb H2S/hr
Required Amount of Type 13X Holacular Slave for B2S Removal:
Aasu&a Hoi Slava replacement avary 3 months: (3 mo.)+(2l days/mo.)+(8 hr/day) ¦ 504 hra be-
tween regeneration/replacement
Raqulrad Typa 13X Hoi Slava - (504 hr)*r0.0656 U>/hr)/(3 lb Q2S par 100 lb Hoi Slava) -
1,100 Lb of Typa 13X Holacular Sieva
Approximate bed dimensions: Use bull density of 40 lb/ft3
Bed Volune; (1,100 lb)/<40 lb/ft3)- 27.5 ft3
(Thla could be eccomodated with a bed of 2 ft. dlaaeter and 9 ft. deep)
Approximate Coat of Type 13X Hoi Sieve Charge: Assume unit eost of 93.00 per pound (par U.S.
supplier at 1,200 pouDd minimum shipment)
• (1*100 lb)*($3.00/lb) - $3,300 par charge every 3 months.
B-3
-------
-------
APPENDIX C
SAFETY CHECKLIST FOR AEROSOL PLANTS USING
HYDROCARBON PROPELLANTS
C-l
-------
SAFETY CHECKLIST FOR AEROSOL PLANTS USING
HYDROCARBON PROPELLANTS
A. RECEIVING, STORAGE, AND HANDLING
NOTE: This section refers to the receiving, unloading, transfer, and
storage of flammable hydrocarbon propellants at the aerosol manufactur-
ing plant site. Minimum hydrocarbon propellant storage for any filling
plant is usually 10,000 gallons (37,850 L).
SAFETY CHECKLIST:
• Storage tanks should be located at least 50 feet (15.2 m) from
property lines and important buildings.
• An unloading station should be at least 10 feet (3.05 m) from the
storage tanks.
• The unloading and storage area should be maintained in a fenced
area with two emergency exits (both unlocked whenever personnel
are in the area).
• Unloading compressors or pumps should be mounted on a concrete
base and kept fairly remote from tanks or other pumps. Pumps may
also be located within a separate pump house equipped with gas
detection and fire extinguishing equipment.
• All electrical equipment within 15 feet (4.57 m) of any outside
hydrocarbon propellant storage tank, bulk trailer truck, or
interconnecting piping must be explosion-proof (U.S. National
Electrical Code, Class I, Group D, Division 2) and be grounded.
[Equipment within 5 feet (1.52 m) must be Div. 1.]
• The land should be kept free of grass and weeds and should have no
low spots. Air should move freely across it to disperse any
possible vapors.
• Shut-off valves at the tank should be accessed readily. Shut-off
valves, emergency shut-off valves, and back-flow check valves
should be used in conjunction with the liquid inlet, liquid
outlet, and vapor lines. Excess flow valves should be installed
in all openings in the storage tank except the pressure relief
valve, gauging, and liquid fill connections.
• Storage tanks should have pressure gauges, thermometers, and
liquid level gauges as per requirements specified in the American
Petroleum Institute-American Society of Mechanical Engineers (API-
ASME) Code for Unfired Pressure Vessels for Petroleum Liquids and
Gases. Minimum design pressure for propane storage tanks is 250
lbs/sq. inch-gauge (17.2 bar). It is recommended that this design
pressure be utilized for butane tanks as well to provide a more
C-2
-------
flexible operation even chough butane tanks can be designed for
125 lbs/sq. inch-gauge.
Tanks should be painted in a white, silver, or pastel color and
marked as to contents.
Water deluge cannons should be present to enable cooling of the
tanks in the event of a fire.
Pipelines should be laid out to allow for expansion of the metal
and for expansion of liquid contents to prevent rupture between
shut-off points. This is handled by hydrostatic relief valves in
each section. Relief valves should be set to discharge at pres-
sures no greater than 120% of the 250 lbs/sq. inch minimum allow-
able working pressure of the system.
Pipes should be painted and labeled as to contents and flow
direction and should be on pipe supports about two feet high from
the ground.
Ethanol storage tanks should be diked to contain the liquid in the
event of a leak or spillage.
B. PROPELLANT FILLING OPERATION
NOTE: The safety items listed below particularly address requirements
or recommendations for propellant filling and pump rooms (gashouses)
physically separated from the main plant building. In instances where
the propellant filling operation is conducted within a large enclosure
also used for other operations such as liquid concentrate filling, can
weigh-checking, and hot-tank leakage detection, the usual safety
approach is to apply the items listed below to the entire area.
Installations of this latter type must be designed with extreme care
since a fire or explosion in such a large area could have far greater
repercussions than if contained in a separate gas charging house.
SAFETY CHECKLIST:
The propellant filling and pump room (gashouse) should be 25 ft
(7.62 m) from any chemical storage and ignition source, and 50 ft
(15.2 m) from any property line. It should be of minimum size,
and be on the ground floor with no basement or other open spaces,
large sewers, or other voids beneath the building. The propellant
filling/pump rooms should be physically separated from the main
plant buildings by at least 5 feet (1.52 m) or by noncommunicating
walls (for example, no penetration of a common wall between the
propellant filling room and main production room by a conveyor
line).
An ignition-free condition must be maintained within 25 feet
(7.62 m) of all openings to the propellant filling room. This
means that electrical requirements, including light fixtures, must
C-3
-------
be Class I, Group D, Division 1 or 2 (classification of the U.S.
National Electrical Code).
• The propellant filling room should be constructed with three
rather substantial walls, preferably of concrete [minimum strength
100 lbs/sq. ft (266 kg/sq. m) ] , plus a fourth wall that contains
large "blow-out" panels. These insulated steel panels should be
light-weight and shear-bolted to the wall frame so that they can
blow outward at internal pressures of about 25 to 30 lbs/sq. ft
(122 to 146 kg/sq, m). A roof is not recommended as the primary
pressure release point since the roof generally supports sprinkler
systems and should continue to support them in the event of an
explosion. Also, in cold climates, snow and ice accumulations on
the roof could hamper explosion relief. The "blow-out" panels
should be positioned in such a manner that they will not strike
pipelines or other structures which could result in intensifying
the problem when the panels are blown outward.
• Floors are constructed of concrete reinforced with steel bars.
The upper layer may be impregnated with carbon to render the floor
conducting and prevent static charge buildup. This property may
be enhanced by placing a welded metal screen just below the
finished surface. Alternatively, the floor may be coated with a
nonconductive, nonslip synthetic material.
• Ventilation is the key to fire/explosion prevention. It is
important to maintain the filling room at a slight negative air
pressure. The ventilation system changes the air in a propellant
filling room a minimum of once every minute, and should be spark-
and explosion-proof. Air flow monitors should be installed in the
propellant filling room to warn if too little air is moving
through it. Another guideline is that ventilation should be
provided at a rate of 1 cfm/sq. ft (0.3 m3/min per sq. m) of
filling room area.
• The ventilation system should allow for an air sweep at floor
level since combustible gases are heavier than air and tend to
accumulate in low places.
• The exhaust of the ventilation system should be physically located
at a good distance (at least 10 feet; 3.05 m) from the air intake
ports to prevent re-entry of exhaust gases into the building(s).
• Rain caps are not recommended for exhaust stacks because they tend
to restrict high velocity air flows and deflect vapors back into
the room.
• A room air exchange rate of once per minute will not prevent an
explosion in the event of a serious rupture in an unprotected gas
line. Therefore, hydrocarbon sensing devices should be installed
at two or three locations in the gashouse to detect a rise to 20%
of the LEL (Lower Explosion Limit) value (about 0.4% gas) to
C-4
-------
trigger an alarm and activate an interlock system which causes the
ventilation rate to be doubled or tripled. Note that the gas
detection heads should be positioned to determine any buildup of
gas within the room itself, rather than to determine the source of
gas discharge from equipment. Usual locations are below the
conveyor openings into the gashouse from the main building and
above the ventilated flow of air across the gassing room floor.
When the hydrocarbon detector system senses a rise to 25-50% of
the LEL value (40% is usual), a different alarm should be acti-
vated (both visual and audible), the gasser shut down automati-
cally, and the hydrocarbon inlet line automatically closed by a
solenoid-operated valve.
Local exhaust ventilation at all propellant gassers may replace up
to 75% of the volumetric flow rate of the ventilation required.
Doubling or tripling the ventilation rate in the propellant filing
room necessitates that sufficient air intakes be installed for
operation during the time of excess ventilation. Steam or hot
water (from a remote boiler) heating of the gas room may be
required to keep the work area comfortable and the equipment from
freezing during cold weather and episodes of high ventilation.
Alternatively, heat nay be supplied to the gashouse via an insu-
lated duct of tempered air from the separate main plant building.
When this approach is taken, it is important to consider the
balance of ventilation air necessary to maintain the room at a
slight negative pressure.
The gas detection system should be fail-safe so that if the sensor
becomes inoperative, the gasser will be shut down and the gas line
shut off until the problem is corrected.
Gas detectors must be calibrated daily with a known amount of gas
and records should be kept on these calibrations.
The gasser inlet line should be protected by one or two excess
flow valves, so that even if a serious rupture occurs, the flow
increase would act to shut off the gas supply.
Since propellant leaks are not uncommon at the gasser machine
itself, the closest excess flow valve should be located quite near
the machine without any accumulators, large diameter pipes or
other high capacity line components in between. Relief valves are
required between any two shut off valves.
All gasser hoses must be fully conductive.
All rotating tables and conveyor equipment must be statically
grounded and bonded.
Enclosing the gasser machine with a separate ventilation and fire
detection system can provide an additional margin of safety. This
C-5
-------
ventilation system should allow for at least 5 air changes per
minute through the enclosure during normal operation.
• It is desirable to maintain the propellant filling room relative
humidity at approximately 65% to reduce buildup of static elec-
tricity. The humidification may be accomplished by steam from the
plant boiler. The steam should be released above the work area
near the room center. Additional humidification may not be
necessary when steam Jets are in use to de-ice gasser heads. Use
of moist air from the hot-tank exhaust system is not recommended
since such air may be contaminated with flammable gas.
• Gashouse personnel should wear antistatic clothing.
• The propellant filling and vacuum pump room(s) should have a fire
extinguishing system. This system may have detection devices
which respond to pressure or heat and react to fires by activating
water sprinklers. Note: In cases where the propellant filling/
pump rooms are located within the main plant building where
explosion venting via "blow-out" panels may not be practical, an
Explosion Suppression System is recommended. (A nonhalon system
is preferred providing one can be suitably designed for the
specific situation.)
• The sprinkler system should be attached to the structural beams
supporting the roof, not to the roof itself.
• It is desirable to have the propellant filling room/gashouse
equipped with a crack resistant plastic window and/or with an open
explosion-proof loudspeaker to allow the gassing room operator to
be seen and/or heard at all times.
• The door to the gashouse should have a Class A fire rating and be
installed in accordance with U.S. National Fire Protection Associ-
ation (NFPA) Standard No. 80. The door should be fitted with
spring, friction, or magnetic latches to allow easy egress in the
event of an emergency. The door and latch mechanism should be
doubly grounded to eliminate static charge buildup. An "open
door" alarm system should be installed to sound an alarm whenever
the door is left open for more than IS seconds. This is necessary
since an open door can adversely affect the floor-sweeping venti-
lation system.
• If the propellant filling room has air conditioning ductwork that
passes through a fire wall, the ductwork shall have fire dampers
installed in accordance with NFPA Standard 90A.
C. HOT-TANK INSPECTION
NOTE: This section addresses the production area wherein the propellant
charged cans are immersed in a tank of hot water (57-66'C) for visual
inspection of leakage', can distortion, or rupture.
C-6
-------
SAFETY CHECKLIST:
• The hot tank should be fitted with an explosion-proof hood
covering the entire trough length. The hood and exhaust duct may
be constructed of stainless steel to minimize possible corrosion
from the moist air and vapors emanating from the hot tank. The
minimum capacity of the exhaust blower should be 4,000 cubic feet
per minute (113,000 liters/min.)
• It is recommended that all electrical systems in the near vicinity
of the hot tank be explosion-proof. Electrical equipment located
within the enclosure shall be Div. 1, and equipment located within
5 feet (1.52 m) shall be Div. 2.
• Hydrocarbon gas detectors may be desirable at the hot tank,
located below the tank to detect leakage of flammable vapors into
the main production room.
D. LIQUID COMPOUNDING
NOTES: Most plant fires arise in connection with either the hydrocarbon
propellants or the aerosol "concentrate" (usually containing ethanol or
petroleum distillates although other flammable components may sometimes
be employed such as methyl ethyl ketone, methanol, isopropanol, and
methyl isobutyl ketone). The usual cause of a fire in the liquid
compounding area of a plant where the concentrates are blended is the
ignition of the air/vapor mixture by a spark from an electric motor,
switch, or static electricity.
SAFETY CHECKLIST:
• Whenever heating the concentrate mix is desired to bring about an
emulsion, the heating must be done in a completely closed, pres-
sure-tight tank and with no electrical equipment within at least
30 feet (9.1 m) unless such equipment is explosion-proof. Also,
the mixing tank should not be opened until the completed emulsion
has been cooled to below 100*F (38°C).
• The primary defense against concentrate fires is proper ventila-
tion. Exhaust registers should be located near compounding tanks,
preferably below the rim to remove any vapors escaping from the
top of the tank.
• Supplementary building heat may be needed in winter months to
offset the cold air being brought into the building via the plant
exhaust system. Steam, supplied from a remote boiler, is recom-
mended for heating purposes.
• Fire hoses and extinguishers should be strategically located in
the compounding area in addition to the room sprinkler system.
C-7
-------
E. QUALITY ASSURANCE/PRODUCT DEVELOPMENT LABORATORY
NOTE: Laboratory operations involve safety concerns often equivalent to
those associated with the propellant filling operation. It is more
practical for the laboratory operation, however, to address safety by
specific laboratory work area rather than for the entire laboratory as a
unit,
SAFETY CHECKLIST:
• Ventilation should be by an enclosed, high ventilation, explosion-
proof hood where a sample is placed whenever flammable gases are
being used as veil as by general laboratory ventilation which
forces an air exchange for the entire room. The explosion-proof
area should extend about 8 feet (2.5 m) from the hood. This means
that nonexplosion-proof laboratory instruments and telephones
should not be located within this area. Reasonable ventilation
and explosion-proof electrical systems must be provided wherever
quantities of finished products are stored for testing.
• Any hood used for other than very small-scale operations should be
equipped with a flammable gas detection system (hot-wire type). A
portable fire extinguisher should be located nearby.
• The laboratory should have separate instrument and hazardous
storage areas. Gas cylinders ideally should be permanently stored
in an outside hazardous storage area such as a gas shed
constructed of metal posts and galvanized sheet metal on a con-
crete pad. A ventilation gap of about 6 inches should exist
around the bottom of the shed walls. One side of the shed is
generally left open for access. Stored cylinder should always
have the cylinder on-off valve tightly closed, the outlet plugged
with the brass fittings made for that purpose, and have the
protective cap in place. The refilling of smaller cylinders from
larger ones for use in the laboratory is not recommended. Ideal-
ly, the gas should be piped into the laboratory from a working
cylinder stationed outside and restrained in place by a length of
chain bolted to the exterior wall.
• At the work area, a manifold can be Installed with quick-
disconnects to facilitate the changing from one propellant to
another. An exhaust pipe should be run from the manifold to the
vent.
• Flammable solvent storage units should be located away from
heavily trafficked areas, in a reasonable vented area, and distant
from electrical equipment and sources of heat.
• Personnel should be trained in proper lab safety procedures.
Fire extinguishers should be placed at strategic locations.
C-8
-------
F. DISPOSAL OF REJECTED/UNWANTED AEROSOLS
NOTE: This refers to the disposal of rejected products; either leakers,
R&D samples, quality control samples, or defective products (overfills,
low weights, unacceptable performance, incorrect ingredient assay,
etc.)' This can amount to several thousand rejected aerosol units per
day for large fillers.
SAFETY CHECKLIST:
• Collection drums or bins for rejected dispensers should be kept
outside and fed through a chute wherever possible. Otherwise,
collection receptacles should be transported outside at frequent
intervals. While in the production plant area, collection recep-
tacles should be fitted with flexible plastic exhaust hoses
connected to an exhaust system such as serves the hot tank area.
• Aerosols containing flammable gases should not be destroyed in-
doors . Vhen more than 5 containers need to be evacuated at one
time, the procedure should be conducted within the propellant
filling room or outdoors, and the containers should be grounded.
• Upon accumulation of 3 to 5 filled collection drums or bins (no
more than 1000 aerosol), the containers should be moved to a
remote outside disposal station.
• Aerosol shredders/crushers should be located in a remote, con-
trolled access area at least 100 feet (30.5 m) from the nearest
building and at least 50 feet (15.2 m) from any property line.
Plant personnel should be kept at a safe distance from the dis-
posal station when aerosol containers are being shredded or
crushed. Fork lift transport trucks should likewise be kept at
safe distances from the operating disposal unit.
• Liquid wastes released from the disposal of defective cans may be
classified as either hazardous or sanitary wastes depending on
properties and applicable regulations and must be processed
according to approved procedures.
F. END OF PRODUCTION LINE TEMPORARY STORAGE
NOTE: This section refers to the storage of flammable aerosol products
in production areas such as in staging areas where finished products
await transfer to a warehouse.
C- 9
-------
SAFETY CHECKLIST:
• In general, no more than 4000 pounds (1816 kg) of Level 2 or Level
3* aerosol products per production line should be permitted In
production areas and should be stored no more than one pallet-load
high. NOTE: Warehouse storage of finished aerosol products is
covered as a separate issue by U.S. National Fire Protection
Association Code 30B (August 1990).
*Level 1 - Aerosols with base products containing up to 25% by weight of
water-miscible or water-immiscible flammable materials.
Level 2 - Aerosols with base products containing:
a. From 25 to 100% of vater-aiscible flammable materials, or
b. From 25 to 55% of water-immiscible flammable materials
Level 3 - Aerosols with base products containing from 55 to 100% of water-
immiscible flammable materials.
NOTE: The following additional considerations apply to the above
definitions of Levels 2 and 3:
(1) When the weight of flammable propellant equals or exceeds 50% of
the contents, the aerosol classification should be increased to
the next higher level.
(2) When the weight of flammable propellant equals or exceeds 80% of
the contents, the aerosol classification should be increased to
Level 3, regardless of the composition of the base product.
(3) "Flammable" ingredients should be those having a flash point of
260'C by a closed cup flash point test.
C-10
-------
APPENDIX D
REFERENCE ORDERING INFORMATION
D-l
-------
REFERENCE ORDERING INFORMATION
National Fire Protection Association (NFPA) Tel 617-770-3000
1 Battery March Park Fax 617-770-0700
P.O. Box 9143
Quincy, MA 02169
USA
1990 National Electrical Code
Item GL-70-90SB $29.50 each
NFPA 30B: Manufacture and Storage of Aerosol Products (A3 pp.)
Item GL-30B-90 $17.50 each
NFPA 58: Storage and Handling of Liquified Petroleum Gases (92 pp.
Item GL-58-89 $19.50 each
Add $3.65 for shipping and handling on all orders
Payment Terms are Net 30 Days.
Payment Due in U.S. dollars.
-------
2. Chemical Specialcies Manufacturers Tel 202-872-8110
Association (CSMA) Fax 202 872-8114
1913 Eye Street, N.V.
Washington, D.C. 20006
USA
Hydrocarbon, DME, and Other Propellants: Considerations for
Effective Handling in the Aerosol Plant and Laboratory
Item TP-7 $85.00
Section Updates to Hydrocarbon Manual
Item TP-7A $10.00
Orders over $10.00 send invoice (Domestic orders only)
Foreign order - check required (in U.S. Dollars)
Checks payable to CSMA.
Multiple copy and foreign orders will be shipped F.O.B. Washington, D.C.
D- 3
-------
British Aerosol Manufacturers'
Kings Building
Smith Square
London SW1P 3JJ
UK
Association (BAMA) Tel 071
Fax 071
Telex 916672
BAMA Guide to Safety in Aerosol Manufacture (2nd Ed.)
Cover Price: £25 sterling
Foreign Orders: £40 (including post and packing)
828 5111
834 8436
Chemin G
Orders accepted only when accompanied by full payment in sterling.
-------
APPENDIX E
FEDERAL REGISTER METHODS FOR FLAME TESTING
E-l
-------
Saturday, Augutl 12, 1961
fEDERAL 1EGI3TEI
7333
111.10 iCMiod oS I—Hn« locJc (UbaiucM.
16U1 ftifUMd of Miuac prtmATf unu&t
l«i I
ma
i»i j
Lil.ia TmiciM-
rula l>r ti«iubu« op«a*tup <^>
lii.it y«tfeaa rat Munuufii imBil;
SMXUBMMM |0i iQUdl.
lit,IB kktAod far OtttRBifiiGg iitrmilf
Itiiirnir— Whr u4 tUmm*bk< «&¦
nau of ¦U^NamnaM obb-
Uuubot
HI If liiiM lor diumialai fitiliiNiii
of utrvmel; Au&atbt* coducis
of aMr-pmnimM wmmw
KaaixtpUooj for food. drufi eca-
m«Oc*. ml fu«u
eaucBpiiAO tm full ub*Uoj rn|ui/«-
(UlOUrid 0—HAXA«»OUI IvlUkKU
PAIT 1*1 — H A Z A a 0 01) 5 SUB-
STANCES: DENNITIONS AND FIO-
CIOUIAL AND INTEIP#£rAJtVl
¦IGUIATIONI
Final Order
U mconst to U* notice ot proponed
nil* maslng published In tfce Pmtt
Haaotse at April M. 1H1 (IS FJt. JTM),
axU&tite VTtttan cct&JEsnU vera re-
scind, Stibawuenttt, on H
K IMl. as opportunity vaa aBorded lor
the ar«l prcKDUtloi ol fkn oa l&e
Brapeaed regulations. PpUovim rrrtrw
el the <««"•»" ncct>MI both in will-
ing and at Lbe or*] presentation. and
otbar releeant material the commis-
sioner ol Food and Dnm Has concluded
thai Um toUoom* rtguJsuons (tumid
Imua with respect to hasardou* mb-
Wlrvcrt pursuant la Use prortMona of
tbt Federal Haaardoui Substances Uid-
In* Act imc IB. n 9U> «»: 19 CJCA
lllti, and under the authority delegated
« hist by the Secretary o< Health, Edu-
cation. IMl ViUtie (3S P R (1231:
DKVIJMVtlOPa {XtnFtfTtTTOR«
DvfiAHtOB*.
Iwma tiptnasM mxh toiMthw*
¦HON (AXIOM
Binrtoui mlitvu«i
| fljMrrad |
f PUwt«|
Luuof or •iroa« muiuw p*fc.
IBI 63 KitopUflu for ntl
¦U-Bar buu-dt, «od »p*rt
¦Mtii or r«p«aJ of rofUJAUoBi Cl>
•bUurUBi p«jni«uiM wMubiw t*
lw (uuuutiou*
INu3bbmtcd toerm Pv ^nza
IIIJIO
191^11 Ou&T^tT
iiijiia pmnmiw ct r
in 4
U| ?
PrtKiucu r*qwu'.n| jp^citJ tfcbMiaf
Mftdwr *KUoo 3
iAbeMAf Aet-
ur«. Containir intandtd
or suitable 1°' nouachrjid us*' meau
an# carton. MtUe, can. ba«. tuw, or anj
otnet aoiilamer vhich under anr eui-
UMDirr or reassnablr forcBeemblr condi-
tion of pwthue, itoraae. or ue mar bf
brauiht lAlu or around a bouM. apart-
ment. or other place •bera people dvall.
or In or amund am related buUiinf or
ahad. Includlnf but not Umlled to t t»-
nme. carport, Kam. or uorate shad. Tha
term tncluda aootalnen ol melt artlelea
u poUibas or tlaanen desuned prtma-
rUy tat prafeulonal use, but available In
ratatl Htm much aa hooftr abopa (u
nerwrolaalMVkl u»». Aiao Included ara
audi llessi aa anUfreexe and radiator
cleawn tftat. alsfiotKb pnacipaii; tor
car use. max be itond Is or around
dvalllnt ptacaa. Tlx tans doea not In-
clude taduatrial nppUa Uiat mubt bi
tafen tslo a boot br a ttracasaas. An
article labeled aa aad sarteted aolel?
lor laduatrtai use docai aot become sub-
ject to UUi aei becauae ol tbe poaalbUlc?
U>at aa induatrtal vorkir mar mlaap-
propnau a auppl; lor bJa on uk Six
la not Lht entt index sI vbeuier uu
•oniainer la -'Billable (or bsuaatuld ue."
The (cat aball b« vbatAair under any rea-
aonablr (arcaeeable condition ol par.
tbMMt. alnn«r. or use uu oontairuLr mar
be round in sr araund a dvclllm.
Id! PromrnanUp and osneplcmonsly.
"Prominently' Is aecuos lip) 111 and
"eanapltuBuslr"* u kcuoo I ipiili and
IpHi 1 o' iha act miana thai under cua^
lomarr condltuna of pufebaae, iiorafe.
and uic, llit rt^umd iniormsUan ahall
ba nUfile, ootkaable. and in clear and
Inible ZniWh. Some lacun affectinc
a varslfifa prominence or eonsploioui-
neu ue: IwaUon. llu st trpe, and con-
tra*; ol printing aaauut backfrsund.
Also bemrinf on uu ecretieenaa ot a
vtmlnt Bkiint be tlx asaci of the
package eontenu ti WUled on me label.
Dnlui Imprmeucabk beeaiue ol the na-
Um or Um iuM«nc«, Um label stall ba
at mcA eonalructlon and aiusb as to
wlUutand reasonably foreseeable iptUafa
ttroufB loiweable uae. I6eel itl.101 >
Night* ioxk mOtisacu. 'Itiahly
(sale" la any lubstance laillnc vitliin any
or IXtt [aliomat ca«*onea-
(1) Any aubitanc* tbal proSuMt
death within It days In ball or mora
man Hal/ of a (nop ol cut* rata >»cfi
•ctohlnc between 200 (rami and 100
grama ai ¦ tingle doae ol SC mllilgrtina Of
1am per Blogria ol body vtigni, vaan
orally mmtnUteted.
Hi Any ¦ibmnrr lhai produeaa
daalO vitltln ¦< dan in hair or mora Una
ball af a group at vblU nti e*ch vaUB-
Ing bccvaen KM (rams and M0 grama
•nan InnabKl aanommuly tor a period
sI I bour or lam In an almoapberlc ooo-
ttntitUfld ol 9M ptrti per by
>o)Mc or I«a> ot ras or eapor or 1 milU-
gimma per lltar by folume or lam at allot
or dual, pnndsd Uiai aaeb coneenum-
Uott U Utaly io ba aDcounurM by tnan
•"ben (be niltanrr l< uaed In any na.
foitseeafeia naxuacy.
(1) Am aubatanca Uial craducaa
deaUlvtUa UdayalahaUarmaKUsaa
ball ol a group at ntbfeiu velg&lng be-
Ivees 13 kttoensma and S.t Ulognma
(•en. toted Is a daaaga of MS mills,
rrami. or leas, par kUocnm of Mr
velgbl vben administered by continu-
ous contatt vi Lb tba bare akin (or M
bows w lam by Um aw mod docribed in
I itt.ia.
Ttn number o/ srilmsll I
wOclant to (!•< a slaimk-sirr BaiUO-
eant raault and be to oanformlty vtlb
tOrf pnCtiOOL
________ 7-N
N« «v>llifel» copy. iy
-------
7334
KUUS AHO IKGUUTIONS
(4) Any substance determined bj Lht
Commissioner lo be "highly toxJc" od
the buu of human experience.
Tasic substances. Toile rub-
stances" la any substance falling within
any of the following categories:
il) aaj gubstanee that produces
death within 14 days Ln ooe-haU of •
group of white rau rich weighing be-
tween 300 gTams and 900 mint, at a
tingle dose of more than M milligrams
per kilogram but act more Lb an S grams
per kilogram of bo /mteais. The term "Irritant" in-
cludes •primary imtaai to the akin" aa
wwfl aa substance* irritant to the eye or
to mucous membrane*
<3) The tern "primary Irritant"
meana a substance that la not corrosive
and that the available dau of buma&
experience Indicate la a primary Irri-
tant: or which refultg to an empirical
¦core of flw or more wben tested by the
me'bcH the eye Mucosa if the avail-
able data on human experience Indicate
that 11 la an Irritant for the eyi mucosa,
or wben tested by the method described
tn | mi 13 shows that their 1a at any
of the readings made at 34. 41. and 73
boun discernible opacity or ulceration
of the csrac* or inflammation of the una.
or that such substance produces In the
conjunctiva* (excluding the cornea and
trlsi 1 diffuas deep-crimson red with in-
dividual vaaaela not easily discernible, or
- an obvious swelling with partial eversion
of the Uda
Corroetar. A "corroaivg iub-
stanee" la one that causes visible de-
struction or Irreversible- alterations In
the tissue at the site of contact A teat
for * corrosive mhstinrt Is whether, by
human erpcrtence. such tissue destntc-
Uon occurs at the ait* of application, a
subatance would be considered corrosive
to the skin, u when tested on the La tact
•kin of the albino rabbit by the tech-
nique described in I 101.11 the structure
of the tissue at the site of contact is
destroyed or changed Irreversibly In 34
hours or ieaa. Other appropriate tests
should be applied wbeo contact of the
substance with other than ikln tissue is
being considered.
Mxlremtiv HammabU en4 /Uniiu-
bte <1> Mxtrtmefg dommo-
bte substances. The term "aticnety
^twwifci**1 means any ¦ubsta&c* that
llii ¦ flxhpolnt at or below 20* P.. ai
4etrrmiiMtf by Um method docrlbad la
I lil.ll.
(2) FlammabU nt/taneci. Th< term
"flammable" maana any aubstence that
has a flashpoint of above 30* P., to and
including H* y. as determined by the
method described In I 161 13
ik) |hfiw It aplodes when subjected to an
electrical spark, or to percuaaloa. or to
the flame of a burning paraAn caodle
Cor I seconds or leas; or
t3> Ii expels the closure of Us ooo-
tnlAar. or bunte I Is container, when (Mid
at or below 130" P. for 3 days or l«. or
(3> It erupts from Its opened con-
tainer at a temperaiurv of llo* P. or kas.
alter having bceo held m the dosed con-
tainer at 130' P. for 3 dan.
(n> Radioactive tobateace. The term
"raiUaactive substance" means a sub-
atance which, because of nuclear In-
stability. en its electromagnetic and/or
particulate rmdiaoon that is capable of
producing lobs Id Its passage through
matter. Source materials, special nu-
clear material, and byproduct materials
described in section 3(f) <3> of the act
are exempt.
4o) "AccompafijrMff hUroturt'. "Ac-
company tag literature" aa used In sec-
tion 2(n> of the act means any placard,
pamphlet, booklet, book. alga, or ot*Kr
vrtiten. printed, or graphic matter or
visual device which provides directions
for use. written or other*i*e. aad la used
la connection with the display, dale,
desaonalration. or merchandising of a
hazardous substance in a rrnfalim in-
tended or suitable for household 9m.
JaAf/aaittJ personal tn^uir or ill-
ness. This term msans anj tllaem or
Injury of a significant nature. It need
not be severe or iraut What ts ex-
cluded by the word "substantial" Is a
wholly insignificant or negligible lAjury
or illness.
-------
Saturday, August It. I9tl
FIDClAl KKISTEI
1339
to lai animals. fecperlenee may Also
other lectors that irt important
10 ikdrmlninf the degres of batard to
bu&A» repreaented by the substance,
for example. that radiator ahufrteic is
Ufcely to be stored In the household or
gtrtfc and likely to be Ingested Ld slg-
pitent Quantities by som« persons. Ex-
perlcnce also indicates that a particular
suln****** in liquid form Is oon likely
to be inftrtrfl than is the substance
in 4 pyu or a solid and that an aeroeol
la more likely to get Into the eyes and the
r-—' 1 than Is a liquid.
| 191J Rnini*it niatam.
Por a mla lure or substances, Che deter-
mine"*"' of whether guch mixture Is
at defined lb section 2(f) of
the icl should be based on the physical,
and pharmacological charac-
teristics of the mixture A mix lure of
eubataooes may therefore be less hasard-
ous or more haisrdous than 1U compo-
Daui became of iTDirHiue or idUio*
niatic reactlona It may cut be possible
to reach a fully satuiactory decision
concerning the toxic, imuou corrouve,
flammable, sensitizing, or pressure-gen-
erating properties of a substance from
what U toMm about lu components or
Ingredients. It U prudenl to test the
mil lure llAell.
| 1*1.4 [HofwJ)
| 191.4 (Rc*er«*d]
| 191.4 Liiiini «T "itrom Mixiiiur11
••brtanct*.
Hie Commissioner of Pood and Drufl.
having considered the frequency of oc-
currence and the aeverity of reactions,
finds the following substances to have
a ci|iUficut poteoual for causing hyper-
¦ofiUnty. and therefore they meet the
definition for "strong senstttscr" as given
In section 2 of the act.
(«i Parapflenyianertismirvr and Prod-
uct! OQBtllillllJ It
OU of berramot and products eon*
'¦'"'"t I percent or more of oil oi bersa*
mot.
1)91.7 Pndadt r«fwHa( ipetkl l«U*
lag muaa S(b) af ifceea.
Human experience u reported In
th« eae&tific iJterature and to the Nho
Control Centers and the National Clear*
in# Bouse for Polsofi Control Can ten es-
tablishes that the following wihsunrft
are haaardous because of their toxicity
*ftd the frequency o/ their involvement
in accidental intwUon:
O) Carton totmhJonde and miaturaa
CAoUJAlQi i|.
(2) Diethylefli slycol mil-
tura rrmtairiinj 10 percent or sore by
*«is&t of dlelhjisne (LycnL
iV ethylene ilyeol including mtttxires
•"¦"'"'"l 10 percent or more by weight
of ethylene ftyooL
(4) Petroleum diatillatea luch ai kero-
•enc. CblDeraJ aeaJ oli. napbLha. vaaoUne.
beuine. mineral cplrlta. paint thinner.
8toddard solvent, and related petroleum
distillates and mixture* containing 10
percent or more by weight of auch
petroleum
*61 Methyl alcohol including mixtures
containing 4 pcrcant or more by weight
of methyl alcohol.
Turpeotine including rum turpen-
tine. rum spirit* of turpentine, ateam*
d la tilled wood turpentine, sulfate wood
turpentine and. destructively distilled
wood turpentine and mixtures containing
10 per cant or more by weight of such
turpentine
Tbe Commissioner Arjls that these
substances present special haiards and
that the labeling required by section
3U) of the act is not adequate for
the protection of the pubbe health. Co-
der section 1(b) of the act the following
specific label statements art deemed nec*
essary to supplement ths labeling re-
quired by section KpHli oi the act-.
(1) Carbon teJracAiorufe Because or
the fenenl systemic poisoning that
might resuJt from the ingestion or
breathing of vapors of carbon tetrachlo-
ride and mixtures containing It, the label
shall include the signal word ''danger."
the additional word "poison." and the
skull and crossbones symbol. The stats-
ment of hazard thai! Include "May be
fatal If Inhaled or cwaUowed," and
"Avoid contact with dame or hot sur-
face.**
<3) Jfrtfty! alcoHoi. Because of death
and blindness that might result from the
Ingestion of methyl alcohol, the label for
this substance (including mixtures)
within the percentaga specified In par-
agraph of this section shall In-
clude the signal word "danger." the ad-
ditional word "poison.** and the skull and
croatoooca gmboi. The statement of
hasard ahafl Include Taper harmful."
"May be fatal or cause Mlnrinnas if #waJ-
loveO/* and "Cannot be mads banpoiaon-
OOS-"
(3) Tarpeariae cad pftrotatm diitO-
IaUs. Became theaa aubatancea lln-
duding mixtures) within the percent-
ages specified above, in sddJUon to oral
todcity reaulUng In gystemic poisoning
are hazardous became of aspiration into
the lungs with resulting chemical pneu-
monitis, pasumoaia. pulmonary
edema, the signal word "danger'1 Is
specified, as weu a* the additional suu-
mants "BarmiuJ or fatal U ewaUowed"
axkd for kerwaenc and related petraleum
do oot induce vomiting."
(«) flAplme 0ifcol end dUlhyltn*
glycol Because tbeaa aubstaacea (in-
cluding mixturea) within the parcantagea
specified above are conns only marketed,
stored, and used in a maoner increasing
the pcmibLUty of accldeotaJ LneaUoo, ths
signal word "warning" Is specified, in
aitrtltiAft for ethylene ilycol the state-
ment "Harmful or fstal LT swallowed"
and for dlethjlene glycol the statement
"Harmful if swallowed' are required.
TO!Leo FUNmna ra Biussooi
Irarisoa
| 1*1.10 MeiM ef Mteg mie »W
Th* method at tasttag the toate sub.
Hermes named Is I 111 J (e> and
(J) la as follows:
ik) Acale dermal toxicity (staffs cz-
pomrs). In (he ecote exposures the
agent Is held tn contact with the etan
by means of a sleeve for periods varying
up to 34 hours. The sleeve, made of
rubber dam or other tmpemous ma-
terial, is so construct** thai ths ends are
reinforced with additional atrtpa
ahould fit snngty around the trunk of
the animal. The ends of the sleeve are
tucked, permitting the central portion
to "balloon" and furnish a reservoir for
the doaa The reservoir must have suf-
ficient capacity to -^In the dose with-
out pressure. In the following table are
given the dimensions of sleeves and the
approximate body surf ace exposed to the
test substance Ibt sleeves may vary tn
else to accommodate nailer or larger
subjects in the testing of unctuoi»ma-
tenals that adhere readily to the
mesh wire lcnu may be employed in-
stead of the sleeve. The aereen u padded
and raised approximately % centimeters
from the expossd skin. In the ease of
dry powder preparations, the skin and
substance are moistened with physiologi-
cal saline prior to exposure. The aleeve
or screen Is then slipped over the gause
which holds the doaa applied to the akin.
In the case of finely divided Powders, the
measured dose la eeoly distributed on
cotton gauze, which Is then secured to
the area of exposure.
Pwmhii m aui*n rm uvn Diuu Tiiort
tie
(TauMlMai
iSRl
II*W«
PagnM
0««4l
MS
Wi
SariT
7.1
at
1SKB
-
iar
(b) Preparafloa of fast aafmdis. The
snlmah are prepared by clipping the skin
of the trunk free of hair Approximately
OAa-h^f of the i&mila tn fu^tacr pre-
pared by making epidermal abrasions
every I canttaeten m ) oeuumeiers
longitudinally over the ana of axpoeure.
The abrasions are euflrirntly deep to
peoetrate the stratum coneum ihorny
layer of the epsdesmis), but not to dis-
turb the rtsraa tftsl la. not to obtain
bleeding.
(c) Procadares for UmU*q. "Hje sleeve
is slipped onto the animal, which Is then
placed m a cmafonable b«(
poalUoo in a animal Imldar.
Selected dooes of Uquidi and solutions art
mtxoduead under the sleeve. If (here is
slight leakage from the sleeve, which may
occur during the first few hours of ex-
posure. It Is collected and reapplied.
Ooeage levels aie adjusted lo subsequent
exposures
-------
7336
¦Ul£S AND IKCUUknONS
il> SO percent Of ¦nlmtla TtUl CiA
be determined from mortality nun ob-
Wined at various dota employed At the
aid or 24 boun Hit sleeves or screens
axe removed, the volume the stia u bui<
and by a patch-test technique oo the
Abraded and Intact akin of the albino
rabbit, elJpped Tree of hair. A minim urn
of tlx subject* ire used Ln abraded and
Intact akin ImU. Introduce under a
square patch such as surgical gauze
mnriftnit 1 lfi£b z l loch, tiro Aa|k
Wen thick. 04 milliliter (is cam of
Uquldi) or 0J piA (1a (he cam of
•oUdJ Aad eemiaolids) of the test tub*
a La oca. Dissolve aolldi in aa appropri-
ate arrant and apply the solution aj lor
Liquidi, toiofj iff iiwnifthiii»«t
•Jth patches secured in pisce by Ad-
beaive tape. Tb* entire trunk of the
anlmaJ is tfien wrapped with ad imper-
ious material such as rabbemtd cioth
for the 24-bour period of tiposure.
tvi> material Aids la maintaining th*
test PAtches to bOUUoa and rturdJ the
•raporation of volatile subsiaaces.
After its nous* of exposure, the patches
art removed aim Um resulting reaction*
arc evaluated on the basis of the desig-
ns iril values La the foUoviag table:
lealttf rvn •/ rMCtlgv F|J«I k
¦rytbaoui Mtw («b»uos :
Na ....... 9
V«7 aiigbi «ryui«mi (b*/«kf ptfup*
able} I
WH)-4i0ii«d arriotau. 2
SSadirata (o M*irv trTTMaa I
BiT«l aTfl&«(Xi& (Ami l—lfi— | |o
aligfci nfhir lanuiuQ (lajunaa ia
e*pUi i .
k ftvauuaa:
four id live th« primary irritation Mart,
a pie:
pubiai
flnad by SaAaiie f^iime>
Hod«tu m>«iu (niaad tppioiUBtulf
I Biilttiur).
•iwv atm T^ia at(boi iaelb« a MM W*~
artwv (« tta siva-amwHs apao^up
Qasbpoioia of nliuii basaab)* Bftitrttii
A*no* OMbpotAU balov its* W.
(6} TbU BMbaod. «hu appUae u patais
•Ad mis Miuussi vbits iaaa u alia crw
v vbicb if* vvry naeoua. (I'm Ua rtprg-
dudble raeolts thae vbso sppUad to
ao*vaoca
OVTUSI Of lllTSflB
X A* ~ru li plaoM la lb* cup of a
T*g Opaa TMW. aad baa*id ai a ilow but
iau. a small Mai Aims is paaaae
as a uaIXorb raia asea ui cup at tpaeibad
mt^TAia. Thi Basapolai m labaa aa tba
bvw tuperange at vbicb ippUcaUoe ct
tba teat baa* oauaii tb« vapor H tba «ur-
faaa ot UM liquid id Oaaa, t&ai ia. i(uu toil
A. Tl| apaa^ip Uiiat H IUimmuS 10
Vl|. I. It ——of tba loUowiAi pana
vblcb auil «B&fova to tba
abovu. aad bava tba addlttooal ebarertarto-
a«a aa fiotad:
Abb altaraata until Jaauary t. IIA It a
anaiaii 10 —90" T.
(A) Olaas can **p. QUa aat cup fP%.
IK a anirtai eaar gusa isnaial. baa*-i»-
flitirt aae &w rrom eurfaoi tefrea.
{•I UwlAf dewee. Taflini gavas m
fulba. for pqpai adjuraaasi or tba Uqui
Mfal a iba ««p CWg t). Tbia aball ka mad*
o* N*- U gags imshal ahiaisum. vim a
pro)acttoa fa adjust^ tba Uquld tova vtea
taa ampls la aodad to exactly *»laah ba-
tba aval a tba adga a na a iaa *19.
(f) Tflaa.' a nalJ gaa bvoar a am a
badtaeoaioa* l« baauag tba tin a
aeiaa clamp maf N «ad a balp ragMlata tba
gas. A «uu tiauic tea tar may ba nad.
ID Igaioea a par, «aieb u a am
•tialgbV bbt>p^a typa fa barvar. t^a
•at naaii t««b prwoibau la tb* -anfcna a
aa far flash aad Or* potata Py (Hnliml
Opaa (A0TM aaipisrinn O H| S
aOaCactory.
(b> AliaraaUw aatbods lo —'-'-¦¦'¦g
ita tap« a Aud bortzoa^ti
¦ ten tb* Uqaie may ba oaad. aa taUova:
UI OuMi wira, fc-tacb lb dlinaia aad
IH Uxbfc a laagtb. vttb a rlgbl-eaga b^a
K-iatb Iran saab aaa. Tfeia vin m pbat
¦Bugif ia Aai«e qniiad id th« na a «&r
bm. ao ifiai iba guiaa wir* k H -lasa INa
tba eaater of tba cup aad rattag a tba
na a tba nip.
11} bvtval-iypa tap* bolder. —- aa la
«M la AMTU MTTBOD D 92. Tba Mgpt
aaa paiua a tba lapar ara flaad by aS-
jtwuag isi boM«r as a eultabla rlDpua
auppan ad)aeaat lo Uu B*ab cup.
(I) Draft ablald. -'*¦'¦""1 ot im raataa-
gular tbaau of 1
1 ae*. pmnbif by binga
a artaaguu# aaaai. H lacbM ¦ M lacha a S4
tbrhaa la ravta&ad by blagaa to 00a a tba
lat0U abaaia (to lam a tap vba& ablekd H
Tba biaw a tba dnft *bt*M aball
W palaus a bat bluL
* T%* +004 aetf Drag Adaiaisiiauw ba
oauiaad paiiiiuiinri from aavricaa fto-
ciuy lor Tauag MiieuU, PMiaaatpnia,
Pa., to rvpriot ibl* aaibod 10 tbaaa rvgula-
Oooa. 71m <**t ba« ailgbUy aodtbad.
for prartlaal ImOM
• AflTM Oaatgoauoo' O UIO-SOT.
ISM IS111 III l»U. KM. IHS. Tbla laftU.
yva matbod be* baa appro ad ay tba ipa-
Mrtag oommtuaa aAd aaoapcad by ua
AmerteAQ Socuty lor T^auag Malarvala ia
accoroaaca vtia slabUahao prgcaduraa, (or
u*a proding *OepUoo a luaaaro. Pugga-
Uoa* fa avtaioaa abouie b* addraaaae a
tb« bUif at Itlg lUca be. Pbll^aipbK
pa.
4. (a> Plaoa iba
b« a viaaboa. la a '*¦"*'> Craa a par*
«piJbla eraA. aae ta a aim ugot.
(tt Sob via. trtai.v na-clywiau>
taoa taa tba baib to a pradatermUMMt laval.
vblcb vlli All tbm aa CO >4-ka^ batov
tap wbaa tba cup a a pl^a la uiaiflua
parmiaiaa tm vaia*Mvai cmvoi.
let niaifiappaR t*i ibavwoMta «vti>
oally baliviy bataaaa Um oaaiar aad adga
a tba cup oa a dlamaia al right aagtaa to
tb« guida Wi. v oa a dlaaaiar paKB|
Uraugft tba enter ot tba nrp aae taa pivaS
a taa tapar. PU tb* wa form ngbt sag mm
via aacb aib« aad tba teaa is asn «•-
E-5
-------
Saturday, Augutl li, 1H1
HSUA1 PECtSTIt
7331
(?)
j^s^Hnsr1
ha !U—Fast
E-6
-------
7338
RULES AND IKCUIATYOHS
novas
pfiin# 4 If t fuJda Wtra U uiid the tapar.
wbao pititi inouid root itf&tiy oc lAa wire.
viiA ui acd fit uii pt bu/ur fuai ciiti of
(Aa adfi al tAo guide wire. U lAa iwt»«J-
(TP* bolder U uaod. Uia boruoetaJ ud vard-
C»J pOBlUOAa Of (ha )•* VI to kdNit^ Ibat
U* )et puts on U» ciiTu«f» LAw •
noaiur, 4110 m 4 plaAa ^ -U cb ibon (Aa
upper adga at U« cvp. Tb« dpti i&ould ba
k*pt ta Um "off" pajiios. it mm tod or iba
Ol&tT Of IA4 *WlAg. OSCapt WbtB (At S*oi
IS ApfltBd •
(t) U|b( iti IgulUoa Oaaia 4od 4d)UJt
ti to fore t Sana of apberieaj form biua-
lA| U) UU Ul fpAb'l
paea Lit* IgoiUoa Audi i£n>af lAa aurf4ca of
aaaplt abouM 04 1 aaccod. Rcdo««
kulbln riuui (Aa aurTacc at lA« aaatpia liquid
halari niniaf « dturmiAaiMo. ftftiicuioua
atteaUea (o 4U di(alla ralaUag le (Aa wpar.
ilM of urii Bona. 4od rota of puiiai (Aa
14pv \g oacaoaa/T far goad rmulu Vltfi
AatartalQlOf ia« OMApotni of viecoue Uquida
4Bd UkOM UqtUdl (A4t Uftd lO fom 4 Ub Of
pajytsw. at*- on (Aa aurfaoa. Uu auffata
Aim 4AOU1A b* dlflktfWOO ¦OCAAAUaUy 4MA
Mart (Aa tops fttat la paaaoo.
4. ftepoot the proeadura by • fr«A
pcruoa of tba aampia. U>« glass rup. (Aa ba(A
4>l\lUoe, 4Ad lA* UMBoMlo 4t I«biI 30" F.
balM (Aa approaiasu BiiApoui n«miT>«
h«(U|. 4Ad paaa (5a taper haa »ooa
(Aa aaapta 4« («e lotamia of i' P. im Un
44 latarrau at a* P. uati) (Aa aaaApoiAt
duatfta) 4rOA4Uc brdror.arbe&i t JL5TU
¦44i(04U00: D 140), or (At m«tAod or im
Ita diaiUl4Uoo ruf« of lacquer aoivabta
4Ad diiiMou (AftTO duioatioo; D 1911).
Tba rtAga aAall (ACluda Um bolllni pelai
of pu/a p
i4U? d«laratB««(AOd of Uol tor B««furtBfti of
ti—6| poiota of hifb-punvy ooapouoda
for a*oiU4Uoo of purity (AffTM daalfno-
Uao- O I0l*>
(II) Jpccl/lcofloitj for Uopropano(. /IojH*
po
form w (Aa 10110*109 r*quU4iMo(i:
0p«et0c gravity: 041 ts (o ojiu 4t ao* Cv
U' C. 44 daureiAtd &y naooi or a tail-
hroM ppBoaiiar.
Oi4till4ttoB t4Af4; &&4J1 aoti/tly dutii)
«t(AtA a 1.0* C. r*Af« vbicA 4A4li loeluda
«Aa uapiratvi M4* C. 44 liumlAM by
AfTH oaibod D 1071.
Ararafa iAa*4 v4|um for tocb cms pound.
If 1A1 dJSarvoca (mIvhd uu nluea for
(Acm two tespMufli ii laoa Uib is* p.
(AS* C 1 or nan ¦*«" TI' P (11* C|. rvpaat
tAt datArmJQ4Uoaj or obioio frvoA atoo^rda.
(b) Calcuiau a oojtkUc
f0Uo«B:
x=n-4
r=u-B
Oon«eUoA
Vboro:
IsObwntd fiMh of p*ryUA«. 4Ad
I ¦Oboanad SaaA of laepropyl oleoboi.
Apply ttu tomcuoB of oil datemiuuoM.
¦AU UAiU LB wnWIOB 4A4II ba diacAAMO
J + T
rma Dat&
7. Tt« at4TB|« of oot tc«i (Ato (A/a* ra-
cordad uala. oiAar 1A4A iba lAitui uat aA4ii
ba U4«d LA da(*rmiAiA| tb« &44&poLAt iAd
||-—im"^""T of (Aa aubataaet
9f « w«4oc&j flow
• <»; M4Aa BrtarmiB4Uoaa LB t/iplmia
ob ui A44Apo&A( of luadirt ptmniiBi tad
of iiABdvd ioopropyi alcoboi which ntti (Aa
foUavtai apKiScaiiooi
111 Sp*fiHe*(«ov« /» p-l)"*' /l4ilp««
c\erA ftmA* p rrfparuUyn 0/ sample—ti) O'on*
kics. potodm. And pastes Pack the
eampte IntA a Aat. rectAncuJax metAl
taoat with Inner dlmensJons I inches kne
s 1 inch vide a one-fourth tact) deop.
Proceturt. The test Is conducted
In a draJl-free area that can be venti-
lated and cleared after each test. Place
lhe self-pressurized contAiner at a dis-
tance of fl Inches from the flame source.
Spray for periods of IS aecoodi to 20
seconds «mm observer noUo« tbe 01 un-
Aon of the flame * t>» other oper-
aunc the oontAineti throuih the lop
third of Ihe flame and at a rlebt ancle
le the flame. Tbe height of the flame
should be appro innately 2 inched. TbJu
thrre readings for «eh test, and aver-
age. As a precaution do not sprmj larie
OUAcUUes in a small. gpMB.
Free 9«(i of preTtoualj disehariwd
material.
| 191.1& Method for determining flaatw
poaoi 0/ aiiRBclr BinubU ronlenia
W adf-proMvriu^ ewUiitn.
T^e apparatus used is the Taghabue
Open-Cup nashpoint Apparatus as de-
scribed in 1111.13 Bome means such as
dry tee In an open container is used to
thin the pressurised container. The
container the flAAh cup. And the bath
nluuon oi Lhe apparatus
-------
Saturday, Auguit 11, 1361
FCDflAl IEGIS7EK
7339
EuvnoM
¦ 191.61 biaptMoi for food, drap,
fMrnniii, tad foek.
(ft) Food. 4ntgt. and cometlcs. Sub-
subject to Lb a federal Food.
Drug, Htd Osmetic Ael art eiempted
by section 2(f) (2) of the act; but where
g food, drug, or cosmetic oCcrs a sub-
stantial nxk ol injur? or illness from any
handling or um that U customary or
usual H may be regarded 40 misbranded
under the Federal Pood, Drug, and Cos-
ro»ue Act beciuse Its label fails lo reveal
i.t>rni facts with respect to coose-
q\»nces that may result from use of Lhe
article (21 C3-C. 321(0)) when its label
lall* tc besr lijonnstloo to alert the
householder to this batard.
FvtU. A substance intended to
be used u a fuel Is eieropt from the re-
quired ecu of tbe act when In coniala-
en that tJ* LA tended to be or air in-
stalled as part of tba beating. cooling. or
refrigeration system of a house. A port*
able container used for delivery or tem-
porary or additional storage. and ctm-
«¦ inim t substance that Is a hazardous
subetasce aj deflned In section 2 ff> of
tbe act. is act exempt from tbe labeling
prescribed in section 2(p> of tbe act.
1 ?ec though it contains a fuel to be used
la tbe beating. cocltnu. or refrtgeraUoQ
UiLcm ol a bouse.
| 191.42 Exemption from fail Ubt)ia(
Anj perwo who believes a par-
ticular hazardous substance la a con-
tainer Is tended or suitable for household
um should be exempted (rem full label
compliance otherwise applicable under
this act. because of the size of lhe
package or because of the minor hazard
presented by trie substance, or for other
Bood aod tufflcitot reasoo, may submit
In the Commissioner ¦ request for ex-
anptioo under section 3(e) of tbe act.
presenting facts La rapport of tbe view
thai foil compliance la Imprattlable or
la not neeesarr for the protection of the
public health. Tbe Coaualuioner thaU
determine on the basis of the facta sub-
mitted and ail other available informa-
ttoo whether the requested exanpUoo is
consistent vilh adequate protect!as of
ttM public health and safety If he so
todJ. be shall detail tbe eimption
treated and the maons therefor by ap-
propriate order published in tb« Puoii.
Ricifm
(b> The Commissioner may. 00 his
own initiative. determine on tbe basts of
facta avaJable to him that a particular
hazardous substance in a container in-
tended or suitable for household use
should be exempted frtm full labeling
ttmpllance otherwise applicable under
Ihli act because of tbe sue of tbe pack-
age, or because of tbe minor hazard pre-
eentad by ihe suhstanee. or fcr other
lood and mXBcieot reason U he so
finds. he shall detail the esempuoh
learned And the reasons therefor by ap-
wopriatr order In the Ptsr*«L Ricom
I 191.Exemptions for •ro»D peeL-
— huidk, and ipccitl
tiftumituKol
The roUowmc eiemptlooj are rranied
^be 11^^ of ^^^^dous substances
In eootaineri tuMable or intended for
household use uader the proriaiona of
I lll.fl2(b»:
4a> When lhe Mk haxud from a
•ubsunc# ia a Mlf-prtuuriiad eoDUiaer
b that It generates pmurc. the name
of the component which contributes the
hftlAxd oeed not be stated.
Common matches, including book
matches, wooden matches, and so-calied
"safely" matches art ez on pied from the
i»K»i,nf raqulxements of section 2(p) (1)
of lhe act Insofar aj they apply to the
product being considered hazardous be-
cause of being "flammable" or "highly
flammable" as deAned in I 191.Hk>
(c> Paper Htms such as oewspgper^.
wrapping papers, toilet and deaaai^g
tissues, and paper wTlUng supplies are
exempted J ram the labeling require-
meau ot itctloa 2(p>(l) of lhe act In-
sofar ad ihey apply to the products being
Murdered baiardouj because of being
"Hu&aable" or "utremeJi' flammable"
as defined la I 1911 ck J.
Id' Thread, string, twine, rope, cord,
and materials art tiuapted from
tbe »*K»i>tiy requiremenu of aecuoa
Jfp) (l) of the aci insofar as they apply
to the products bamg cuuidered haz-
ardous because of being "flammable'* or
"aiLremely flammable'* ad defined jn
» 191.1Uc>.
LaBCLXMC RnUTVCM OT9
6 191.101 Plicrmfnt, ewaapkvouineu,
tonuaiL
Tbe signal word, the statement
of the principal haxard or hazards, and
Instruction* to read cartfully acy cau-
Uonar7 Infonaauoo that ma7 be placed
elsewhere on the labe.' anall appear to-
gether 00 the main DaneJ of the label
Such information shall be placed to-
gether and diiunetirely apart from other
wording or dcsicna. Hie neceasary
prominence shall be achieved by place-
ment within the borders of a square or
rectAogle with or without a borderline,
and by u*e of cuitable contrasts with
the backxTousd achieved by dlitincu^t
Lrpograpby or color, and by both eclor
and typography when needed
AU the items of (abet mSormstton
nquixed by aecuoo 2>'pMl) of the act
tor by regulations prescribing additional
information under secuoD 3 Tbe trpt Sb required
for additional lnlormaUoa shall
benr a reaaonshle ralauoothlp to the
other type uaad aad ahall be no smaller
than 10 point unless the available label
•pace requires reductions, la which trc&t
It shall be reducad no • than
necessary and ia 00 event smaller than
4 point type unless becau* of small
label apace an UenpUoa has been
granted under aecUon 2 (c) of the act
aod I 1B1.U.
0 191.103 CwadevuaTwa mf UM tfor-
¦iliOA.
Whenever the statement of the princi-
pal hazard or hazards itself providee the
precauuoEiar7 otesaires to be followed
or Avoided, a clear statement of tbe prin-
cipal hazard will eaUafy both the provi-
sions of section 2tp> (S) aad CP) of the
act. When the statement of prwcauDoo-
ary meajurcs In efeci provides instruc-
tion for flrat-AJd Utttmtot, the state-
rnent of the precautionary measures will
satlsir both section 2(p) 1F) Ahd iO) of
the act
9 191.10S Libding rf^ftiraMAU for m<
eovpaAytog llwntait.
When any acoompanyiag literature
includes or bears any directions fov use
tby Printed word, picture, itrign or com-
bination of such methods), such placard,
pamphlet, booklet, book. gga. or other
graphic or vigUAl device ahall bear all
the Information required by anion J(p>
of the act.
| 191.106 Subatiaee* dcu/aintd u b
"special bind*."
Wtenever the —l"^tnmT deter-
mines that for a parucular hazardous
•ubstaoc* la a oontalaar intrnrtrrl or
suitable for bouaebold uae, the require-
ments of sec tins 2tp) of Um act Are hot
Adequate for the protocuoa ctf the public
health and safety became of ambc g»<
elal hazard, be shall by order m
the FkAgnat Bccom such fsiinnsliia
nhatiofis or additional kabel require-
ments as be finds oeceasar7 for the pro
tect^D of the public health aad safety.
9och order shall specify a date not lea
than M dayi after the order Is
emergency oouUUone staled la
the order specify aa earlier dai*. aflc
which any container of such hazardous
substance intended or suitable for house-
bold use which fails to bear a label in ac-
cordance with such order shall be deemed
to be a misbnaded package of a hazard-
ous substance.
$ 191.107 SmUhh <¦ ¦ 1 | k BMlliyia
kiurdft.
must be labeled with an affirms*
tlve statement of tach *^¦¦*** hazard;
precautionar7 metAires debiting tbe
acLioo to be followed or avoided for each
such hazard: UutnKtlooi. vbaa nffff*
¦ary or appropriate, for flnt-aid ueat-
meni of paraooa asffenog tra the HI
E-8
-------
7340
IULES ANO tSGULATIONS
effect* that say result from each sueh
hazard. uuLruccioD» (or haadlihg uui
atormce of packages thai require special
care Ln handling and storage bec&ute ol
mor? than one ln>t of hatard orwenud
fay the Article, as well as Um eosunon
or uiutl DAae (or Uit chetnJeaJ nine
tf ttfere 1* oo common or usual name!
for each hazardous component prtaent
Is the article
(b> Label information referring to the
potability of one hu&rd may be com-
bined with parallel inJormauoc concern-
lug any additional hazards preseoted by
the article: Provided, That tile resulting
eondewd label statement shall eontain
all of the information needed lor dealing
vlLh each lype of hazard presented by
the artleie
§ 191.101 Libel commrnl.
TTk Commissioner will offer in/ortnal
comment on any proposed label and ac»
companjnrg Literature involvi/vg • haz-
ardous substance LI he is furroshed with.
(a) Complete labeling or proposed
labeling. *Mch may be in d/art form.
complete duaauuu«e formula.
U5 of ilie
Pe^eral Hazardous Sufcj'-ancei Label-
ing Ac: are not adequate (or lhe protec-
Uon of Lhe puolir health Labeling for
those jubilances, la the coDceotrations
listed in the Pederal Caustic Pouoo Act.
were required to bear the signal word
"pouoo." The Commissioner believes
thai U>e lack of the designation "poison"
would LDdicau to the consumer a leaser
hazard than heretofore and that ruch
would C£i be La the Interest o< the public
health UDder the authority granted in
¦rclion 3(b) of the act. the Commiaajoner
therefore finds that for the foUovuif
aubatances. and at the f oliowin# concen-
tration*. the word "pclaon" Li neccaaary
Instead of any signal word
(a) Hydrochloric acid And any prepa-
ration conlaUur* free or chcaueaUy un-
oeu trained hydrochloric acid in a concentra-
tion of 3 percent or more
Carbolic acid iCJ^OH'. also
Lnovn aJ> phenol, ano arr prcparauon
contaiAina carbolK acid to a concentra-
tion of 5 percent or more
%t' Oi&iic acid ano any prcparauon
ccniairur^ free or chemically unneutral-
iced oxalic acid (HfCiO.> In a concentra-
tion of 10 percent or more
Ai\y salt of oaaJic acid and any
preparation eontalnint any auch aalt Ln
a con centra uon of 10 percent or more.
(gi Aeetie acid or any preparation
contatnini free or chemically unneutral-
bed acetic add (UCtH<0>> In a concen-
tration ol 30 percent or more.
,
Including eauiuc soda and lye lr a con-
centration of 10 per can l or more
(fcj Silver nitrate, sometimes known
as lunar causue, and any preparation
coniaiiuag lUvtr tutrmu oat>!e to
conclude that facts caxi be established by
reliable evidence at the hearing which
wiu call for changing the provisions
specified la Lhe objections. Whenever
legally vaUd objections have been (Led. a
public bearing on the objections will be
held.
0 U-SC
2112.
Piohtbitu Acts ams Pinaltiaa
i 191.210 G*nrr«!.
The provisions of Lbett regulations
with respect U> the doing of any act shall
be applicable also to the causing of sueh
act to be done.
{ 191.211 Cuaraatr<
In case of the giving of a guaranty or
undertaking referred to In section lib)
<2> ol the act. each per sod signing such
guaranty or undertaking, or causing it
to be signed, shall be considered to have
given it. Each person causing a guar-
anty or underts Llog In be false la charge-
able with violations of section « of the act*
ill Limited form /or kj* on inootoe
or bit/ of m/c.
(Numo( p«raoQ (loioe Ltaa gut/aniy
or uo4«ruAiaf)
timcy guar«ei*a tan bo «aicIc mud
ia ia lo i auOraoard pactagi wiiaia ia«
mraoiQi of tfi< Pvotral BuA/doua 9ub-
¦liscn Lamiiti aci
(9)|oalu/« u4 poai-odcv
u3 of p*r*cn ft*.
lag the guaruiy em
unornaAiog)
(2) Gmtrol Qn4 continuing lorttm
Tiki i/uclt ccApntJog ttcb iSlpmtDt or
otb«r ociivcfi bJrtafWr mac* oy
d poit>cOc4 add/cai at ptnoe ia
• 6ob Um guATMiy or uiMMrvaauig u )
E-9
-------
Saturday, Augiut 12, mi
HoriAi ifcinii
H kanlr fUaraaieed. m of tfea tUla Of nuch
aAtpBB«ot ov d«U*erj.*to be. oa tucb 4am. dm
IB ¦ SU»briMBd*l pfceJUkg* vtifua Uu m«tOlO«
el ID* faflarai BaaarOoiii 6uhuuuh Ub4i-
aac *««•
(Blfltturt l£d pMlooSca
MlUli Of pttWB fit.
Ib| (&• piuuif or
Ua4«naJtla|}
le> The application of & guaranty or
undertakus# rtierred to in section
9 of tfce act to any sfcipmem or
ether delivery of as artscic thail expire
when such article. after shipment or
delivery &i ptrMo who gave such
guaranty or underrating, becomes mis-
faraaded rutin Uhe meaning or the act
| 191,219 Pre»«nuiimi mf vie»« under
kfttiOD 1 of li\« •«,
(a) Praenutloa of views under sec*
tiao 1 of the act &h*JU be private and In.
formal The views presented shall be
eoafi&ed to Batters relevant to the ean-
lampiabed proceeding, Sueb vkwa may
be Pretested by ietur or iz, person by
Ihe pers«ns to »hoo the notice was
given, er by his representative In cut
wen person hold* i guaranty or under-
taking referred to La ipcUcd SUU?e body Only uaptes ao
desigBAled bt ilo officer er citployee of
the Dep*rQB»ent be eocuDdejretf to
be oQciaJi nisplu.
4»i ibe purpose ot detensLning
vtitiher or ooi i sample la ccileeteti for
¦xuuraia. Ltoe Lean "aiulysu" UBcludca
4iimTiU0M and UiU.
(b) The owner of a hiaardoui eub-
rtance ot whieb an oAcUl aanpk la col-
lected la the pcr«m who ovna the ahlp-
c&eot or other lot oi Lhe article from
which Hie aample la collected.
| 19I4IIS TraiuriiiMut ppiiitwi for rr-
kbdi«|.
The Commissioner r
-------
APPENDIX F
HYDROCARBON GUIDE
(reproduced with permission from Aerofill, Ltd.)
F-l
-------
Hydrocarbon Guide
The Aerosol fillers guide to using
Hydrocarbon PropeUants
Published in the interests of safe practice by Aerofill Ltd.
-------
M&OflLL
CONTENTS
INTRODUCTION 2
Section 1 Preliminary Considerations 3
Section 2 Notification of Authorities 4
Section 3 Hydrocarbons as Aerosol propellants 5
Section 4 Hydrocarbon Propellant supply 8
Section 5 Small Scale Storage of Hydrocarbon
Propellant 10
Section 6 Bulk Storage of Hydrocarbon Propellant 13
Section 7 Solvent Storage and Use
19
Section 8 Aerosol Filling
Section 9 The Laboratory and Pilot Line
Section 10 Disposal of Waste and Scrap
Section 11 Finished Goods
22
29
32
34
Section 12 Safety and Fire Precautions
35
Section 13 Further Information
39
Bibliography
Aerofill Ltd acknowledges the inclusion of photo reproductions
by kind permission ol:
AEROSOLS INTERNATIONAL LTD
CALOR GAS LTD
40
F-3
-------
INTRODUCTION
2
This handbook has been designed to act as an easy reference book and
guide to aerosol fillers using or considering the use of hydrocarbon
propellents. It is not intended to replace reference to the relevant authorities
and their publications but to highlight their relationship to aerosol filling.
The storage and use of hydrocarbons is governed by various Factory Acts,
statutes and regulations most of which relate, wholly or in part, to its use in
the aerosol industry. In addition the Health and Safety at Work Act places
responsibility on the employer and his mangement to operate in a manner
that safeguards his employees and the public.
The information in this handbook provides a link between the various
statutory regulations, codes of practice and other trade and industrial
publications, indicating how these relate to the storage, handling and
supply to aerosol filling lines of hydrocarbon propellants. It also covers the
safe installation and operation of equipment in the factory and related
matters such as finished product storage and waste disposal. The handbook
is a guide not a definitive instruction manual since each installation will vary.
However, the information given here may help save time, money, eflorl and
risk.
Although the information is biased toward current rules and regulations in
the UK and the experience of Aerofill and its customers, it may be assumed
that, with minor variations, the contents of this handbook will apply to any
installation. Care has been taken to investigate all sources of regulations
which may effect hydrocarbon filling installations but all work should be
carried out with due reference to the authorities indicated at various points
in the text.
The parameters of this handbook have been fixed to deal only with
hydrocarbon propellants and related installation operation and usage. No
attempt is made to argue the case for hydrocarbon propellants or to deal
with formulations which are outside of Aerofill Ltd's field of activity.
Aerofill Limited
Printing House Lane
Hayes
Middlesex UB3 1AP.
Tel: 01-848 4501.
F-4
-------
Section 1
PRELIMINARY CONSIDERATIONS
Hydrocarbons are flammable and explosive, however, if handled and used
properly they offer the aerosol filler several advantages over other
propellants in certain circumstances and formulations. As expected, where
any new undertaking is planned using propellants in the form of
Liquified Petroleum Gases (L.P.G.) with their hazardous possibilities,
there are certain authorities to be consulted. However, the feasibility of
installing and using hydrocarbons can be determined by examining
certain fundamental requirements.
First Is there room for the storage tanks?
L.P.G. storage must be isolated, fig. 1 shows the
required separation distances for bulk storage
above and below ground. Fig 2. shows some
examples of how to apply these separation
distances. Storage is dealt with in more detail in the
relevant chapters.
Second How much propellent will be needed on a dally
and weekly basis?
(Hydrocarbon fill in each can) X (the number of cans
to be filled) X (the number of days between deliveries
and the minimum level to be maintained in the tank.)
Third Are the factory premises adaptable to hydrocarbon
filling?
Space, as indicated by the above, is likely to be a
critical factor and other matters are highlighted in the
following chapters relating to layout, operation and
safe usage.
If these considerations can be satisfied, a deeper study can commence in
consultation with the authorities and suppliers.
F-5
-------
Figure 1.
Separation Distances for Bulk Storage Vessels.
Storage Categories Siting Categories - Distance in Metres
Water Capacity of
Nominal
from Building/Property
Between Vessels
Individual Storage
LPG
Line or Fixed Point of
Vessels in Litres
Capacity
Ignition
ITonnes)
(Above
Under
(Above
(Under
Ground)
Ground)
Ground)
Ground)
Up to 450
0-0.2
None
3
None
1.5
Over 450 to 2.250
0.2-1.0
3
3
0.9
1.5
Over 2.250 to 9,000
1-4
7.5
3
0.9
1.5
Over 9.000 to 135,000
4-60
15
3
1.5
1.5
Over 135.000 to 337,500
60-150
23
5
1.5 or J sum of
1.5
diameter of adjacent
Over 337,500
150-
30
5
vessels, whichever
is the greater.
Storage
Siting Categories - Distance in Feet
Categories
Water Capacity of
Nominal
From Building/Property
Between Vessels
Individual Storage
LPG
Line or Fixed Point of
Vessels in UK Gallons
Capacity
Ignition
(Tons)
(Above
(Under
1Above
(Under
Ground')
Ground)
Ground)
Ground)
Up 10 100
0-0.2
None
10
None
5
Over 100 to 500
0.2-1.0
10
10
3
5
Over 500 to 2.000
1-4
25
10
3
5
Over 2,000 to 30,000
4-60
50
10
5
5
Over 30,000 to 75,000
60-150
75
15
5 or ^ sum of
5
diameter of adjacent
Over 75,000
150-
100
15
vessels, whichever
5
is The greater.
Note 7: The maximum total water capacity of all storage vessels in a group must not be greater than three times the water capacity of
the largest vessel permitted in any particular siting category. The maximum number of vessels in a group must not exceed six.
2: For underground storage vessels up to 2,250 litres (500 UK gallons) water capacity, the distance from the valve assembly on
the manhole cover and the loading/unloading point to the building/property line or any fixed source of ignition must be at least
3m. 110 ft.); for vessels above 2,250 litres 1500 UK gallons), this distance must be at least 7.5m. (25 ft.).
The information given in this chart is based on the Health & Safety Executives' Code of Practice for the Storage of LPG at Fixed
Installations. The Nominal Capacities listed are based on the Specific Gravity of Butane 30 at 0 57 S.G. Conversion must be
made for Propane or intermediate blends.
Separation Distances for the Storage of Cylinders
Min. Separation Distance to Boundary, Building or
Fixed Point of Ignition.
From Nearest Cylinder (where From Radiation
no rsdistion wall exists) Wall where provided.
1 metre Nil Empty & Full
3 metres 1 metre Cylinders must
4 metres 1 metre be separated
within the
compound.
Although the Code of Practice for keeping LPG in Cylinders and similar containers lilts greater LPG capacities we feel that bulk storage
should be given urgent consideration for capacities beyond 4,000 KG*.
Total Storage
LPG Capacity
.50-100 KG
above 100-1,000 KG
above 1,000-4,000 KG.
F-6
-------
fig J
SITE BOUNDARY
SITE BOUNDARY
SITE BOUNDARY
10
in
m
10
FUTURE BUILDING LINE
5.1 Layout lor 20tn Tank showing
extent of separation distance
5 3 In the event that there is
insufficient separation distance
20 th]
NEW BUILDING
5 2 Additional 20tn Tank installed
whilst maintaining separation distance
T)
I
-J
SITE BOUNDARY
5 3 In the event that there is
insufficient separation distance
a 2nd tank may be accommodated
with the use of vertical tanks
site boundary
z
CO
>
tv
p
ur*
CM
Or
n
*2
x
15
BOILER.(J. SERVICES
lOO,
i oa
|_oo
PRODUCTION
WAREHOUSE
office
1
PRUM5
15
-I
3
15
5 4 Although required separation distance has
been satsified the tank is enclosed by
existing buildings with possibility of future
building beyond site boundary giving rise to
poor natural ventilation
5.5 Good layout with tanks isolated with good natural ventilation
& room for extension. Required separation from highly flammable liquids
is observed whilst boiler house & services are well away from tanks
All dimensions are Metric
Examples of tank installations showing separation distances
-------
- 3Mr
Section 2
NOTIFICATION OF AUTHORITIES
Having made your own evaluation of the feasibility, practicality and
desirability of using hydrocarbon propellants you cannot proceed without
notifying the relevant authorities. Knowledge of your requirements and
intentions prior to consulting the authorities will assist and expedite matters.
The authorities you are obliged to consult are:
a) HM Factory Inspectorate
The Factory Inspectorate are divided into areas and within each area
there are Specialist Field Consultant Groups to advise the Local and
Area Inspectors. Especially where there are projects calling for special
consideration, a consultant may be brought in to advise and assist
the company in planning. The Inspector will normally provide
considerable assistance and interpret regulations as they apply to your
particular site. Matters will be expedited if you have scale layout
drawings of your proposal and general data available.
Your local inspector should be known to you with his address on either
your Factory Register or your copy of the Abstract of the Factories Act.
b) Local Planning Authority
Changes and alterations effecting the factory site may need Planning
Permission and in any case the Planning Authority should be informed
of the creation of a hazardous area. The work will have to conform to
Building Bye-laws and regulations with inspection during progress.
Again expediting will be assisted by scale layout drawings.
c) The Fire Prevention Officer
The Fire Prevent ion Officer lor your district should be consulted, usually
attached to the local fire station but sometimes located at the area
headquarters. The Fire Prevention Officer has reporting responsibilities to
H M Factory Inspectorate and his co-operation and clearance is
necessary to obtain the Certificate of Fire Exit' required by the Factories
Act. He will provide recommendation on fire alarms, fire points,
ventilation and the storage and use of Petroleum substances and
Highly Flammable Liquids. He will require information on layout,
quantities of propellant to be stored, storage of finished product and
intended fire precautions.
d) Insurance Company
Advisable, though not obligatory, is early consultation with your insurers
concerning risk cover and precautions they would wish to see.
Compliance with the Fire Prevention Officer's recommendations or
installation by your own choice of a sprinkler system may result in a
favourable premium adjustment.
F-8
-------
e) Works Safety Committee
Under the Health and Safety at Work Act you are obliged to discuss
the project with the Works Safety Committee if you are a company
with official Trade Union representation. If Trade Union recognition
is not established, it is still advisable to consult your employees
especially as you are obliged to instruct and train your employees in
working with hazardous materials.
Section 3
HYDROCARBONS AS AEROSOL
PROPELLANTS
Hydrocarbons comprise a family of petroleum fractions and in respect of
aerosol propeilants we are concerned with propane (Cs He) and butane (C<
Hie) produced generally to British Standard 4250:1975. The hydrocarbon
gases are obtained from three sources: natural gas wells, gas issuing from
crude oil wells and the 'cracking' of crude oil. In the UK, at present, butane
and propane are derived from 'cracking' crude oil, that is breaking it down
into its constituent product or fractions.
Both propane and butane are gases at normal ambient temperatures, but are
readily liquified by the application of relatively low pressures and stored in
bulk vessels at ambient conditions in their liquified state (Liquified
Petroleum Gas). The ratio of gas volume to liquid at standard temperature
and pressure is approximately 274 and 233 to 1 for propane and butane
respectively. This will vary as the gases are blended. The density of the liquid
gas is approximately half that of water whilst the density of the vapour gas is
approximately 1V4 and 2 times that of air.
Liquified Petroleum Gas will burn where its concentration in air lies between
the narrow range of approximately 2% to 10% of vapour gas to air by volume.
Because the gas vapour is heavier than air it will accumulate at low levels in
enclosed and unventilated areas and, since it has a high gas to liquid volume
ratio, small quantities in air can produce an appreciably large volume of
potentially flammable mixture. These may be ignited by any naked flame or
hot surface as well as more subtle ways, such as incendive sparks,
unprotected lights, non-flameproofed electrical equipment and static
electricity.
5
F-9
-------
JiaofJii
Hydrocarbons are therefore hazardous and must be handled and used with
care and attention to safety and by competent and properly trained persons,
as can be seen from the stress placed in the Codes of Practice and attendant
publications indicated in this handbook.
Stanching
As a safety precaution, the hazardous presence of hydrocarbon gas is
signalled by a stenching agent (ethyl mercaptan sulphur or dimethyl
sulphide) added during the production process. All hydrocarbon gas
producing plants make this addition during the process in compliance with
BS 4250. Their process is irrevocably committed and the plant therefore
contaminated by the stenching agent.
Since the aerosol industry's requirement is small in relation to total
hydrocarbon production, non-stenched supply is not commercially viable.
It therefore falls to others to offer a de-stenching or sweetening and
blending process and to arrange distribution to aerosol fillers in
uncontaminated cylinders and bulk tankers. Removal of the stenching agent
is normally by absorption into a molecular sieve.
There are certain special mixtures and blends supplied in relatively small
quantities for use in high grade cosmetic and toi letry formulations; research
and development; and pharmaceutical and medical requirements. These
gases are generally the technically superior ISO-butanes in the unstenched
condition (imported) with de-stenched propane added to obtain the
required vapour pressure. The odour is less noticeable than normal de-
stenched butane and propane.
One of the principal drawbacks from a formulation point of view is the odour
of the commercially available hydrocarbon propellant even after de-
stenching, especially for cosmetic formulations. The source of the crude oil,
over which the propellant suppliermay have little control, may influence the
effectiveness of the de-stenching process.
Grades
To formulate for aerosols using hydrocarbons as a propellant and to cover
the wide range of product requirements, it is necessary to use propane and
butane, or mixtures of both, to produce the required vapour pressure at
25°C (70° F). It is also necessary, at the same time, to identify the grade or
blend of propellant.
The most common grades of hydrocarbon propellant currently in use in the
UK are listed below. As will be seen, these are identified by the vapour
pressure (psig) at 25°C (70°F), a procedure which is similar to that used in
the USA and Canada.
F-10
6
-------
Hydrocarbon propellent 30 = Vapour pressure 2.05 bar (30psig) at 25°C
Hydrocarbon propellant40= mix to produce V.P. 2.72 bar (40psig) at 25°C
Hydrocarbon propellant 48 = mix to produce V.P. 3.26 bar (48psig) at 25° C
Hydrocarbon propellant 110 = vapour pressure 7.5 bar (1 lOpsig) at 25°C
No attempt has been made in this handbook to detail the physical properties
of the various hydrocarbons or the specification of each grade. This
information may be obtained from the propellant suppliers along with
necessary toxicological data.
The foregoing paragraphs relate mainly to UK suppliers of hydrocarbon
propellant. Imported sources are available for butane/propane mixtures, but
the fact that they are not commonly used is probably a reflection of their
price where transport and distribution is a dominant factor. ISO-butane is
not available from UK based refining and must therefore be imported.
7
F-ll
-------
Fig 3
\E7
&
o
lo
5
5
O
0s
CM
£
£
o
144 PIA
LIQUID TAKE-OFF
TARE 46-75 K§6
TAKEN FROM CALOR LTD. DR^ 1455/2
HYDROCARBON CYLINDER
47 K$s CAR6CITY
F-12
-------
O
& ^
3952
11'
8
£ *
^ r
__
152
6'
137O
4' 6"
/52
6'
2 TONNES HYDROCARBON TANK APPROX 3850 LITRES
254
10'
$ &
to c
Vs>
o ^
^ • «l
^ —
4774
15'6*
8534
28'
12 TONNES HYPRO CARBON TANK APPROX Z5,000 LITRES
HYPR0CAR30N TANKS
Z $ 12 TONNES CAPACITY
F-13
-------
Section 4
HYDROCARBON PROPELLANT SUPPLY
Normal butane and propane mixtures to the designations as listed in Section
1 and supplied in the destenched condition are obtainable from Calor Gas
Ltd., Calor House, Windsor Road, Slough SL1 2EO, telephone Slough
23624, and their regional offices.
The destenching process is carried out at their works at Millbrook,
Southampton, from where U.K. distribution is carried out in cylinders and
bulk tankers of up to 15 tonnes capacity.
Calor supply in portable, refillable 47kgs (104lbs) cylinders for laboratory,
pilot plant and small scale production use (fig 3) and 2 tonnes and 12 tonnes
capacity tanks (fig 4). The cylinders are supplied on a 'free loan' basis, but
the 2 and 12 tonnes tanks are supplied on a rental basis, the cost of the
installation, civil engineering, pumps and pipework being totally charged to
the client to become his property.
Although Calor Gas Ltd. offer a full consultancy service for any installation
of hired tanks and for tanks of larger capacity, or installations calling for
underground tanks, these projects must be financed by the client.
Calor Gas Ltd. maintain their own laboratories at Weybridge, Surrey with a
section devoted to aerosol formulations. The company is an active member
of British Aerosol Manufacturers Association and participates in its
technical activities.
Because of technical and commercial constriction, standards for odour are
difficult to establish. The origin of the feedstock will determine the degree to
which the propellant may be sweetened and the size and capacity of the
molecular sieve filter for a given flow rate. Odour acceptance will depend
upon agreement with the supplier and may be monitored by the critical
opinion of the chemist in charge or by agreed standards of repeatability
based on gas chromotography.
After these standards have been agreed it may well be that the user may wish
to install an inline destenching column for further security. However, a flow
capacity related to the weight of molecular sieve will need to be established
by trial.
Molecular sieves are synthetic alumino silicate crystal powders which range
from 1 to 3 microns in diameter and are bound together to form pellets
1.5mm in diameter. The size and position of the metal ions in the crystal
controls the effective diameter of the channels that interconnect the millions
of tiny cavities in each crystal. This micro "sponge like" form permits the
absorption of the molecules of sulphur compounds.
F-14
-------
£
5
O
rsi
CVJ
3
B O.C. CYLINDER WOP
CONTENTS 50 ka
TARE WEIGHT 55 ka
3dO MM
PIA.
¦*
15'
2110 mm APPRO*
83'
>-
\
/
>
1
\
/
\
/
<
0
\
/
s
ruLi.
/ LTLT nl
s
Jo
rO
1
0
'II
\
*1-
CO
/!!
\
/ 11
\
/ U
\
>
'
B.O.C. DRUM TANK
CONTENTS 385 kg
\ TARE WEIGHT 690 m
Valve 4, termination £ a&a . n? 300 flange
OUTLINE I? DETAILS FROM INFORMATION FROM
BRITISH OXYGEN C* LTD. SPECIAL MASSES
F-15
HYDROCARBON CYLINDERS
50 k« $ 3&5« DRUM TANK
-------
The saturated and spent molecular sieve must be regenerated or discarded
under controlled conditions to enable the hazardous hydrocarbons to safely
disperse and the noxious smell of the sulphur compounds not to cause
offence.
Special blends and mixtures of unstenched ISO-bulane and destenched
propane are supplied by B.O.C. Ltd., Special Gases, Deer Park Road,
London SW19 3UF, telephone 01-542 6677.
As stated in Seclion 3, special grades are supplied for those who require a
technically superior specification which is 99% pure, used principally where
there is a need for less odour and residual contamination. These grades may
be preferred for high class cosmetics and toiletries, research and
development and pharmaceutical and medicinal formulations.
Whilst these grades are more expensive and mostly supplied in returnable
refiliable cylinders of 50kg capacity, they can be supplied in 385kgs
refillable drum tanks (fig. 5). Should a requirement demand a bulk
installation, B.O.C. Ltd., may be willing to investigate the feasibility.
F-16
9
-------
H•produced from
b««1 avails* eopy
Portable cylinders containing propane located outside a building
and connected to a change over valve and pressure reducing valve to
supply gas to appliances within the building through fixed piping.
15 tonnes Propellant Tanker
F-17
-------
wHaofJL!
Section 5
SMALL SCALE STORAGE OF
HYDROCARBON PROPELLANT
Laboratory or pilot line operation and certain small filling operations may
no( require or accommodate even a small fixed bulk storage installation. In
these instances cylinder and drum tank storage may be considered.
Refillable, 47kg (1041b) cylinders are the most common, however their
limited capacity should be taken into account — at an average fill size four
cylinders manifolded together will fill approximately 2,000 aerosols.
For an aerosol filling installation using cylinders, sections of the 'Highly
Flammable Liquids and Liquified Petroleum Gases Regulations 1972" and of
the Health and Safety Executive's 'Code of Practice for the Keeping of
Liquified Petroleum Gas in Cylinders or SimilarContainers' will apply. Other
requirements may be made by local bye-laws, trade recommendations and
good safety sense.
The use of cylinders containing hydrocrabons for aerosol filling can be
divided into tv.o separate categories — Cylinders awaiting use and
Cylinders in use.
a) Cylinders Awaiting Use
Cylinders awaiting use should be stored in open air in a well ventilated
position. The cylinders may be full awaiting use orempty awaiting collection
by the supplier. The part of the Health & Safety Executives 'Code of Practice'
that refers to storage deals mainly with large quantities of cylinders or
cartridges as may be stored in a distribution depot and not an aerosol
factory. Part 2 of the code deals with open air storage areas whilst other
parts refer to safe handling and procedures. For Aerosol use the quantity of
cylinders is not likely to be very large, the total stock required should be
fixed and from this the separation distance governing the area can be
obtained from fig 1. Any boundary, building or fixed source of ignition must
be beyond these distances which may be extended by H.M. Factory
Inspector upon examination of the site and the overall layout of the factory.
In certain circumstances a radiation wall may be permitted to overcome the
problems of borderline situations.
The area should be identified and secured by a chain link fence at least 2
metres high (6 feet) with two outward opening gates. All cylinders should be
stored on their base and in an upright position with protective valve cap in
position. Empty and full cylinders should be segregated and identified.
The area shall be free of drains and at least 3 metres (10 feet) from any other
cylinders containing oxygen, hydrogen, materials of a corrosive or toxic
nature or highly flammable liquids. No combustible materials shall be kept
within the area.
F-18
10
-------
uHrtofliA
Where 385kgs (V4 ton) drum tanks are used, a gantry type lifting tackle may
be needed to unload the tanks, whilst cradle trolleys are used for moving to
point of use. Use chocks to secure the tank.
b) Cylinders In Us*
Cylinders in use, except for special laboratory use and under strict
conditions should not be used inside a building. They should be set up for
use in the open air possibly against an outside wall in a well ventilated place
at least 3 metres (10 feet) from any fixed source of ignition, other cylinders
and Inflammables as stated in a).
Cylinders may be manifolded together, in an approved manner with
changeover valves and non-return valves in the pipeline from cylinder to
manifold to prevent flow from one cylinder to another with the possibility of
danger resulting from high pressures.
Manifolded cylinders may be stood on mechanical platform scales as an
easy indication of use of hydrocarbon from gross and tare-weights. The
cylinders should be secured in the upright position with a supporting cradle
or harness chain around the bodies of the cylinders.
The key or shut-off valve knob should not be removed and it is
recommended that a notice be fixed around the neck of the cylinder in use:
vis
'Cylinder in use — shut-off valve open — do not
tamper with or close except in an emergency without
reference to '
(enter name of suitably qualified and competent person).
The position should be provided with an earth point with earthing strips and
provision for earth continuity from cylinder through to the filling equipment.
Empty cylinders and those not connected to the manifold should be
returned to the storage area for safe keeping.
The cylinder connection to the manifold may be flexible with self seal
coupling. It is preferred that the fixed end be protected by a valve that cannot
freeze open in the event of gross leakage. From the manifold to the filling
equipment there should be rigid fixed pipework in steel to appropriate
British Standard (copper should only be used for vapour lines). Note: under
no circumstances should plastic air line hose and compression fittings be
used.
11
F-19
-------
The pipe route to the filling area should be planned to miss steam pipes,
electrical cables and distribution should be as safe and direct as possible —
planned in co-operation with H.M. Factory Inspector and the Fire Prevention
Officer. Pipes should be identified in compliance with British Standards and
direction of flow indicated. All valves should be fire safe and approved for
L.P.G. Pressure relief valves, vented safely, should be strategically
positioned to prevent any possibility of hydrostatic pressures building up in
the pipework with volume changes of gas due to increases in ambient
temperatures when plant is idle.
Separate pipelines should be installed for each grade of propellant to be
used with proper procedures and description laid down. It is safer to change
over pipelines than purge a single pipeline each time a change of propellant
is made.
Good safety procedures should be carried out by competent persons
properly trained in accordance with the appropriate parts of the relevant
codes.
F-20
-------
15 tonnes Tanker in process of unloading
F-21
-------
Fig. 6.
CD
CD
O
r*
i
L.
¦T
.J
is
z
NOMINAL
BUTANE
CAPACITY
LENGTH
DIAMETER
B
HEIGHT
C
CENTRES
D
20 11m 2.25m 2.6m 8.00m
TONNES 36' 7' 6" 8' 6" 26'
25 12.25m 2.5m 2.25m 8.00m
TONNES 40" 8' 9' 26*
30 7m 3.65m 4.00m 2.5m
TONNES 23' 12' 13' 8'
50 10.25m 3.65m 4.00m 4.25m
TONNES 34' 12' 13' 14'
ALL DIMENSIONS ARE APPROXIMATE FOR EACH CAPACITY AND
MAY VARY WITH MANUFACTURERS DESIGNS
HYDROCARBON TANKS LARGE CAPACITY
-------
Section 6
BULK STORAGE OF HYDROCARBON
PROPELLANT
Experience has shown that the conditions for a bulk installation vary widely
from site to site, the information given in this section therefore represents
acceptable practice and basic guidelines
The size of any bulk tank installation will depend on seven basic
considerations:
a) The maximum daily off-take required.
b) The number of different propellant grades required.
c) The size of tanker delivery and ease of access.
d) The minimum quantity required in the tank to ensure good gravity head
for pumping.
e) The time taken to process an order and receive deliveries.
f) Sudden demand and overtime working potential requirements.
g) Allowance for future increases in demand.
When the approximate overall storage capacity required has been
determined, dimensions can be obtained from fig. 6 which shows nominal
tank sizes. It should be noted that the maximum number of tanks
permissable in a group is six.
Tanks used should be designed for L.P.G. storage in compliance with B.S.
1515:1965 for butane at a working pressure of 7 bar (100 psig) and propane
at 15 bar (220 psig) both at 37.8°C (1008F). In view of the increase in
available grades and developments in formulation work, the use throughout
of propane rated tanks may be considered a wise investment.
The Code of Practice for the 'Storage of Liquified Petroleum Gas at Fixed
Installation' published by the Health and Safety Executive lays down
separation distances which will be determined by the size of the tanks
chosen. (The data in fig 1 differs from the code only by the inclusion of
metric units and the converson of water capacity to nominal L.P.G. capacity.
Water capacity refers to the total fill of the tank whilst L.P.G. capacity must
allow a headspace of 15% for expansion due to increases in ambient
temperature.)
The 'separation distance' is the minimum permitted distance from the tanks
to the site boundary, a building or future building line and any fixed source
of ignition. To this may be added the distance from the hose connection for
tanker unloading, the unloading area being classified as a hazardous area to
13
F-23
-------
ftoad tanker vehicle unloading bay, and the manually operated fixed water drenching system over it.
-------
P.
n
1
n
I '
:
V
>
J
i
t
I
(
—
)
i
15
LEN^FH OF TAN*
— "pp*
_N»
o
I 6
TANK TO INSIDE. 01 FLNCE
u
CONCRETE RAFT
^J
DOUBLE TANK INSTALLATION
SIMPLE TANK. INSTALLATIONS
LADDER & CATWALK IS NORMALLY MOUNTED
AROUND THE MANLID FOR SAFETY. FOR
CLARITY & TO SHOW CONNECTION LADDER
& CATWALK IS SHOWN ADJACENT
TO MANLID
1 Contents Gauge
2 Manlid 560mm dia
3 Pressure Gauge Connection
4 Combined Safety Relief Valves
Vent Pipes & Rain Caps
5 Vapour Return (Balance) Connection
6 Liquid Return from Supply Pump
7 Thermometer Connection
8 Tank Earth Point & Earth Rod
9 Liquid Fill Valve
10 Liquid Supply to Pumps & Filling Lint
11 Fixed Liquid Level Gauge
SEPARATION DISTANCE EXTENDS FROrt
SIDES & ENDS OF TANK(S)
6 RAVEL
CHAIN LHK FlflCt
overall dimensions op tank c position of mam m a Muucmnuc.
VAW ACCORDING TO MAHUF^TWERS PESfGN * COmECT,0m
All dimensions are Metric.
2S0 mm WKWU
360 mm H1^
SITE OUTUHE $ TANK 0LTWL6
TYPICAL FOR 25/50 T0NNE& Tf&>
-------
Zone One up to 1.5 metres (5 feel) and Zone Two up to 4.6 metres (15 feet).
As both Zones demand flameproof electrical equipment, it should be
interpreted that the 4.6 metres should be entered into the separation
distance calculations, as such it would only extend the layout for tanks
under 1 tonne nominal hydrocarbon capacity.
Under certain circumstances the separation distances may be reduced by
the inclusion of a radiation wall or by the installation of a fixed water spray
system. Dispensations of this nature should be sought from the Factory
Inspectorate and the Fire Prevention Officer. Equally, however, distances in
excess of those given in fig. 1 may be required If the site lacks good natural
ventilation.
Any calculations must also take into account the siting of existing or
proposed tanks for solvents or other highly flammable liquids since these
should have a separation distance of 15 metres (50 ft) from any hydrocarbon
tank farm.
Finally the layout should provide access for tankers of up to 15 tonne
capacity using discharge hoses of 9 metres effective length. A turning circle
of 16 metres or a reversing space of 8 metres long must be provided for the
tankers as they are not permitted to reverse into public highways.
Above Ground Storage
The site for above ground vessels should be as level as possible, free of
drains, low lying depressions, pits or water courses. The maximum number
of permitted tanks in a group is six and the total combined water capacity
should not exceed three times the capacity of the largest permitted vessel in
the group. Tank sizes are shown in fig. 6 although dimensions may vary from
one manufacturer to another.
There should be a concrete raft sloped to drain any spillage from beneath
the tanks to a safe evaporation area within the compound. The area should
be protected by a perimeter fence, minimum 2 metres (6 feet) high at a
minimum distance of 1.5 metres from the side or ends of the tanks. The
fence, in chain link, may be erected on a low continuous wall, maximum
height 380 mm (15 inches), to secure the area and prevent trespass or access
by unauthorised personnel (bund walls are not permitted). The fence shall
have a minimum of two outward opening gates which should be non-self-
locking and kept unlocked when the tank farm is in operation — fig. 7.
The footings and plinths for the tanks shall be to appropriate design,
strength and fire resistance, which in turn will depend upon local sub-soil
conditions and water table. A survey should be conducted to check for
buried pipes, drains, culverts and cables which may affect the installation. H
is advisable to mount the tanks on plinths as high as possible (minimum 1.25
metres) to produce a good gravity head into the propellent pumps.
F-26
14
-------
PLklMETER AREA OF PIT 10 BE MAKKfcL> OUT
PLAN VIEW OF SINGLE TANK INSTALLATION /ALL VALVES CONNECTIONS *
FENCE WALL 4 $ATE6 ARE OPTIONAL / FITTINGS ARE MOUNTED ON
BUT IF OMITTED PRECAUTION MUST BE TAKEN / MAN LID COVER INVARIABLE
TO PREVENT SUPERIMPOSED LOADS 4 / TWO ARE NEEDED TO
POSSIBILITY OF DAMAGE TO FITTJNQS / ALL REQUIREMENTS
1!
CD
ix
v
O X
£
lO
t <£>
o to
»o
csj
C*
CO
SUB SOIL
CONCRETE SIDES
6 foundation
water BARRIER'
AT JOINT
CONCRETE RMsr
150 m m AS
I60>«»v1 FOR
SL)P£RlMP06kO
LOADS
c
c ¦
6UB SOIL
WASHED SIFTED
$ DR1EP SAND
TANK FIRMLY
SECURED TO
FOUNDATION
ALL DIMENSIONS
ARE METRIC
F-27
S/TE LAYOUT* SECTOR
FOR UNDERGROUND 7>Mtf
-------
I I
OANKER /
nq y
Smtr SEPARATION DI6T
PERIMETER FENCE
OUTLINE OF PIT
UNDERGROUND TANK
LESS THAN 2250 litre*
CAPACITY
example a
TMtKS NOT EXCEEDING 2250 LITRES WATER CAPACITY
3mtr RAP I US
OF SUPPLEMENTARY WSWHCE
i\
j \
•underground tank
I . OVER 2250 LITRES
| ' CAPACITY
\ -/ lC
T \ / yf RADIUS
u=x^ y | /of 8UPPL£MENTARV
ROAD TANKER
/X PITTANCE
Example B
Tanks over 2250 Litres Water Capacity
Underground tanks have a supplementary stipulation on
separation distance (see note 2 Fig 4). For a road tanker with
delivery hose fixed at tanker the supplementary distance of 3
mtrs (for tanks under 2250 litres capacity) will radiate from
the connection of hose & tank point & if made at the manlid
will be absorbed in the normal separation distance Example A.
For installations of over 2250 litres capacity the
supplementary distance of 7.5 mtrs. will extend beyond the
normal separation distance. Example B.
Where loose hoses are carried by a tanker the supplementary
distances will radiate from the connections to the tank & the F~28
tanker
All dimensions
are metric
Underground tanks
separation layout
-------
Vertical Tanks
Certain savings in space may be achieved by the use of vertical tanks, since
separation distances radiate from tank surfaces.
All the requirements lor the installation of horizontal tanks will apply, to
which must be added the following considerations:
1) A vertical tank installation will be more expensive than an equivalent
size horizontal tank.
2) The greater concentration of weight in the tank and its contents will
require much stronger foundations.
3) Overall height which includes the vent tubes may invoke planning
objections.
4) Height of tank may present Fire Brigade with fire fighting problems.
5) Fixed spray drenching system may be a condition of approval even on a
single tank installation.
Underground Storage
Where conditions for above ground tanks cannot be met, it may be possible
to install underground tanks where the separation distances are reduced
(see fig 8). It should be noted that for vessels up to 2250 litres (500 gallons)
water capacity, the distance for the valve on the manlid and the unloading
point to boundary buildings, building line or any fixed source of ignition
shall be a minimum of 3 metres (1 Ofeet) and for vessels above 2250 litres the
distance shall be a minimum of 7.5 metres (25 feet) — fig 9.
The pit excavated for the tank shall be in waterproofed reinforced concrete,
to suit sub-soil and water table, large enough to permit 1 metre access
between tank and sides for maintenance and inspection. The tank should be
secured to the base and should be covered by a minimum of 600 mm of
washed and sifted sand used to fill the pit. The tank itself should be properly
prepared against corrosion, usually the entire external surface is
shotblasted and zinc coated, bitumastic primer and enamel coats are
applied and the manways or nozzles wrapped in Thermoglazeorequivalent
(cathode protection may be advisable).
The area of the pit above the tank should be finished in concrete to prevent
any superimposed load affecting the tank. The perimeters of the pit area
shall be permanently marked and identified.
The manways or nozzle should protrude sufficiently above the concrete raft
as to allow the lids to be removed for inspection. All relief valves, vent pipes,
liquid and vapour connection points and other fittings shall be mounted on
the lids and be suitably protected against damage. A security fence should
be erected around the perimeter in the same manner as for above ground
tanks.
15
F-29
-------
Below ground tanks should be avoided if possible. They are some two or
three times more expensive to install than above ground tanks and periodic
tests and inspection are also expensive and time consuming, the below
ground siting makes pumping difficult and submersible pumps are not
recommended. The only advantage of underground tanks is the reduction of
the separation distances required to comply with the regulations. It is
strongly advised that specialist technical advice be taken concerning the
problems of underground tanks, corrosion and pumping.
Pumping
The pumps to supply the propellent to the filling machinery, as liquid at the
correct pressure to prevent vaporisation, should be sited within the tank
farm but not underneath the tanks. L.P.G. has no lubricating properties and
low viscosity. The pumps therefore should be designed and approved for
L.P.G. and continously rated. They may be electrically driven multi-stage
centrifugal type or air operated reciprocating.
The pumps should beset as low as possible and be provided with a pressure
relief to discharge back to the vapour phaseof the tank on overload or when
the filling lines have little or no demand.
The pumping pressure to the filling lines will depend upon the typeof filling
machine, the length and diameter of the pipework, the filling offtake and the
need to keep the L.P.G. hydraulic in the pipelines to prevent vaporisation on
sudden surges. It is advisable to have a standby pump for changeover in
case of breakdown, maintenance and repair.
The pumps should be set as low as possible and the tank a minimum of 1 25
metres (4 feet) above on its plinth. Appropriate pipe sizes and a reasonable
minimum liquid level should be maintained in the tank to present adequate
gravity head to the pumps for operation at correct pressures in all conditions
of ambient temperature.
An open-sided shelter in non-combustible materials may be built over the
pumps as a weather shield.
Pipework
All pipework shall be steel with flanges, filling valves, etc., to the appropriate
British Standards. Pipelengths should be welded or flanged, below 50mm
diameter, screwed joints are permitted by the Codes of Practice. Welding to
approved standards is preferred as a better earth continuity is possible; in
any case P.T.F.E. tape should not be used as a joint sealant.
Sections of pipework should be in manageable lengths, firmly mounted with
adequate flexibility for settlement and changes in ambient temperature and
routed to the filling area as approved by H.M. Factory Inspectorate and the
F-30
16
-------
Fig. 10
REQUIREMENTS AND EXTENTOFCLASSIFI ED AREAS FOR FIXED TANKS
For the UK Zone Areas indicate the degree of risk of fire or
explosion from the presence of flammable liquids gases or vapour.
In so far as Hydrocarbon for aerosol use the two applicable Zones
as set out in BS CP 1003 & BS5345 are reprinted below.
Zone 1 An area within which any flammable or explosive substance,
whether gas vapour or volatile liquid is stored, handled or
processed, tnd where during normal operations an explosive
or ignitable concentration is likely to occur in sufficient
quantity to produce a hazard.
Zone 2 An area within which any flammable or explosive substance
whether gas vapour or volatile liquid, although processed or
stored is so well under conditions of control that the
production (or release) of an explosive or ignitable
concentration is sufficient quantity to constitute a
hazard is only likely under abnormal conditions.
Extent of classified area Area classification
Within 5ft (1.5m) in alt directions from Zone 1
the tank connections or shell
Up to 5ft (1.5m) above ground level and Zone 2
within the distances set out for pressure
storage
Factor
Storage tanks
Relief valve
discharge
Within direct path of discharge
Within 5ft (1.5m) in all other directions
from point of discharge
Beyond 5ft (1.5m) but within 15ft
(4 6m) in all other directions from point of
discharge (10ft for tanks not exceeding
2250 litre cup)
Fixed electrical
equipment should not
be Installed
Zone 1
Zone 2
Tank vehicle Within 5ft (1.5m) in all directions from Zone 1
loading and a point where connections are regularly
unloading made or disconnected for product transfer
Beyond 5ft (I.Sm) but within 15ft Zone 2
(4.6m) from point of connection or
disconnection (10ft for tanks not exceeding
2250 litre cup)
Pumps, compressors
and destench Within 5ft (1.5m) in all directions Zone 1
columns
a) Outdoors in open Beyond 5ft (1.5m) but within 15ft Zone 2
air. at or above (4.6m) in all directions (10ft (3m) in
ground level the case of storage vessels not exceeding
500 UK gallons (2250 litres) capacity)
F-31
-------
"\
Fire Prevention Officer. Valves should be approved for L.P.G. and fire safe.
Where relief valves are fitted to prevent build up of hydrostatic pressures,
they should vent to a safe place and be protected for inspection and
maintenance by locked open shut off valves on either side.
If the use of underground pipes is necessary, ideally they should be in a
protective duct, coated and wrapped in suitable protective wrapping
material. The duct should be back filled in washed and sieved sand to at (east
500 mm (16 inches) below the surface. Cathode protection may be
advisable. The duct must be marked and suitable protection provided
against superimposed loads or traffic.
All pipes should be painted and marked for direction of flow and
identification to British Standard 1710 — 1975. Flexible hoses, where
necessary, should be to British Standard 4069 and suitably protected at
each end with shut-off valves. If a self-sealing coupling is used, it should be
with a valve protecting the fixed end.
Information Note: A flameproof enclosure for electrical equipment is one
that will withstand without injury by explosion of flammable gas that may
occur within it, under operating and overload conditions withi n the rating of
the equipment and will prevent the emission of any flame that will ignite
flammable gas that may be in the atmosphere outside the flameproofed
enclosure. Design and application is dealt with in British Standard 229-1957.
A guide to selection for Zone 2 areas is available in British Standard 4137 —
Fig 10.
Intrinisically safe applies to apparatus and circuits where the electrical
energy is so small that any sparking which may occur is incapable of
causing ignition, see British Standard CP. 1003 Part 1 and BS 5345.
Not*:
British Standard 5345-7976 of which pan 1
has been published is intended to update
4 bring into Una with tha International
Eloclrotechnical Commission's (IEC)
requirements for the selection,
installation, A maintenance of Flameproof
6 Intrinsically Sate electrical equipment &
apparatus.
There wilt be a transition period as Parts 2
to 12 are published during which time
certain requirements of other British
Standards will still apply, among lhase are
CP1003, BS229 A BS4137.
F-32
17
-------
Safety Procedures
Good safety procedures must be observed in accordance with the Codes of
Practice for the tank farms and pipe runs. The whole precincts of the area
should be designated non-smoking with suitable notices and restricted to
authorised personnel. The tanks should be checked to ensure that there is
sufficient space to accept deliveries, and each tank should have its
maximum fill capacity clearly marked — this should never be exceeded.
Always ensure that the tanker is connected to an earthing rod before
discharging tanker contents.
All bulk tankers carry an unloading pump, a meter to gauge the discharge
and a flexible unloading hose (9 metres effective length) with standard
connections for the bulk tank. Ideally, the tanker parking space should be
protected with an overhead sprinkler drenching system, but in any case
suitable dry powder fire extinguishers to British Standard 3465 or equivalent
should be located adjacent to the unloading area.
A sample of propellant may be taken for approval before discharge, using a
sampling unit.
The tanker discharge procedure should be agreed beforehand with the
suppliers' technical staff and the management and personnel of the
company who will operate the tank farm, staff must be properly trained in all
aspects of L.P.G.; safety, fault finding, testing, fire fighting and emergency
procedures.
The unloading and factory start up and shut down procedures should be
posted at vantage points, numerically itemised in correct and logical
sequence.
Assuming reasonable conditions, the total turnround time for a tanker of 10
tonnes capacity is about 2-3 hours. It is usual in the UK to be able to
discharge from a tanker without the use of a vapour return line from tank to
tanker for pressure balancing.
At all times a competent member of the company's staff and the tanker driver
should be in attendance during unloading.
The possibility of fire from an outside source affecting the tank farm and
pipeline can be minimised by good plant design and layout, consultation
with professional advice, proper training and discipline.
An adequate water supply should be provided for fire fighting and fixed
spray system which, in case of fire, will drench the fittings equipment and
the tank surfaces at the rate of 10 litre persq. metre. Small installations may
find a 20 mm hose reel adequate. In addition, dry powder portable fire
extinguishers to British Standard 3465 should be located at strategic points
and clearly marked
18
F-33
-------
'No Smoking', 'Keep Out' and other signs as considered appropriate should
be posted at reasonable intervals around the complex. Signs should also be
posted at the approaches beyond the separation distance, preferably with a
fronliertype barrier on the approach road to keep out unauthorised vehicles
especially with petrol engines.
Important Note: L.P.G. fork lift truck and similar vehicles should not have
their fuel cylinders refilled with aerosol propellant.
Although this handbook has been written with hydrocarbon in mind, it is felt
that it also presents an opportunity to stress the need for correct and safe
procedures for the storage and use of solvents, petroleum substances and
Highly Flammable Liquids, since the hazards are similar to L.P.G. and
irrevocably linked in the formulation and filling of aerosols.
As with L.P.G., petroleum substances and highly flammable liquids are
defined by and subjected to the Petroleum Acts and Orders and the Highly
Flammable Liquids and Liquefield Petroleum Gases Regulations 1972, as
well as local regulations and bye-laws as may be applicable. Furthermore,
any proposed installation can only be carried out with the co-operation and
acceptance of your local authorities, H.M. Factory Inspectorate and the Fire
Prevention Officer.
In the case of any solvent or chemical deemed to be covered by The
Petroleum (Consolidation) Act 1928, The Petroleum (Mixtures) Order 1929
and The Petroleum (Inflammable Liquids) Order 1971, a licence to store, mix
and use is required from the County Secretariat. Granting of the licence is in
the main upon clearance by Ihe Fire Prevention Officer of the safe site
layout, handling and use. A schedule of substances is set out in Part 1 of the
Order of 1971, but it should be noted that this schedule is not necessarily
complete and that substances are covered by the Regulations subject to
tests and that have a flash point below 23° C.
Broadly speaking, Highly Flammable Liquids are identified as having a flash
point below32°C subject tocertain tests as laid out in the Highly Flammable
Liquids and Liquefied Petroleum Gases Regulations 1972.
Section 7
SOLVENT STORAGE AND USE
F-3^
19
-------
11
Recommended Minimum separation distances for storage tanks
Capacity
of tank
litres
1000
1000-5000
5000-33000
33000-100000
100000-200000
Total Capacity
of tanks in group
litres
3000
15000
100000
300000
600000
Distance Distance from Bund to
between building, site boundary
tanks or fixed source of igniticn
1 1
1 4
1 6
1 8
1.5 10
NOTE Distances indicated are not subject to a code of practice
& are given as a minimum recommendation subject to
site conditions & opinion of H.M. Factory Inspectorate &
Fire Prevention Officer whose advice should be sought.
FILLING LINE FROM TANKER
DIPSTICK PORT
VENT PIPE WITH
FLAME ARRESTER
SUPPLY PUMP
OUTSIDE BUM
600mm MANLID
v mmmSi
CONTROLLED DRAIN
THROUGH BUND WAR
EARTH ROD (EXTRA EARTH
REQUIRED FOR TANKER)
ALL DIMENSIONS
ARE METRIC
F-35
SEPARATION DISTANCE
$ LAYOUT FOR HFL'6
-------
JUKO-MLL
Other solvents or chemicals with a flash poi nt of up to 66® C, whilst normally
regarded as only flammable, must be regarded as highly flammable if stored
at or approaching temperatures near their flash points.
Storage of these liquids in 200 litre drums and similar smaller containers
should be in the open or in open sided type structures without walls in a well
ventilated position with a bund wall on all sides (maximum height 1.5m) and
a ramp or sill for entrance. The net volume of the bunded area should be at
least 10% above the capacity of the largest container, and the ground should
be impervious to the liquids stored and should be sloped to a spillage drain
for evaporation.
In certain circumstances, a radiation wall, of two hour fire resistance, to the
height of the highest stack may be included (commensurate with good
safety), where required by the layout.
Empty drums must be stored within the area, as they will contain vapour
which is potentially hazardous.
Within the bund area, drums should be a minimum of one metre from the
bund wall and the compound itself a minimum of four metres from any
boundary, building or fixed source of ignition. The compound shall be
separated from any bulk tank installation of L.P.G. by a minimum of six
metres. These distances may be subject to change dependent upon the
geography of the site and consultation with H.M. Factory Inspectorate, the
Fire Prevention Officer and your local authorities.
Any forklift truck of similar handling device for use in the area or the mixing
room should be spark suppressed or flameproofed to H.M. Factory
Inspector's satisfaction.
Certain solvents and chemicals in constant use by the filler may be better
contained and more economically purchased in bulk storage tanks. It is
usual to employ mild steel tanks tested to 0.76 bar (10psig). These cylindical
tanks are generally mounted on plinths and cradles and sized to take the
maximum economic delivery based on daily usage and time taken for
delivery. The site chosen should have good access for tanker discharge.
Ideally, tanks should be sited above ground, sloped to collect spillage away
from the underside of the tanks and surrounded by a bund wall. If more than
one tank is bunded, the area shall be able to contain the net volume of 10%
above the capacity of the largest container (maximum bund height 1.5m). All
pumps and switch gear and valve sets, shall be outside the bund area.
F-36
20
-------
-dlaoMli
Underground tanks may be used to reduce separation distances but these
require special conditions of either vaulted construction or concrete jacket
and asa rule are some two to three times more expensive than similar above
ground installations.
Fig 11 shows the generally accepted safe distances for above ground tanks.
Pipework (suitably marked), into the factory area, should be in accordance
with appropriate British Standards and the routing should be decided in •
consultation with H.M. Factory Inspectorate.
Bulk tanks should not be located inside a building or on roofs.
Mixing
The mixing room or rooms should be totally enclosed and separated from
the production and storage areas of the factory by suitable fire resistant
walls and doors. The whole area should be flameproofed but dispensation in
this regard may be obtained from the H.M. Factory Inspectorate. Certainly
the area in the vicinity of the mixing vessels and holding tanks should be
considered a Zone 2 area (British Standard BS5345). Mixing and holding
vessels should be totally sealed or provided with access lids as small as
possible with good tight fit.
Ventilation should be adequate throughout the whole area, firstly to
eliminate the concentration of any highly flammable vapour likely to be a fire
hazard and secondly to provide a safe fresh air atmosphere for the
protection of the health of personnel under the Health & Safety At Work Act
(see note concerning chemical data sheets and handling and safety
precautions, Sections 9 and 12).
Ventilation rates will beset in co-operation with H.M. Factory Inspectorate,
but as a general rule the two requirements of the preceeding paragraph
should be followed. As the emphasis is on containing the chemicals in
closed containers, mixing, stirring and pumping should be kept to a
minimum (heat input increases evaporation). Where vessel lids must be
opened for the introduction of solvents and ingredients, ventilation should
be from within the vessel to a safe place, so that the velocity over the lid
opening shall be at least 46 metres per minute to prevent evaporation to
surrounding areas
The area under the mixing vessels and the general mixing area should be
bunded or silled and the whole floor fitted wilh gutters to drain to an effluent
sump lor disposal (see Section 10).
The aerosol product filling should be fixed by an area of demarcation
dependent upon the type of machinery and size of operation and is dealt
with in Section 8.
-------
Section 8
AEROSOL FILLING
There is no single piece of legislation that de&ls with aerosol filling; in other
sections of this handbook we have referred to and listed most of the
regulations and laid stress to those of particular reference to hydrocarbon
storage, etc. Certain parts of those regulations apply to aerosol filling, the
most important being The Highly Flammable Liquids and Liquefied
Petroleum Gases Regulations 1972', the interpretation of which, coupled
with the special considerations of aerosols, should govern the approach to
the filling and packaging operations.
From other sections of this handbook it can be readily appreciated that,
whatever the size of the filling operation, we must:
1. Understand the nature of the hazard of hydrocarbon and highly
flammable liquids.
2. Consider the hydrocarbon propellant filler as a Zone 1 area.
3. Consider the surrounding area as a Zone 2 area.
4. Contain the propellant filling operation in as small an area as possible
commensurate with the rate and needs of production and ventilation.
5. Ventilate to remove any hazardous and harmful vapour.
6. Ensure a safe routing of propellant pipework through the factory.
7. Evaluate, install and maintain a safe operating procedure at all times and
for all personnel.
An exact specification for filling cannot be laid down, for it will alter with the
changing circumstances and machinery at each factory and to some extent
upon the requirements of the Factory Inspector and his Field Consultants in
your region. It is therefore unreasonable to expect H.M. Factory
Inspectorate to have a unified and detailed policy for the whole country.
The British Aerosol Manufactuers Association have published a 'Guide to
Safety in Aerosol Manufacture' covering generally aerosol filling using all
types of propellants. We subscribe to its objectives and agree with its
recommendations, good counsel ideas and procedures and commend them
to the reader. We do not wish to repeat them in this section, but to
concentrate on the seven points mentioned earlier, and to show how we feel
the line layout should be tackled, and accept that in the process repetition in
part at least will be inevitable.
1. Understand the nature of the hazard of hydrocarbon and HFL't
In all the preceding sections, we have stressed the nature and the hazards of
hydrocarbons and highly flammable liquids (HFL's) and have quoted and
made reference to Codes of Practice and relevant regulations and
recommendations. Whilst reiterating the seriousness of the hazard, use of
hydrocarbons and HFL's may be safely carried out with containment and
adequate ventilation as the first line of defence.
F-38
22
-------
2. Consider the hydrocarbon propellent filler a Zone 1 area
Dangerous area designations are shown in Figure 10 and are abstracted
from the British Standard Code of Practice CP1003 Parts 1.2 and 3,1967 and
BS5345. From these designations and with the inevitable release of a small
quantity of hydrocarbon when the aerosol disconnects from the filling
adaptor, we must accept that the propellent filler orthe total machine (if the
propellant filler is an integral part of the complete aerosol filling machine),
must be considered a Zone 1 area and that electrical equipment must be
flameproofed or intrinsically safe to the appropriate standard.
3. Consider the surrounding ares a Zone 2 area
The Code of Practice CP1003 states that in an indoor situation a Zone 1 area
must be separated to ensure that there is no uncontrolled flow of flammable
liquid gas or vapour from that area to a Zone 2 area or a safe area. We must
accept that the area adjacent to a Zone 1 area must always be considered
Zone 2 by virtue of the aerosol conveyor inlet and outlet openings i n the wall
of the Zone 1 area. Where concentrates are filled separately from propellant
and where those concentrates contain HFL's, that area may be Zone 2
provided proper controls are exercised — fig. 12.
4. Contain the propellant filling operation In as small an area as possible
commensurate with the rate and needs of production and ventilation.
Dependent upon the size of the filling operation, factory space available,
throughput of cans, the type of machinery used, the formulation and valves
to be used; the propellant filling area or booth may vary in size and
layout.The following examples are all based on indoor installations:
a) Manual filling operation (Dual Pak 'equipment) — since the propellant
filling is integral with the complete equipment, the whole should be housed
in a Zone 1 enclosure of sufficient floor area to permit good operation,
access to the equipment for adjustment, space for concentrate header tank
and space to offset possible claustrophobic effects and to provide operator
comfort, see fig. 12-1. Can and valve space should be limited to reasonable
quantities, say 2/3 hour supply; and combustible outer packing materials
should be removed from the area at regular intervals, although passage
through the doors or door opening should be kept to a minimum.
b) Rotary Index type filling (Star Pak 'machinery) — the same
considerations should be taken as in 4a), especially where the propellant
filling is integral with the complete machine, fig. 12-2, but it may be
considerably larger in area if two back to back machines are employed. A
preferred alternative is to segregate the propellant filling by the use of a
selfcontained rotary index unit housed in its own Zone 1 enclosed area, fig.
12-3, whilst the concentrate filling and crimping operations are carried out
on the main rotary index machine housed in a Zone 2 area under
flameproofed conditions; back to back can also be accommodated in this
fashion. The advantage of this alternative is that the main hazard of
hydrocarbon is isolated in an area without the need for operators.
Note: the extent of the Zone 2 concentrate filling area may be reduced if non-
flammable concentrates are used.
23
F-39
-------
f ZONE 2 A
2 AREA
ZONE 2AREA
L_.L _
CANS
1 '
o
Oo oO
PUAL PAK
ZONE 1 AREA
—i—
VALVES
ZONE 2 AREA
ZONE 2 AREA
COMBINED PRODUCT $ PROPELLANTT FILLER
0
O
©
ZONE 1 AREA
ZONE 2 AREA
ZONE Z ARJ
PRODUCT fill
VALVE $ CRIMP
0
fO
o
PROPELLANT FILLER
a
0
\o
ZONE 1 AREA
ZONE ZAREA
EXAMPLES OF FILLING AREAS
Fig 12-1 Hand filling
Complete filling operation enclosed
in Zone 1 Area with local extraction at
filling head level & main extraction at
floor level inlets (min4) so positioned
as to prevent any vapour reaching
Zone 2 area which will extend (or be
enclosed) to a distance as required
by H.M. Factory Inspector.
Fig 12.2 Medium speed filling
Complete filling operation enclosed
in Zone 1 Area with same
considerations as Fig 12-1
Unscrambler may be located in Zone
2 Area if all electrical equipment is
flameproofed.
Fig 12-3. Medium speed filling
Whilst product filling, valving,
crimping is carried out in a Zone 2
area the Hydrocarbon is separately
filled on a smaller machine in a self
contained Zone 1 Area The product
filling area will require its own
Separate ventilation if Highly
Flammable liquids are used.
NOTE: In all cases separate
ventilation may be required for
operator comfort & health protection
Drawings are Schematic & not to scale
-------
L. ZONE 2 AREA f
ZONE 2 AREA
PRODUCT FILL
CRJMP
PROPELlANr FILLER
a
Zr
ZONE ] ARM
ZONE 2 AREA
PRODUCT- FILL
CRIMP
a
PROPELLANT FILLER
ZONE 2 AREA
ZONE I AREA
PRODUCT FILL
| ZONE 2 AREA |
CRIMP
n
ZONE 2 AREA
PROPELLANT FILLER
u
ZONE 1 AREA
=r~^=
ZONE 2 AREA
V
EXAMPLES OF FILLING AREAS
Fig 13-1 Rotary Machine Filling
^ All filling operations housed in Zone
ZONE 2 AREA 1 Area propellant filler requires
>- special ventilation with total Area.
Since area tends to be large this
method is not recommended
Examples 13-2 or 13-3 are preferred.
Fig 13-2 Rotary Machine Filling
The separate enclosure of the
propellant filler in a Zone 1 Area
ensures better extraction with
enclosed Zone 2 Area for the filling of
products containing Highly
Flammable Liquids
Fig 13-3 Rotary Machine Filling
Zone 2 Area to extend to a distance to
satsify the Factory Inspector
7nMF , adfa especially for products with Highly
ZUNL c akca^ Flammable Liquids. Zone 1 Area may
^ be constructed for single or multiple
lines with ventilation to suit.
NOTE: In all cases separate
. ventilation may be required for
-f— operator comfort & health protection.
Drawings are schematic & not to scale
-------
EXTERNAL
WALL
/nff
Fig 14
PRODUCT FILLER 6 CRIMPERS
X)
£>
£
(V
<
CM
LlI
2:
o
N
/=
ZONE 2 AREA
(V
Ui
d
£
O (V
Ik5I-_i
£
IJ' 21
I ii a
ZONE 2. AREA
f
EXTENT OF ZONE 2 AREA INSIDE BUILPlNG MAY" BE 6ET BY H.M. FACTORY IN3PECT0R
AND WILL INCLUDE PRODUCT FlLLlNGj IF INFLAMMABLE 30LV£N]"5 ARE USED
PRODUCT FILLER
ZONE Z AREA
CRIMPER
Z0NE Z AREA ONLY IF
INFLAMMABLE products are filled
ZONE Z AREA
I
THE REMOTE PROPELLANT FILLING BOOTH ENSURES A SAFE ARM
INSIDE THE FACTORY PROVIDING NON FLAMMABLE PRODUCTS ARE FILLED
DRAWINGS ARE SCHEMATIC NOT TO SCALE
LAYOUTS SHOWING FILLING BOOTHS
F-42 EXTERNAL TO MAIN FACTORY 6UIUM63
-------
In all layouts it is advisable to locate the rotary unscrambler tables outside
the filling area and to pass the cans by conveyor through apertures in the
separating walls, so keeping this can feeding, its associated combustible
packing and any fork lift trucks, in a safe area. Filled cans may, of course, be
conveyed from the filling room to the test and final packing operations in the
same manner.
"Dual Pak' and 'Star Pak' are machine names registered by Aerofill Ltd.
c) Rotary filling machines (high speed) — because of the greater output of
these machines, the longer lines employed, the possibility of automatic
valve sorting and insertion, the filling room Zone 2 may be fairly large
with can handling through apertures as in 4b). The propellant filling
machine may be housed in a "walk-in" filling booth, fig. 13-1 or in a more
restricted enclosure fixed to the machine itself, fig. 13-2.
If the former alternative is used with adequate ventilation and a controlled
discipline on the opening of access doors, the rest of the filling room may be
a Zone 2 area; with the latter the area surrounding the machine should be
classified Zone 1 (by virtue of the opening of doors or hatches exposing the
machine and possibly flammable liquid, gas or vapour to the surrounding
area). No great advantage is secured apart from a possible saving in
ventilation, except where a number of filling lines feed a common Zone 1
room, fig. 13-3, for propellant filling.
In situations where the filling room does not have a wall separating it from
the rest of the factory area, Zone 2 conditions will extend, radiating from the
enclosed propellant filling booth for a distance which will be decided upon
by H.M. Factory Inspectorate.
Where space permits or during the consideration of new projects, the use of
a self contained, isolated filling room in open air may be considered as a
further alternative. With this method, the concentrate filled and crimped
cans would be transferred by conveyor through an aperture in the factory
wall to a separate filling room built on the existing building or remote from
the main building — fig. 14. These two alternatives would still be classified
Zone 1 with Zone 2 areas adjacent as indicated If this principle is adopted
the extent of the Zone 2 to Safe Area around the filling booth must be agreed
with H. M. Factory Inspectorate and no subsequent building or intrusion
made.
Where Fluorocarbon propellents are no longer to be used, vapour purging
previously carried out with the use of propellant 12 vapour may be continued
where compatible by the use of compressed gases; where the use of
compressed gases is unsuitable vacuum crimping can be used.
Where an automatic checkweigher is to be sited after the propellant filler but
within the Zone 2 filling room, for ease of data feedback, that machine shall
24
F-43
-------
Flfl 15
FOUR balanced
VENTILATION DUCfS
WITH FLOOR. LEVEL
INLETS
VENTING ROOF LAID
ON RAFTERS WITH
CHAIN RESTRAINTS
0R.SIN/1ILAR.
CAN INLETOUTLETS
MlN. OPENIHq SlZt
FRESH AIR INLET
BRICK
MIN.SIZE POOR WTTh
JRlP-FfcEE RAMP OR SILL
CONCRETE
PUCTlNq EARTH POINT
r
ELEVATION
SECONDARY VENTILATION
AT FILUN6 HEAJ) LEVEL
CANS Ih
/=.-^rr=rE::=:
CANS OUT
PLAN
-------
Fig 16
ROOF MOT SHOWN
ELEVATION
CONCRETE
FLOOR. LEVEL ^RlLL
I—
I
PLAN
Layout shows propellant filler surrounded by a
ventilation channel surmounted by a floor level grill.
The channel leads underground to the vertical
ventilation duct. Care must be taken to design
channel & duct to give a balanced ventilation in all
directions around the machine. An alternative is to
construct two ducts in opposite positions shown
thus Gas Sensors ® moved nearer to doors
fresh air inlet is from above
Drawing is schematic & is not to scale.
Possible scheme for below ground ventilation
F-45
-------
uiL'iaPJii
be flameproofed or intrinsically safe to approved standards. The
checkweigher may be sited outside of the filling room, a reasonabledistance
from the aperture in the filling room wall and be ventilated at conveyor
height.
Filling Room
The filling room enclosure and the propellant filling booth enclosure may be
of brick or double skin steel partitioning sections bolted together and to the
floor with a good seal and earthing bond, windows in clear shatterproof
polycarbonates should be kept to a minimum, but where operators are
permanently present, should be sufficient in size to overcome any
claustrophobic effect. The doors should be smaller than standard, have a
raised threshold, be close fitting in the architraves and open outwards. A
minimum of two doors is recommended — their positioning to be more
suitable for emergency exit than for servicing equipment. The roof shall be
laid or) rafters where necessary, with a good seal, but with corner chain
restrictors common to explosion venting. Ideally, the venting should be
through the roof of the factory, but where high roofs exist, the filling room
and booth may have individual roofs at lower levels, providing there is an
uninterrupted space above. In all cases, the height of the filling room and
propellant filling booth should be adequate to the operation — 3m. may be
considered sufficient for rotary machines.
Since the rooms and booths in our recommendations are square or
rectangular in plan, we would recommend four balanced ventilation ducts in
the corners with openings at near ground level as primary extract and with
secondary ventilation at filling head level, — fig. 15. The gas sensor heads
should be mounted adjacent to the lower duct openings at a side to take
account of the position of the booth doors. The extract should pass through
the roof to the highest possible point away from the roof valleys and rain
water gulleys. Fresh air inlet should be remote from the outlet and should be
so calculated as to supply sufficient air to create a negative pressure within
the booth and be fed in at propellant filling room or booth roof level.
A channel in the floor surrounding the base of the propellant filler connected
with the extract duct and topped with a perforated grille at floor level may be
an alternative method of providing ventilation — fig. 16.
Smoke tracers and a portable velocity meter may be employed to test for
draught patterns and the balancing of ventilation ducts.
In a well designed system, it may be agreed that normal operation will be
conducted at 25% of the L.E.L. An 'orange' warning should be made by the
sensors on detecting this level and above, whilst a 'red' warning (shut down)
could be made when a head reports 50% of the L.E.L.
From the circumstances of the filling layout, consultation with H.M. Factory
Inspector and the factors mentioned earlier plus a safety factor of say 2, a
F-46
25
-------
uJUiOi'JiL
formula for the amount of air in cubic meters per minute to be introduced,
mixed with any hydrocarbon vapour and extracted can be determined and
duct and fan size gauged accordingly.
The time of progression from sensing at 25% of the L.E.L. to 50% of L.E.L.
and shut down procedure may be increased or averted by the switching in of
additional ventilation at the 25% level.
Any ventilation ducts, fans, light fittings and pipework shall not obstruct the
venting roof principle.
All machinery should be guarded to ensure reasonably safe operation and
protection for the workforce, but it should be noted that machine guards do
not in themselves provide protection from the spread of hydrocarbon gas or
vapour.
There may be superimposed upon these recommendations certain
requirements of fire resistant structures in the segregation of Zone 1 and 2
areas from the rest of the factory.
In the packing area, the drive and equipment of the hot water test bath
should be flameproofed with safe means of disposal of reject cans by
automatic conveying or by collection in vented bins (metal) for frequent
removal to a safe place.
Automatic actuator placing machines should be flameproofed and
conveyor height ventilation installed.
Other operations, in particular shrink wrapping, are dealt with in the
B.A.M.A. publication.
S. Ventilate to remove any hazardous and harmful vapour
From the health point of view, there should be adequate ventilation to
remove any toxic and noxious vapours with duct inlets at positions where
any evaporation may occur and certainly at the concentrate filler nozzle
level, with a minimum velocity of 46m. per minute across openings. For
operator comfort within the filling room, air changes should be a minimum
of the order of 25-30 changes per hour.
Ventilation is the first line of defence in the control and elimination of the
hazard of hydrocarbon and should be so used to neutralise the inevitable
release of a very small amount of hydrocarbon when the aerosol valve
disconnects from the propellant filler. This gas amount can be calculated
from the clearances between valve and filling adaptor, the rate of filling
(cans per minute) is known, so is the expansion ratio (liquid gas to vapour)
26
F-47
-------
12 tonnes and 30 tonnes tanks with Fixed Drench Sprinkler System
F-48
-------
TT Fig 17
14 15 16
BRICK
CONCRETE
VIEW SHOWING SECTION OF PROPELLANT FILLING BOOTH
1 Extract Ventilation Duct with Floor Level Inlet
2 Solenoid Shut Off Valve (normally closed) Operated by Gas Sensors
3 Shut Off Valve (locked open — maintenance use only)
4 Hydrostatic Relief Valve
5 Vent Pipe to Atmosphere with Rain Cap
6 Pressure Gauge (Pump Line Pressure)
7 Shut Off Valve
8 Flexible Hose with Self Seal Quick Release Coupling
9 Shut Off Valve
10 Position of Flexible Hose for Gas Purging
11 Bleed Valve with Controlled Leakage into Ventilation Duct
12 Filling Booth Wall
13 Gas Sensor Head
14 Filter 10 Micron
15 Pressure Accumulator
16 Pressure Regulator — Line Pressure down to Machine Operating Pressure
17 Rotary Joint
18 Secondary Ventilation at Can Filling Level (into duct not shown)
19 Rotary Propellant Filling Machine
20 Machine Earthing Point
Drawing is schematic & is not to scale
Scheme for Supply & Connection of Propellant Line to Filling Machine
F-A9
-------
juaowii
of the hydrocarbon, at say 20°C (70°F). We also know that the lower
explosive limit of butane in air is approximately 2%. In order, therefore, to
create a safe atmosphere, we must supply to and mix with the released
hydrocarbon sufficient quantitites of environmental air to produce a mixture
that is below the Lower Explosive Limit (L.E.L.). The actual percentage
below the L.E.L. which may be considered acceptable for normal operation
(for an 'orange' warning and for a 'red' warning as detected by electro-
catalytic monitoring systems) will be determined by the size and layout of
the filling booths and the disposition of the ventilation openings.
The 'orange' warning should be somewhat muted to give warning of level
change without provoking alarm. The 'red' warning should, through the
sensors' relay system, shut off propellant supply at the filler and tank pump
by use of flameproofed 'energised open/normally closed' solenoid valves;
operate evacuation warning and any other procedures agreed with H.M.
Factory Inspector and the Fire Brigade. The shut down procedure will
switch off all electrical supply to the filling line and other equipment.
The ventilation system should be interlocked so that the filling line cannot
be started without the ventilation and the ventilation shall be monitored by
an air flow switch in the ducting that will shut down the line if the air velocity
drops below set levels.
6. Ensure a safe routing of propellant pipework through the factory
Ideally, pipework should be routed from the tank farm to the filler in open air
as far as possible. In its passage inside the factory, the pipework should be
fixed firmly as high as possible but in accessible positions. The pipes should
not be routed alongside electrical ducts or cables, steam pipes or heating
systems, a continuous earth bond shall be maintained and pipes identified
for hydrocarbon and directional flow in accordance with British Standard
1710—1975
Immediately prior to their entry to the propellant filling booth, an emergency
shut down valve should be fitted, with a manual shut off valve immediately
inside the booth. It is advisable to pass incoming propellant through a fine
filter, say 10 micron, to remove any fine particles that may affect seals and 'O'
rings. To eliminate fluctuation in flow and pressure caused by intermittent
demand it may be necessary to fit a hydraulic accumulator; whilst a pressure
regulator should be fitted to reduce line pumping pressure down to that
needed to support pressure filling ratios and filling accuracies. The final
connection to the propellant filler may be flexible, but to British Standard
4089, whilst any quick release couplings should self-seal (all valves should
be fire safe) fig. 17.
On machine changeover, the unwanted propellant within the machine may
be safely purged by plugging the quick release coupling into a valve in the
vent ducting to permit controlled release that will not overload the system.
F-50
27
-------
7. Evaluate, Install and maintain a tale operating procedure at all times and
tor all personnel
The sections of the B.A.M.A. 'Guide to Safety in Aerosol Manufacture'
dealing with aerosol filling and subsequent testing and packing should be
referred to; these recommendations and suggestions, together with
procedural recommendations in the Health & Safety Executive's Code of
Practice, etc; and the additional recommendations that we have set out in
this handbook may be collated with numerical references to serve as official
procedures for your company:
a) Start up procedure
b) Operational procedure
c) Shut down procedure
d) Changeover procedure
e) Emergency procedure
These procedures will vary according to the circumstance of each factory,
its size, type and number of filling lines, a layout service plant and equipment
and other factors. It is part of the Aerofill Service to undertake this task and
to work with company representatives to produce a series of satisfactory
procedures and to operate a check list service in order that necessary up-
dating and maintenance of the procedures is carried out.
28
F-51
-------
^aaaoj?Jii
Section 9
THE LABORATORY AND PILOT LINE
Most aerosol filling operations will be supported by laboratory facilities for
formulation, test and evaluation and perhaps process and quality control
with pilot line operation in larger companies. It therefore follows that the
scale of the laboratory operation will be proportional to the total size of the
enterprise.
There is no single statutory regulation governing the operation of a
laboratory and such as do apply do so in part. Abstracts from the Shops,
Offices and Railways Act: the Highly Flammable Liquids and L.P. Gases
Regulation; Regulations for Storage and Use of HFL's and Solvents; the
Petroleum Consolidation and Mixtures Order 1928 and 1929 for storage
mixing and use; the Medicines Act where appropriate as well as sensible and
applicable parts of the various codes of practice identified in this handbook
may all apply.
Where not governed by mandatory requirements, the laboratory layout and
operation should be dictated by good safety sense in the same manner
applicable to the main factory area and staff properly trained and instructed
in the handling and use of hazardous materials.
Advice should be sought from H.M. Factory Inspectorate, the Fire
Prevention Officer and from the technical advisory service of the supplier of
propellants, solvents and raw materials.
In any event, the suppliers of these raw materials are required to present you
with technical datasheets for each material, that identifies its physical
properties, its hazards (flammability, flash point, toxicity etc.) safe handling,
precautions and emergency action if required. These information sheets are
mandatory under the Health & Safety At Work Act.
As the data contained in these information sheets applies to your total
workforce in the factory as well as the laboratory, it is sensible that the
Laboratory Manager be entrusted with the duty of requesting, receiving,
cataloguing and ensuring thai safe handling, mixing and use procedures
based on these information sheets be disseminated throughout the factory
in a correct manner.
Your Factory Doctor should be informed, consulled for advice and good
procedures.
The design, construction and set-up of the laboratory will, of course,
depend upon the size of the total undertaking, but it is unlikely that the
supply of hydrocarbon will be required in anything larger than refillable
cylinders. The cylinders awaiting use or empty awaiting collection by the
supplier will be stored as set out in Section 5.
-------
Those cylinders in use should be stored in the open at least on an outside
wall in a well ventilated place with separation from other combustables, high
flammable liquids and other gas cylinders. The cylinders should be chained
secure in an upright condition suitably marked and identified as to their
purpose, the key or shut-off valve knobs should not be removed and it it is
recommended that a notice be fixed around the neck of the cylinders in use:
vis
'Cylinder in use — shut-off valve open.
Do not tamper or close except in emergency
without reference to '
(enter name of suitably qualified and
responsible person).
If the laboratory is small, sample filling may be carried out in a fume cabinet
that is completely flameproof and properly ventilated to a safe area; the front
cover should be lowered as low as is practicable for hand operation of
propellant filling. The air flow of ventilation across the opening should not
be less than 46 metres per minute.
Whilst the filling of samples is in progress, all ignition sources in the
laboratory should be turned off, a portable gas detector should be used to
monitor the operation.
Ideally, the fume cabinet should be located on an outside wall and as
isolated as possible, certainly from naked lights or flame and any source of
ignition.
On a larger scale, the filling by laboratory °'io' or Dual Pak equipment
including the product filling should be enclosed in a self-contained room
well ventilated to a safe area with at least 25-30 air changes per hour. All
equipment should be flameproofed and gas detectors strategically placed to
sense unwarranted concentrations of hydrocarbon and able to bring a halt
to filling until the atmosphere is cleared Personnel should be trained to shut
down and evacuate in the event of excessive escape.
A pilot line operation using a Dual Pak or the larger Star Pak equipment
should be contained in a room which, in turn, should be considered a Zone 1
area and flameproofed and treated accordingly as with a production line of
this type mentioned in Section 8.
Hot water leak and container testing should be carried out on all aerosols
more especially since they will be formulated for test and evaluation and
should be given 100% inspection. Leak test should be stringent to prevent
unwarranted accumulation in store rooms and hot store.
-------
- S.Mr
Actualors should be fitted with a screwing action to prevent any
hydrocarbon present in the dip tube being released by accidental operation
of the valve.
Test spraying, evacuation tests and residue tests, etc., should be conducted
in a fume cabinet with good ventilation with fan rate guaged to the rate of
spray testing.
It is normal to expect that filled samples will be stored at ambient and
elevated temperatures and for this reason we again stress the importance of
the leak inspection. Leakage under hot storage conditions, of between
20°C-25°C, presents a greater hazard, since the hot store cannot be
continuously ventilated to combat gas leaks. Detection units should be
installed within the store to provide adequate warning of hydrocarbon gas
and to switch on ventilation to clear the accumulation whilst switching off
the source of heat.
In all cases it is recommended that windows in the room, fume cabinets and
the filling room be fitted with clear polycarbonate sheet and that these
windows be kept to the minimum area.
Personnel should wear cotton overall clothing to obviate static, should wear
eye protection and be properly trained and instructed in safety procedures.
F-54
-------
JUSOjull
Section 10
DISPOSAL OF WASTE AND SCRAP
Regardless of the efficiency of any operation, there will be waste and scrap
and since this contains highly flammable liquids, toxic materials and
hydrocarbons, and combinations of all three, the disposal of this waste
should be tackled with care and a sensible appreciation of its hazard.
Waste, whether liquid, solid or scrap aerosols is subject to the Control of
Pollution Act 1974 which lays down certain controls, whereby the burden of
responsibility for safe removal and disposal is chiefly with the aerosol
manufacturer. Using the correct procedure, notify the local authorities of
the nature and amount of waste; the contractors name and address; the
location of approved disposal site; the nature of the disposal means. The
local authorities in the disposal area if outside of the jurisdiction of the local
authorities applicable to the manufacturer's works, should also be notified.
For disposal, we should consider two distinct categories: 1) Liquid and/or
solid waste — Aerosol concentrates, left over concentrates after a run,
surplus or obsolete and reject mixes, washings in either water or solvent
thereby contaminated. 2) Scrap aerosols — Line scrap; empty, full or
partly full, laboratory and quality control scrap; and obsolete aerosols from
whatever source.
1) Llquld/tolld watte
It is extremely unlikely that any company engaged in the production of
aerosols may be granted any consent for the disposal of waste into surface
water or foul drains.
However, consultation with your water and/or local authorities will establish
what'permitted quanitities'may beaccepted; any such waste would need to
be biodegradeable and in quantities acceptable to the drainage/river system
or the filter beds. At the very best the waste water from the hot water test
baths may be acceptable under certain conditions.
It therefore follows that the concentrate mixing and the area in the vicinity of
the product fillers be drained to a sump for periodic removal and disposal
within the requirements of the Act.
2) Scrap aerosols
There are two methods of dealing with scrap aerosols.
i) Shredding — this process passes the scrap through powerful jaws from a
funnel type hopper which punctures and shreds the can into manageable
pieces. This releases the hydrocarbon propellant to evaporate around the
32
F-55
-------
machine and the product to be drained by gravity down chutes for collection
in a sump. This type of installation needs proper siting under flameproof
conditions with the best possible separation distances from any fixed
source of ignition. The machine, chutes and sump should be well ventilated
to a safe height and the plant operated at frequent intervals throughout the
working day as the scrap is produced; rather than operating for a set period
to process the day's scrap in one quick batch. The hopper should be fed in
small quantities on a 'little and often' basis for good safety, for an
overworked shredder can release an appreciable amount of vapour gas in a
very quick time, i.e. a scrap rate of 0.5% and a fill of 10,000 units with a 50gm
butane fill will produce a flammable cloud in air to the order of 60 cu. mtrs.
(2000 cu. ft.) and as the machine can shred the 25 cans of scrap of the
example in less than 3 minutes, the gravity of the hazard may be readily
appreciated.
ii) Tip disposal — this method may be more acceptable where there is
insufficient 'natural ventilation' for a shredding operation. Within the
requirements of the Act and with proper procedure, it is possible for tip
operators, where sanctioned, to supply on a hire/demurrage basis a large
open skip (20-30 cubic metres) for collection and transport of scrap to the
tip. It is necessary to site the skip in a well ventilated area with a suitable
portable shield to prevent the ingress of rain diluting any ensueing liquid
waste for possible leakage on public highway during transport from the
factory. To prevent the possibility of leakage due to pressure from weight of
cans in the skip, it is recommended that scrap aerosols are fitted with an
overcap and that scrap is bulldozed immediately upon receipt at the tip to
prevent any unauthorised salvage.
In all cases it is recommended that the Factory Inspectorate and the Fire
Prevention Officer be consulted concerning the siting of shredding
machines or portable skips.
Local authorities have the power of inspection under the Act.
Those companies who may wish to consider on site treatment of trade
effluent should note that this is only economic for very large operations or
where waste is produced from other processes as well as aerosols. This
treatment is not total, leaving a concentrated sludge to be disposed of as laid
down in the Act.
Incineration ol waste may be_considered but again demands high
throughput or a specially designed project in conjunction with a fuel
burning boiler.
F-56
33
-------
Section 11
FINISHED GOODS
The storage of finished goods in the factory warehouse area may be
governed in some way by local regulations and bye-laws. Apart from these
requirements aerosols, dependent upon formulations and contents, may be
governed by:
a) The Petroleum Mixtures Act and Orders, wherein a petroleum licence is
required (see section 7) to store, mix and use products containing
petroleum substances within the meaning of the Act. Advice may be sought
from Fire Prevention Officer and County Secretariat.
b) The Highly Flammable Liquids and Liquified Petroleum Gases
Regulation 1972, applies to aerosols containing more than 500cc of total
contents. Aerosols containing in excess of 500cc are classified as flammable
when they contain more than 45% or 250gms of liquids with a flash point of
less than 32°C (90°F) aggregated with any flammable gas. Aerosols
classified as flammable must be labelled 'Flammable — do not use near fire
or flame' in accordance with agreements with H.M. Factory Inspectorate and
stored in a fire resistant structure as set down in the regulations.
In the interests of safe storage, the filler is advised to check against
accidental spraying and release of hydrocarbons due to weight of stored
and palletised aerosols:
1) In cases and cartons, check the total weight of the stack against the
collapse resistance of the carlon and overcap.
2) Check total weight of stack against collapse resistance of overcap when
shrinkwrapping is used without support from any outer carton.
It is recommended that smoking be prohibited throughout the whole
storage area and notices displayed.
It is recommended that there be adequate gangways and that goods are not
left in these gangways.
The warehouse should be dry and as cool and as well ventilated as possible
Hydrocarbon filled aerosols should not be stored in basements orareas with
open drains.
34
F-57
-------
All storage should be away from stoves, radiators, boilers and other heat
sources.
Adequate means of fire fighting and fire exit should be provided in
consultation with the Fire Prevention Officer.
Section 12
SAFETY AND FIRE PRECAUTIONS
The possibility of any outbreak of fire can best be minimised by sound
engineering in the initial design and layout of the tank installation and the
filling line, and also by a critical analysis of each facet of the total operation
and its hazards. In co-operation with authorities and competent advice,
written procedures for start up, shut down and operation of emergency
procedures should be produced. From these masters an itemised checklist,
numbered and in logic sequence should be prepared and used for each
individual part of the process. Tanks, pumps, valves, pipelines, etc., should
be given numerical or alpha-numeric references and identified on the
checklist. Ideally, the procedures should be a two man operation and
signatures obtained to record the correct operation and sequence of each
phase.
Staff of adequate education and training should be instructed in these
procedures, not just to follow a sequence of operations but with a
knowledge of the principles of the operations and the need for adherence to
the discipline.
Maintenance and leak check procedures should be drawn up and a 'permit
to work' system installed where maintenance or overhaul is required. The
work and conditions of any subcontractor should be closely controlled and
monitored at all times.
Periodic meetings of all concerned in the total operation should be held and
from this feed back update, revision and improvementof procedures may be
made.
F-58
35
-------
Adequate water supply either mains or from storage tanks should be
provided for fire prolection, hose reels may be suitable for smal I installations
but fixed spray systems are strongly recommended both within the factory
and at the tank farm (favourable insurance premiums may result). The
strategy for fire precautions should be aimed at keeping a fire unconnected
with the hydrocarbon storage or use from effecting the hydrocarbon
installation as well as protecting the hydrocarbon installation itself.
The production and warehouse areas of the factory may be protected by a
sprinkler system with individually fused spray heads, but it may be preferred
to protect areas such as the mixing room tanks, solvent tanks and the
hydrocarbon installation with a total deluge system where a number of spray
heads in a group or groups are activated automatically from the fuse bulb in
any one spray head. The system should also be capable of manual
operation. In the case of the hydrocarbon tanks, in an emergency the
surface area shall be drenched at a rate 10 litres per square metre (0.2 gals,
per square foot) whilst pump sets, destench columns etc. should also be
covered by the water spray heads.
Suitable fire points and alarm systems should be installed in consultation
with the insurance Company and the Fire Prevention Officer. The sprinkler
installation company can also advise on good practices and on the setup of a
master control and enunciator to give fire incident location warning. Gas
sensor modules should be located in a position that can be monitored
during normal working hours and is easily accessible for the local Fire
Brigade.
The Fire Prevention Officer and Insurance Company may be consulted for
advice on number, type and siting of hand fire fighting appliances. It should
be noted that CO2 and Dry Powder units to British Standard 3465 may be
used on hydrocarbon — foam units are not considered suitable.
All operators should wear cotton or similar non-static producing clothing.
All matches and smoking materials should be prohibited in the factory area
and advice sought from the Fire Prevention Officer and H.M. Factory
Inspectorate concerning the type, wording and location of No Smoking and
other warning and instructional signs.
According to the category of Zone areas, all electrical equipment shall be
flameproofed to British Standard Code of Practice CP1003 and BS5345 and
the selection to British Standard BS4137, with design to British Standard
BS229. Where intrinsically safe equipment is required, this shall also be to
CP1003 certified by the manufacturer.
Other standards applicable to t^e electrical equipment and fire alarms may
be found in the Bibliography of Standards and Codes of Practice at the rear
of the handbook.
36
F-59
-------
30 tonnes tank showing Double destench column
F-60
-------
JH'.AOi'JU
The gas sensors, may be electro-catalytic suitable for hydrocarbons and as
described in the Department of Employment Technical Data Note No.45.
'Industrial Use of Flammable Gas Detectors'. These units usually have two
adjustable settings which trigger relays to actuate shut down valves, alarms,
etc. In accordance with agreed procedures.
The units may be used in the presence of fluorocarbons, however, in
extreme circumsntances the hot element may become inhibited due to
possible coating by chlorine from the fluorocarbon vapour. This does not
cause any permanent damage and will be burnt off by hydrocarbon passing
over the element, the response time may be slightly impaired.
A method to offset this problem is to fit a blanking cap overthe sensing head
during the filling of fluorocarbons.
Multi-point infra red sensor/analyser systems may also be used and may be
considered where fluorocarbon and hydrocarbon propellants are filled
simultaneously causing concern regarding the possible contamination of
the electro-catalytic systems.
The principle of the infra red system is to extract a sample of the atmosphere
in the monitored area and to convey the sample in cyclic pulses via plastic
tubes to the remotely located analyser which may be calibrated to give
warnings at appropriate levels of the L.E.L.
These systems usually employ a number of sampling tubes (multi-point)
leading to one analyser and the frequency and sequence of the samples
from the tubes would be decided upon examination of each separate
installation. The tubes may be of lengths up to 500 metres which, in turn,
may affect the response time.
The units must be recalibrated from time to time using trace gases for the
appropriate orange and red warning levels of the L.E.L. Since the instrument
module is remote from the sensing head a portable two way phone system
may be used by the two man team for calibration purposes at a time when the
production unit is shut down.
Precautions should be taken against static electricity by ensuring good
design of instal lation and earth continuity throughout the tank farm, pumps
and pipework, filling machinery as well as solvent storage, handling mixing
and filling. Precautions should also be taken within the laboratory.
Static is the electrification of materials through physical contact and separation
(single or multi-cycle) and the resultant static effects stem from the positive and
negative charges so formed. The generation of static cannot be prevented; it is
inherent in the interface of any dissimilar materials.
21
F-61
-------
*dttctfiLL
To reduce the risk of ignition, the following guidelines should be observed:-
1. Reduce risk of static built-up by firm fixing of all equipment and
pipework to reduce vibration and use anti-static materials
wherever possible.
2. Ensure all equipment is adequately bonded and checked regularly
for continuity, to prevent accumulation of charges and differences in
electrical potential occurring.
3 Flameproof all electrical equipment and avoid naked light and
incendive sparking.
4. Ventilate well and adopt good safety and checking procedures to
leakage or accumulation of ignitable mixture.
In our opinion, the statements in this Section represent good practice and
therefore form recommendations. Any compliance does not confer
immunity from relevant statutory or legal requirements.
-------
JS&OAIL!
Section 13
FURTHER INFORMATION
Aerofill Limited, as a major supplier of aerosol filling equipment, will be
happy to provide advice and assistance to existing and prospective
customers on installations using any category of propellent.
In recognition of the trend towards the use of hydrocarbons as
aerosol propellants, considerable research has been undertaken. Much of
the data obtained, as may be generally applied, is contained in this
handbook. Our sales engineers, supported by our internal engineering
expertise, will provide such assistance in interpretation to particular
installations as may be practical.
Copies of the main Statutes, Codes of Practice and other publications
mentioned in the text may be supplied with this handbook or obtained from
Aerofill. These are charged for, simply saving the time, effort and research of
customers obtaining them direct from the various sources. These
mandatory requirements are supported by our 19 years of accumulated
experience in the industry.
Aerofill Limited
Printing House Lane
Hayes
Middlesex UB3 1AP.
Tel: 01-848 4501.
39
F-63
-------
Bibliography
In anticipation of a need Aerofill Ltd have acquired a stock of the principal
publications mentioned in this handbook. This stock enables the readerto
obtain a library of Codes of Practice, Recommendations, British Standards
and other publications from one source.
1. Code of Practice for the storage of LPG at fixed installation — Health
& Safety Executive.
2. Code of Practice for the keeping of LPG in Cylinders and Similar
Containers — Health & Safety Executive.
3. Code of Practice for Electrical Apparatus associated equipment for the
use in explosive atmosphere of gas or vapour — British Standard
CP1003 — 3 parts.
4. Code of Practice for the selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmospheres
— British Standard 5345.
5. Code of Practice for Fire Precautions in chemical plant — British
Standard CP 3013.
6. Flameproof enclosure of Electrical Apparatus — British Standard 229.
7. Guide to the selection of Electrical Equipment for the use of Division
(now referred to as Zone) 2 Areas — British Standard 4137.
8. Rubber Hose and Hose Assemblies for LPG Lines — British Standard
4089.
9. Specification for Identification of Pipelines — British Standard 1710.
10. Petroleum Acts 1928-1929 — H.M. Stationery Office.
11. Petroleum (Inflammable Liquids) Order 1971 -• H.M.S.O.
12. The Highly Flammable Liquids and Liquiefied Petroleum Gas
Regulations 1972 — H.M.S.O.
13. Guide to Safety in Aerosol Manufacture — British Aerosol
Manufactures Association.
14. Threshold Limit Values — Technical Data Note — Health &
Safety Executive.
15. Industrial use of Flammable Gas Detectors — Technical Data Note
— Health & Safety Executive.
Additionally there are many other Codes of Practice, Recommendations
and British Standards that cover every facet of an installation which may be
easily compiled from the lengthy Bibliography that will be found in the
appendix of the aforementioned list of publications.
Representation to the following may be made for full lists of publications on
the subjects of>
1. Tanks, pipelines, pumps, valve-fittings foundations and installations in
respect of LPG.
2. Electrical apparatus, lights, fire alarms and wiring.
3. Fire precautions, appliances, sprinkler systems and installation.
F-64
40
-------
4. Good operational practices. Codes of Practice etc.
British Standards Institution
2 Park Slreet
London W1A 2BS
Tel: 01-629 9000
Publications from: 101 Pentonvitle Road
London N1 9ND
Tel: 01-837 8801
The Liquiefied Petroleum Gas Industry Technical Association
All publications obtainable from: William Culross & Son Ltd
Coupar
Angus
Scotland
Her Majesty's Stationery Office
49 High Holborn
London WG1V GHB
For: Acts of Parliament & Statutory Orders
Health & Safety Executive publications
British Aerosol Manufacturers Association
Alembic House
93 Albert Embankment
London SE1 7TV
Tel: 01-582 1115
Fire Protection Association
Afdermary House
Queen Street
London EC4N 1TJ
Tel: 01-248 5222
The information in this guide is as accurate as possible but Aerofill
Ltd cannot accept any responsibility should it be found that the
information is inaccurate or incomplete, or becomes so, as a result of
future developments.
Printed in England by Lithgow Printers Ltd., East Sussex.
Designed by Jonathan Cantor & Assocs., London.
41 F-65
-------
-------
APPENDIX G
METRIC (SI) CONVERSION FACTORS
G -1
-------
APPENDIX G
METRIC (SI) CONVERSION FACTORS
Quantity
To Convert
From
To
Multiply By
Length:
in
cm
2.54
ft
m
0.3048
Area:
in2
cm2
6.4516
ft2
m2
0.0929
Volume:
in3
cm3
16.39
ft3
m3
0.0283
gal
m3
0.0038
Mass (weight):
oz (avoir.
)
kg
0.0283
lb
kg
0.4536
short ton
(ton)
Mg
0.9072
short ton
(ton)
metric ton (t)
0.9072
Pressure:
atm
kPa
101.3
mm Hg
KPa
0.133
psia
kPa
6.895
psig
kPa*
(psig)+14.696)x(6.895)
Temperature:
°F
cc*
(5/9)x("F-32)
°C
K*
"C+273.15
Caloric Value:
Btu/lb
kJ/kg
2.326
Enthalpy:
Btu/lbmol
kJ/kgmol
2.326
kcal/gniol
kJ/kgmol
4.184
Specific-Heat
Capacity:
Btu/lb-c F
kJ/kg-"C
4.1868
Dens ity:
lb/ft3
kg/m3
16.02
lb/gal
kg/m3
119.8
Concentration:
oz/gal
kg/m3
quarts/gal
cm3/m3
25,000
Flowrate:
gal/min
m3/ain
0.0038
gal/day
m3/day
0.0038
ft3/min
m3/day
0.0283
Velocity:
ft/min
m/min
0.3048
ft/sec
m/sec
0.3048
Viscosity:
centipoise
(CP)
Pa-s (kg/m-s)
0.001
^Calculate as indicated
G-2
-------
APPENDIX H
AEROSOL FORMULATIONS
H-1
-------
The following tables present current formulations for several aerosol
products in the categories of:
• Personal Products (Tables H-l through H-6);
• Household Products (Tables H-7 through H-10);
• Automotive/Industrial Products (Tables H-ll and H-12);
• Paints and Finishes (Table H-13);
• Insect Sprays (Tables H-14 and H-15);
• Food Products (Table H-16); and
• Animal Products (Table H-17).
The formulations list typical product weight, chemical compound names, and
composition by percent and weight as "propellant" and "other."
H-2
-------
TABLE H-l. HAIRSPRAY FORMULATIONS
Average
Product
Propellant
Other
Weight
Product Formula
oz.
%
oz.
%
oz.
Hair Spray: Reg Hold - 1 (l)a
10.10
Gantrez ES-225 (50% in EtOH)
0.00
4.00
0.40
N,N,-Dimethyl-octadecylamine
0.00
0.29
0.03
Dimethyl Phthalate
0.00
0.03
0.00
DC Fluid #193
o.oo
0.02
0.00
Fragrance
0.00
0.10
0.01
S. D. Alcohol 40-2 (Anhydrous)
0.00
67.56
6.82
Propellant A-31 or A-40
28.00
2.83
0.00
TOTAL
10.10
28.00
2.83
72.00
7.27
Hair Spray: Reg Hold - 2 (1)
10.10
Gantrez ES-225 (50% in EtOH)
0.00
4.00
0.40
Amino-methyl-propanol (95%)
0.00
0.09
0.01
DC Fluid #193
0.00
0.02
0.00
Fragrance
0.00
0.10
0.01
De-ionized Water
0.00
8.79
0.89
S. D. Alcohol 40-2 (Anhydrous)
0.00
61.00
6.16
Propellant A-31 or A-40
26.00
2.63
0.00
TOTAL
10.10
26.00
2.63
74.00
7.47
Hair Spray: Reg Hold - 3 (1)
10.10
Resyn 28-2930 (100%)
0.00
2 . 50
0.25
Amino-methyl-propanol (95%)
0.00
0.20
0.02
Dimethyl Phthalate
0.00
0.03
0.00
DC Fluid #193
0.00
0.04
0.00
Disodium Dodecylsulfosuccinate
0.00
0.20
0.02
Sodium benzoate
0.00
0.08
0.01
Fragrance
0.00
0.15
0.02
De-ionized Water
0.00
16.00
1.62
S. D. Alcohol 40-2 (Anhydrous)
0.00
44.80
4.52
Dimethyl ether
36.00
3.64
0.00
TOTAL
10.10
36.00
3.64
64.00
6.46
(Continued)
H-3
-------
TABLE H-l. (Continued)
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Hair Spray: Reg Hold - 4 (1) 10.10
Resyn 28-2930 (100%)
0.00
2.50
0.25
Amino-methyl-propanol (95%)
0.00
0.18
0.02
DC Fluid #193
0.00
0.06
0.01
Disodium Dodecylsulfosuccinate
0.00
0.20
0.02
Sodium benzoate
0.00
0.08
0.01
Fragrance
0.00
0.15
0.02
De-ionized Water
0.00
32.00
3.23
S. D. Alcohol 40-2 (Anhydrous)
0.00
28.83
2.91
Dimethyl ether
36.00
3.64
0.00
TOTAL 10.10
36.00
3.64
64.00
6.46
"Indicates sources of formulation data (see References at end of this
Appendix).
H- 4
-------
TABLE H-2. SHAVING GEL/CREAM FORMULATIONS
Average
Product
Propellant
Other
Product Formula
oz. %
oz.
%
oz.
Shaving Gel (2)
8.00
Stearic acid (95% purity)
0.00
2.00
0.16
Palmitic acid (97% purity)
0.00
5.80
0.46
Polyoxyethylene cetyl ether
0.00
1.00
0.08
Hydroxyalkyl cellulose
0.00
0.07
0.01
Carbopol 934
0.00
0.18
0.01
Propylene glycol dipelargonate
0.00
2.75
0.22
Sorbitol (70% solution)
0.00
10.00
0.80
Propylene glycol
0.00
3.30
0.26
Triethanolamine
0.00
4.20
0.34
Water
0.00
67.95
5.44
n-butane
0.55
0.04
0.00
n-pentane
0.00
2.20
0.18
TOTAL
8.00 0.55
0.04
99.45
7.96
Shaving Cream - 1 (1)
8.00
De-ionized Water
0.00
74.90
5.99
Lauric/Mystiric Acids
0.00
1.50
0.12
Stearic Acid (Triple X)
0.00
6.00
0.48
Lauryl/Myristyl Diethanolamine
0.00
0.50
0.04
Triethanolamine (99%)
0.00
3.90
0.31
Cetyl Alcohol, N. F.
0.00
0.50
0.04
Glycerin - 96%, U. S. P.
0.00
5.80
0.46
Mineral Oil, N. F. Grade
0.00
2.40
0.19
Methyl p.hydroxybenzoate
0.00
0.10
0.01
n.Propyl p.hydroxybenzoate
0.00
0.03
0.00
Fragrance
0.00
0.67
0.05
Lanolin Derivative
0.00
0.50
0.04
Propellant A-46
3.20
0.26
0.00
TOTAL
8.00
3.20
0.26
96.80
7.74
(Continued)
H-5
-------
TABLE H-2. (Continued)
Average
Product
Propellant
Other
Weight
Produce Formula
oz.
%
oz.
%
oz.
Shaving Cream - 2 (1)
8.00
De-ionized Water
0.00
79.50
6.36
Lauric/Mystiric Acids
0.00
1.00
0.08
Stearic Acid (Triple X)
0.00
7.00
0.56
Lauryl/Myristyl Diethanolamine
0.00
2.00
0.16
Sodium Hydroxide
0.00
0.50
0.04
Potassium Hydroxide
0.00
2.25
0.18
Glycerin - 96%, U. S. P.
0.00
4.00
0.32
Polyvinylpyrrolidone K30
0.00
0.15
0.01
Fragrance
0.00
0.30
0.02
Lanolin Derivative
0.00
0.20
0.02
Propellant A-46
3.10
0.25
0.00
0.00
TOTAL
8.00
3.10
0.25
96.90
7.75
Shaving Cream - 3 (1)
8.00
De-ionized Water
0.00
78.10
6.25
Lauric/Mystiric Acids
0.00
0.70
0.06
Stearic Acid (Triple X)
0.00
8.00
0.64
Sodium Lauryl Sulfate (30% Water
Solution)
0.00
1.50
0.12
Potassium Hydroxide
0.00
0.40
0.03
Triethanolamine (99%)
0.00
3.00
0.24
Glycerin - 96%, U. S. P.
0.00
2.50
0.20
Methyl p.hydroxybenzoate
0.00
0.10
0.01
n.Propyl p.hydroxybenzoate
0.00
0.04
0.00
Fragrance
0.00
0.36
0.03
Lanolin Derivative
0.00
2.00
0.16
Propellant A-46
3.30
0.26
0.00
TOTAL
8.00
3.30
0.26
96.70
7.74
H-6
-------
TABLE H-3. DEODORANT/ANTIPERSPIRANT FORMULATIONS
Average
Product
Propellant
Other
Product Formula
oz. %
oz.
%
oz.
Antiperspirant - (1)
4.00
Aluminum Chlorohydrate
0.00
8.00
0.32
Quaternium 18 Hectorite
(Bentonite 38)
0.00
0.82
0.03
S. D. Alcohol 40-2 (Anhydrous)
0.00
0.80
0.03
Dimethylsilicone (500 cstks.)
0.00
1.50
0.06
Isopropyl Myristate
0.00
1.00
0.04
Cyclomethicone F-251
0.00
7.63
0.31
Perfume Oil
0.00
0.25
0.01
Propellant A-31 or A-46
80.00
3.20
0.00
TOTAL
4.00 80.00
3.20
20.00
0.80
Personal Deodorant -1 (1)
4.00
Irgasan DP-3000* Germicide
0.00
0.11
0.00
Propylene Glycol
0.00
1.50
0.06
Fragrance
0.00
0.35
0.01
S. D. Alcohol 40-2 (Anhydrous)
0.00
58.00
2.32
Iso-butane (A-31)
40.00
1.60
0.00
TOTAL
4.00 40.00
1.60
59.96
2.40
Personal Deodorant - 2 (1)
4.00
Benzthionium Chloride
0.00
0.20
0.01
Dipropylene Glycol
0.00
1.05
0.04
Fragrance
0.00
0.25
0.01
S. D. Alcohol 40-2 (Anhydrous)
0.00
68.50
2.74
Propellant Blend A-46
30.00
1.20
0.00
16 w.% Propane in Iso-butane
TOTAL
4.00 30.00
1.20
70.00
2.80
(Continued)
H-7
-------
TABLE H-3. (Continued)
Average
Product Propeilant Other
Product Formula
oz. %
oz.
%
oz.
Personal Deodorant - 3 (1)
4.00
Methyl p-Hydroxybenzoate
0.00
0.03
0.00
n.Propyl p-Hydroxybenzoate
0.00
0.06
0.00
Benzyl p-hydroxybenzoate
0.00
0.08
0.00
Propylene Glycol, U. S. P,
0.00
1.03
0.04
Fragrance
0.00
0.30
0.01
S. D. Alcohol 40-2 (Anhydrous)
0.00
63.50
2.54
Propeilant Blend A-46
35.00
1.40
0.00
16 w.% Propane In Iso-butane
TOTAL
4.00 35.00
1.40
65.00
2.60
Personal Deodorant - 4 (1)
4.00
Irgasan DP-3000* Germicide
0.00
0.12
0.00
Dipropylene Glycol
0.00
2.00
0.08
Zinc Phenolsulfate***
0.00
1.00
0.04
Fragrance
0.00
0.38
0.02
S. D. Alcohol 40-2 (Anhydrous)
0.00
13.35
0.53
De-ionized water
0.00
47 .00
1.88
Sodium Benzoate
0.00
0.15
0.01
Dimethyl ether
36.00
1.44
0.00
0.00
TOTAL
4.00 36.00
1.44
64.00
2.56
*2,4,4'-Trichloro-2'-hydroxydiphenylether
H-8
-------
TABLE H-4. COLOGNE FORMULATIONS
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Cologne - 1 (1) 2.00
Fragrance
0.
,00
4.
,00
0.
08
Di-n.butyl Phthalate
0.
,00
2.
.00
0.
04
Sodium Saccharinate
0.
,00
0.
.01
0.
.00
FD&C and/or D&C Dye Solution
0.
00
0.
09
0.
.00
S. D. Alcohol 40 of 39C (Anhydrous)
0.
00
65.
00
1.
.30
De-ionized Water
0.
,00
13.
00
0.
.26
HFC-152a or HFC-22
15.
,90
0.
32
0,
.00
TOTAL 2
.00
15,
.90
0.
,32
84.
.10
1.
.68
Cologne - 2 (1) 2
.00
Fragrance
0.
.00
4
.00
0,
.08
S.D. Alcohol 40 or 39C (Anhydrous)
0.
00
76.
.00
1,
,52
Iso-butane A-31
t
o
.00
0.
.40
0,
.00
TOTAL 2,
1 o
o
20.
1 o
O
0.
.40
00 I
°
.00
1
.60
H-9
-------
TABLE H-5. OTHER HAIR PRODUCTS FORMULATIONS
Product Formula
Average
Product
Weight
oz.
Propellant
oz,
Other
oz.
Hair Mousse - 1 (1)
10.00
Polyquaternlum 4
0.00
0.60
0.06
Dimethacone
0.00
0.15
0.02
Arquad T-50
0.00
0.10
0.01
Octoxynol 9
0.00
0.15
0.02
Emulsifying Wax NF
0.00
0.15
0.02
Deionized Vater
0.00
75.B5
7.58
Perfume Oil
0.00
0.10
0.01
S.D. Alcohol 40-2 Anhydrous
0.00
14.90
1.49
Propane/Iso-butane (A-46)
8.00
0.80
0,00
TOTAL
10.00
8.00
0.80
92.00
9.20
Hair Mousse - 2 (1)
10.00
Polyquaternium 11
0.00
1.32
0.13
Polyquaternlum 4
0.00
1.00
0.10
Silicone
0.00
0.15
0.02
Lexein CP-125
0.00
0.20
0.02
Lexein S620
0.00
0.14
0.01
Aloe Vera
0.00
0.05
0.01
PEG-150
0.00
0.26
0.03
Quaternium 52
0.00
0.20
0.02
Polysorbate 20
0.00
0.05
0.01
Deionized Water
0.00
85.42
8.54
Fragrance
0.00
0.21
0.02
S.D. Alcohol 40-2 Anhydrous
0.00
3.00
0.30
Propellant BIP-55
8.00
0.80
0.00
TOTAL
10.00
8 .00
0. B0
92.00
9.20
Hair Lusterizer - 1 <1)
10.00
Isodecyl Oleate
0.00
5.00
0.50
Odorless Mineral Spirits
0.00
35.00
3.50
Mink Oil
0.00
0.10
0.01
Fragrance
0.00
0.10
0.01
S.D. Alcohol 40-2 Anhydrous
0.00
19.80
1.98
Propane/Iso-butane (A-46)
40.00
4.00
0.00
TOTAL
10.00
40.00
4.00
60.00
6.00
H-10
-------
TABLE H-6. MEDICINAL AND PHARMACEUTICAL FORMULATIONS
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Beta-Adrenergic Bronchodilator 0.50
Formula (1)
Terbutaline Sulfate
0.00
0.71
0.00
Sorbitan Trioleate
0.00
1.00
0.01
CFC-11
24.57
0.12
0.00
CFC-114
24.57
0.12
0.00
CFC-12
49.14
0.25
0.00
TOTAL
0.50
98.29
0.49
1.71
0.01
iginal Contraceptive Mousse (1)
2.50
Nonxynol 9
0.00
8.00
0.20
Lauric/Myristic Acids
0.00
2.50
0.06
Stearic/Palmitic Acids
0.00
3.50
0.09
Triethanolamine
0.00
2.20
0.06
Glyceryl Monostearate
0.00
2.50
0.06
Polyoxyethylene (20)
0.00
0.00
Sorbitan Mono-oleate
0.00
2.50
0.06
Polyoxyethylene (20)
0.00
0.00
Sorbitan Mono-laurate
0.00
3. 50
0.09
Polyethylene 600 Glycol
0.00
1.50
0.04
Polyvinylpyrrolidone K-30
0.00
1.00
0.03
Benzethonium Chloride, USP
0.00
0.20
0.01
Deionized water
0.00
67.60
1.69
Propellant A-46
5.00
0.13
0.00
TOTAL
2.50
5.00
0.13
95.00
2. 38
H-11
-------
TABLE H-7. HOUSEHOLD CLEANER FORMULATIONS
Average
Product
Propellant
Other
Product Formula
oz.
%
oz.
%
oz.
Oven Cleaner - 1 (1)
12.00
Sodium Hydroxide
0.00
5.00
0.60
Sodium Nitrite
0.00
0.20
0.02
Triethanolamine - 99%
0.00
1.00
0.12
Tetrosodium EDTA - 38%
0.00
1.00
0.12
Deionized Water
0.00
87.80
10.54
Iso-butane (A-31)
5.00
0.60
0.00
TOTAL
12.00
5.00
0.60
95.0
11.40
Oven Cleaner - 2 (1)
12.00
Potassium Formate
0.00
6.00
0.72
Potassium Acetate
0.00
6.00
0.72
Calcium Dodecylbenzene Sulfonate
0.00
3.00
0. 36
Compatible Thickener
0.00
0.50
0.06
Sodium Nitrite
0.00
0.20
0.02
Deionized Water
0.00
78.30
9.40
Iso-butane (A-31)
6.00
0.72
0.00
TOTAL
12.00
6.00
0.72
94. 00
11.28
Rug & Carpet Cleaner Product
(1) 20.00
Sodium Lauryl Sulfate
(Very low in Chloride)*
0.00
1.60
0.32
Magnesium Lauryl Sulfate
(Very low in Chloride)**
0.00
1.20
0.24
Sodium Lauryl Sarkosinate
30% in water***
0.00
3.00
0.60
Styrene Maleic Anhydride Copolymer
15% in water
0.00
20.00
4.00
Optical Brightener; as Calcofluor SD
(Optional)
0.00
0.02
0.00
Ammonium Hydroxide (28% NH3
in water)
0.00
0.16
0.03
Fragrance
0.00
0.08
0.02
Deionized Water
0.00
66. 44
13.29
Iso-butane A-31
7.50
1. 50
0.00
TOTAL
20.00
7.50
1.50
92.50
18.50
(Continued)
H* 12
-------
TABLE H-7. (Continued)
Product Formula
Average
Product
Weight
oz.
Propellant
oz.
Other
oz.
Window Cleaner - 1 (1)
12.00
Isopropanol - 99%
0.00
4.00
0.48
Propylene Glycol Monoethyl Ether
0.00
3.00
0.36
Ammonium Lauryl/Myristyl Alcohol
0.00
0.20
0.02
Sodium Nitrite
0.00
0.10
0.01
Ammonia (29% NH3 in water)
0.00
0.20
0.02
Deionized water
0.00
89.00
10.68
Iso-butane A-31
3.50
0.42
0.00
TOTAL
12.00
3.50
0.42
96.50
11.58
Window Cleaner - 2 (1)
12.00
Isopropanol - 99%
0.00
5.00
0.60
Propylene Glycol Monoethyl Ether
0.00
2.50
0.30
Sodium Lauryl Sulfate
0.00
0.20
0.02
Lauryl Di-isopropanolamide
0.00
0.10
0.01
Sodium Nitrite
0.00
0.20
0.02
Ammonia (29% NH3 in water)
0.00
0.20
0.02
Deionized water
0.00
88.50
10.62
Iso-butane A-31
3.30
0.40
0.00
TOTAL
12.00
3.30
0.40
96.70
11.60
Window Cleaner - 3 (1)
12.00
Isopropanol - 99%
0.00
4.00
0.48
Butoxyethanol
0.00
2.00
0.24
Lauryl Di-isopropanolamide
0.00
0.10
0.01
Ammonium Lauryl/Myristyl Alcohol
0.00
0.10
0.01
Sodium Nitrite
0.00
0.10
0.01
Ammonia (29% NH3 in water)
0.00
0.20
0.02
Deionized water
0.00
90.00
10.80
Iso-butane A-31
3.50
0.42
0.00
TOTAL
12.00
3.50
0.42
96.50
11.58
(Continued)
H-13
-------
TABLE H-7. (Continued)
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Disinfectant Cleaner - (1) 12.00
Sodium meta-Silicate 5-Hydrate
0.
.00
0,
.10
0.
00
Tetrasodium EDTA (38% A.I. in
Water)****
0.
.00
4.
.12
0,
,50
BTC 2125M (50% A.I. in Water)
0.
,00
0.
.40
0.
04
Sodium Benzoate
0.
,00
0.
.10
0.
01
Sodium Tetraborate 10-Hydrate
0,
,00
0.
.10
0.
01
Morpholine
0.
.00
0.
,20
0.
.02
Ammonium Hydroxide (29% NH3 in
water)
0.
,00
0,
.10
0.
13
Atlas G-3821 Non-ionic Surfactant*****
0.
.00
0,
.50
0.
06
Butyl Cellosolve
0,
.00
6,
.00
0.
,72
Potassium Hydroxide (45% A.I.
in Water)
0,
.00
0,
.05
0,
.01
Fragrance
0
.00
0,
.15
0
.02
Deionized water
0
.00
80
.18
9
.62
Iso-butane A-31
7.00
0.
.84
0,
,00
TOTAL
12.00
7.00
0.
.84
93,
.00
11,
,16
* As Maprofix 563, by the Onyx Division of Witco Chemical Co.
** As Maprofix Mg.
*** As Maprosil 30.
**** Tetrasodium Ethylenediamine-tetraacetate, such as Cheelox BF-13, or
Versene 30 (Dow).
***** By ICI America, Inc.
H-14
-------
TABLE H-8. ROOM DEODORANT/DISINFECTANT FORMULATIONS
Average
Product
Propellant
Other
Weight
Product Formula
oz.
%
oz.
%
oz.
Air Freshener - 1 (1)
8.00
Fragrance
0.00
1.00
0.08
Odorless Petroleum Distillates
0.00
6.28
0.50
Lampolamide 5 Liquid (Croda)
0.00
0.72
0.06
Sodium Benzoate
0.00
0.15
0.01
Deionized water
0.00
59.85
4.79
Propellant A-60
32.00
2.56
0.00
TOTAL
8.00
32.00
2.56
68.00
5.44
Air Freshener - 2 (1)
8.00
Fragrance
0.00
1.50
0.12
Propellant A-60
90.00
7.20
0.00
Dimethyl Ether
8.50
0.68
0.00
TOTAL
8.00
98.50
7.88
1.50
0.12
Air Freshener - 3 (1)
8.00
Fragrance
0.00
2.00
0.16
Odorless Petroleum Distillates
O.OO
6.00
0.48
S.D. Alcohol 40-2 (Anhydrous)
0.00
38.00
3.04
Deionized water
0.00
4.00
0.32
Propellant A-60
50.00
4.00
0.00
TOTAL
8.00
50.00
4.00
50.00
4.00
Room Disinfectant - 1 (1)
8.00
o.Phenyl-phenol (95% purity)
0.00
0.11
0.01
S.D. Alcohol 40-2 (Anhydrous)
0.00
73.38
5 .87
Fragrance
0.00
0.11
0.01
Sodium Benzoate
0.00
0.20
0.02
Morpholine
0.00
0.20
0.02
Deionized water
0.00
21.00
1.68
Carbon Dioxide
5.00
0.40
TOTAL
8.00
5.00 0.40
95.00 7.60
(Continued)
H-15
-------
TABLE H-8. (Continued)
Average
Product Propellant Other
Weight
Product Formula oz. % 02. % oz.
Room Disinfectant - 2 (1) 8.00
BTC-2125M (50% in Water)
0.00
0.28
0.02
Atlas G-271 (35% in Water)
0.00
0.12
0.01
S.D. Alcohol 40-2 (Anhydrous)
0.00
52,07
4.17
Fragrance
0.00
0.11
0.01
Sodium Benzoate
0.00
0.22
0.02
Morpholine
0.00
0.20
0.02
Deionized water
0.00
25.00
2.00
Propellant Blend A-40
22.00
1.76
0.00
TOTAL
8.00 22.00
1.76
78.00
6.24
H-16
-------
TABLE H-9. LAUNDRY AID FORMULATIONS
Average
Product
Propellant
Other
Product Formula
oz.
%
oz.
%
oz.
Pre-laundry Cleaners - 1 (1)
16.00
Linear primary or secondary alcohol
polyglycol ether (2-4 mol ETO)
0.00
12.00
1.92
Linear primary or secondary alcohol
polyglycol ether (7-10 mol ETO)*
0.00
12.00
1.92
Diethylene Glycol Monomethyl Ether
0.00
12.00
1.92
Sodium Laurate/Myristate
0.00
0.40
0.06
Isopropanol - 99%
0.00
4.00
0.64
Low-odor n.Paraffinic or iso.Paraffinic
Solvent (C10-C14 hydrocarbons)
0.00
20.00
3.20
Ammonium Hydroxide (28% NH3 in water)
0.00
0.50
0.08
Fragrance (Typically lemon/lime)
0.00
0.50
0.08
Enzyme Concentrate (Optional)
0.00
1.00
0.16
Deionized Water
0.00
30.10
4.82
Propane A-10B or Propellants A-B5
7.50
1.20
0.00
TOTAL
16.00
7.50
1.20
92.50
14.80
Pre-laundry Cleaners - 2 (1)
16.00
Linear primary or secondary alcohol
polyglycol ether (7-10 mol ETO)*
0.00
10.00
1.60
Diethylene Glycol Monomethyl Ether
0.00
5,00
0.80
Isopropanol - 99%
0.00
5,00
0.80
Low-odor n.Paraffinic or iso.Paraffinic
Solvent (C10-C14 hydrocarbons)
0.00
76.70
12.27
Fragrance (Typically lemon/lime)
0.00
0.50
0.08
Carbon Dioxide
2.80
0.45
0.00
TOTAL
16.00
2.80
0.45
97.20
15.55
Spray Starch - 1 (1)
16.00
Amaizo No, 513 Pearl Starch
0.00
2.30
0.37
Sodium Tetraborate 10-Hydrate
0.00
0.30
0.05
Silcone Emulsion LE-463,346 or equal
0.00
0.40
0.06
Silcone Antifoam Emulsion
0.00
0.15
0.02
Sodium Nitrite or Sodium Benzoate
0.00
0.15
0.02
Fragrance
0.00
0.02
0.00
Glutaraldehyde (50%) or
0.00
0.00
Formaldehyde (37% in Water)
0.00
0.04
0.00
Optical Brightener
0.00
0.02
0.00
Deionized Water
0.00
91.10
14.58
Iso-butane
5.50
0.88
0.00
TOTAL
16.00
5.50
0.88
94.50
15.12
(Continued)
H-17
-------
TABLE H-9. (Continued)
Product Formula
Average
Product
Weight
oz.
Propellant
% oz.
Other
% oz.
Spray Starch - 2 (1)
16.00
Penford Gum 290 or Equilvalent
0.00
2.75
0.44
Sodium Tetraborate 10-Hydrate
0.00
0.40
0.06
Silcone Emulsion LE-463,346 or equal
0.00
0.50
0.08
Silcone Antifoam Emulsion
0.00
0.10
0.02
Fragrance
0.00
0.03
0.00
Glutaraldehyde (50%) or
Formaldehyde (37% in Water)
0.00
0.06
0.00
Deionized Water
0.00
90.16
14.43
Iso-butane
6.00
0.96
0.00
TOTAL
16.00
6.00
0.96
94.00
15.04
Spray Starch - 3 (1)
16.00
EO-Size 5795 Starch or Equivalent
0.00
3.00
0.48
Sodium Tetraborate 10-Hydrate
0.00
0.45
0.07
Silcone Emulsion LE-463,346 or equal
0.00
0.44
0.07
Silcone Antifoam Emulsion
0.00
0.10
0.02
Sodium Nitrite or Sodium Benzoate
0.00
0.10
0.02
Fragrance
0.00
0.03
0.00
Glutaraldehyde (50%) or
Formaldehyde (37% in Water)
0.00
0.04
0.01
Deionized Water
0.00
90.00
14.40
Iso-butane
5.84
0.93
0.00
TOTAL
16.00
5.84
0.93
94.16
15.07
Absorbent Silica Cleaner - (1)
7.00
Fumed Silica Powder
0.00
6.00
0.42
1,1,1-Trichloroethane
0.00
68.00
4.76
Isopropanol - 99%
0.00
10.00
0.70
Fragrance
0.00
0.05
0.00
Propane A-108
15.95
1.12
0.00
TOTAL
7.00
15.95
1.12
84.05
5.88
May be replaced with octyl or nonyl phenol polyoxyethylene (9-13 mol ETO)
of other non-ionics of similar HLB value.
H-18
-------
TABLE H-10. WAX/POLISH FORMULATIONS
Average
Product
Propellent
Other
Weight
Product Formula
oz.
%
oz.
%
oz.
Furniture Polish - 1 (1)
14.00
Wax S and Wax N (1:1 ratio)
Hoechst
0.00
1.25
0.18
Silicone Emulsion LE-461
(50% A.I.) UCC
0.00
1.40
0.20
Silicone Emulsion LE-462
(50% A.I.) UCC
0.00
0.35
0.05
Arlacel C (Non-ionic surfactant)
1CI Am.
0.00
0.15
0.02
Isopar C or E
0.00
2.00
0.28
Lemon Oil, Technical Grade
0.00
0.75
0.11
Glutaraldehyde (50% A.I.) UCC
0.00
0.05
0.01
Sodium Nitrite
0,00
0.05
0.01
Deionized Water
0.00
87.00
12.18
Iso-butane A-31
7.00
0.98
0.00
TOTAL
14.00
7.00
0.98
93.00
13.02
Furniture Polish - 2 (1)
14.00
Wax S and Wax N (1:1 ratio)
Hoechst
0.00
1.25
0.18
Silicone Emulsion LE-461
(50% A.I.) UCC
0.00
1.40
0.20
Silicone Emulsion LE-462
(50% A.I.) UCC
0.00
0.35
0.05
Arlacel C (Non-ionic
surfactant) ICI Am.
0.00
1.25
0.18
Isopar C or E
0.00
33.00
4.62
Lemon Oil, Technical Grade
0.00
0.60
0.08
Glutaraldehyde (50% A.I.) UCC
0.00
0.03
0.00
Sodium Nitrite
0.00
0.05
0.01
Deionized Water
0.00
44.57
6.24
Iso-butane A-31
17.50
2.45
0.00
TOTAL
14.00
17.50
2.45
82.50
11.55
(Continued)
H-19
-------
TABLE H-10. (Continued)
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Wood Panel Polish (1) 14.00
D. C. 536 Fluid*
0.00
2.00
0.28
D. C. 200 Fluid**
0.00
2.00
0.28
Uitcamide 511 -
Witco Chem. Co.
0.00
1.00
0.14
Isopar L and/or Isopar
M - Exxon
0.00
26. 50
3.71
Isopar K - Exxon
0.00
65.20
9.13
Fragrance
0.00
0.05
0.01
Isopropanol (Anhydrous)
0.00
0.25
0.04
Carbon Dioxide
3.00
0.42
0.00
TOTAL
14.00 3.00
0.42
97.00
13.58
* An aminofunctional polydimethyl-siloxane copolymer - Dow Corning
Corporation
** Dimethylsiloxane polymer - Dow Corning Corp. (12,500 cstks)
H-20
-------
TABLE H-ll. MAJOR AUTOMOTIVE/INDUSTRIAL PRODUCT FORMULATIONS
Product Formula
Average
Product
Weight
oz.
Propellant
oz.
Other
oz.
Spray Lubricant (2)
Mineral Oils
Isobutylene polymers
Propellant
TOTAL
Carburetor/Choke Cleaner (2)
Aliphatic/Aromatic Hydro-
14.00
14.00
12.00
5.00
0.00
0.00
0.70
5.00 0.70
90.00
5.00
95.00
12.60
0. 70
0.00
13.30
carbons (e.g., Toluene,
0.00
88.00
10.56
Acetone)
Butane
12.00
1.44
0.00
TOTAL
12.00
12.00
1.44
88.00
10.56
Engine Starting Fluid (1)
8.96
Diethyl ether
0.00
91.00
8.15
Carbon Dioxide
9.00
0.81
0.00
TOTAL
8.96
9.00
0.81
91.00
8.15
Rotary Tablet Machine Die
14.00
Lubricant - 1 (1)
Lecithin
0.00
2.00
0.28
Sorbitan Trioleate
0.00
0.50
0.07
Ethanol (Anhydrous)
0.00
2.50
0.35
CFC-113
0.00
70.00
9.80
CFC-12
25.00
3.50
0.00
TOTAL
14.00
25.00
3.50
75.00
10.50
H-21
-------
TABLE H-12. FORMULATIONS FOR MISCELLANEOUS AUTOMOTIVE/INDUSTRIAL AEROSOLS
Product Formula
Average
Product
Weight
oz.
Propellant
oz.
Other
oz.
Gasket Adhesive (1)
16.00
Isopropanol
0.
,00
10.
,00
1.
.60
Resin 80-1211
0.
,00
5.
,00
0,
.80
Stabilite Ester Number 3
0,
,00
5
,00
0
.80
Methylene Chloride
0.
,00
50,
.00
8.
.00
Xylenes
0.
,00
10,
.00
1.
.60
Propellant Blend A-70
20,
.00
3.
.20
0
.00
TOTAL
16.00
20
.00
3.
,20
80
.00
12
.80
Brake Cleaner (3)
Alcohol (methanol or
ethanol) or chlorinated
solvents-propellant not
specified
TOTAL
Spray Undercoating (2)
Pigment
Propellant (unspecified
non-CFC VO)
Solvent (unspecified
non-CFC VO)
Total
Tire Inflator/Sealant (4)
Unspecified non-CFC VOs
(One "active"ingredient
also serves as propellant)
Total
18.10
18.10
12.00
0.00 100.00 18.10
25.00 3.00
0.00 0.00 100.00 18.10
0.00 50.00 6.00
0.00
0.00 25.00 3.00
12.00 25.00 3.00 75.00 9.00
11.00
0.00 100.00 11.00
11.00
0.00 0.00 100.00 11.00
(Continued)
H- 22
-------
TABLE H-12. (Continued)
Average
Product Propellant Other
Product Formula
oz.
%
oz.
%
oz.
Vinyl/Upholstery Cleaner (1)
18.00
Sodium Lauroyl Sarcoslnate
(30% A.I. in Water)
0.00
1.50
0.27
Sodium Lauryl Sulfate Powder
USP (CI- free)
0.00
1.55
0.28
Dupanol WAT
0.00
1.10
0.20
Ammonium Hydroxide (26-28%)
0.00
0.09
0.02
Silicone SM-62 General Electric
0.00
0.90
0.16
Perfume
0.00
0.05
0.01
Isopar C Exxon
0.00
2.75
0.50
Sodium meca-Silicate 5-Hydrate
0.00
0.10
0.02
Deionized Water
0.00
85.96
15.47
Propellant Blend A-46
6.00
1.08
0.00
TOTAL
18.00
6.00
1.08
94,00
16.92
Electronic Cleaners (5)
16.00
CFC-113
75.00
12.00
Propellant (CFC-12)
25.00
4.00
TOTAL
16.00
25.00
4.00
75.00
12.00
Engine Degreaser (1)
14.00
Non-ionic Surfactants
0.00
5.00
0.70
Xylenes
0.00
20.00
2.80
Deodorized Kerosene
0.00
72.00
10.08
Carbon Dioxide
3.00
0.42
0.00
TOTAL
14.00
3.00
0.42
97.00
13.58
Windshield De-icer (1)
16.00
Methanol-Technical Grade
0.00
54.00
8.64
Propylene Glycol - Technical
Grade
0.00
18.00
2.88
Deionized Water
0.00
25.00
4.00
Morpholine
0.00
0.10
0.02
Span 80 or Igepal CO-410 Non-
ionics
0.00
0.05
0.01
Sodium Benzoate
0.00
0.05
0.01
Carbon Dioxide
2.80
0.45
0.00
TOTAL
16.00
2.80
0.45
97.20
15.55
H- 23
-------
TABLE H-13. PAINT/PRIMER/VARNISH FORMULATIONS
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Paint - Acrylic Metallic (1) 12.00
Acryloid B72 (50% A.I.)
0,
,00
8.
,00
0.
96
Acryloid A101 (40% A.I.)
0,
,00
1,
,00
0.
12
Gold Powder #6238
0.
.00
4,
.00
0.
,48
Propylene Glycol Monomethyl Ether
0.
00
2.
.00
0.
,24
Nonylphenoxy Polyethoxy Ethanol
0.
,00
0,
.10
0,
,01
Toluene
0.
.00
28,
.20
3,
,38
Xylenes
0.
,00
12.
,40
1,
,49
Acetone
0.
,00
15,
.40
1,
,85
Hydrocarbon Propellant Blend A-85
28
.90
3.
.47
0,
.00
TOTAL
12
.00
28
.90
3.
.47
71,
.10
8~
"53
Paint - Acrylic (1)
12,
.00
Corboset 514H (40% A.I.)
0.
.00
25
.00
3,
.00
Tint Aid (Black WD-2350)
0,
.00
5
.00
0
.60
Titanium Dioxide Powder (R-940)
0,
.00
1
.00
0
.12
Propylene Glycol Monomethyl Ether
0,
,00
5
.00
0
.60
Isopropanol
0,
.00
8
.00
0
.96
Nonylphenoxy Polyethoxy Ethanol
0.
.00
0
.35
0
.04
Fluoroacrylic FC-430 Surfactant
0,
.00
0
.02
0
.00
Hi-Sil T-600 (Silica)
0
.00
0
. 14
0
.02
Magnesium Aluminum Silicate
0.
.00
0
.30
0
.04
De-ionized Water
0,
.00
10
.19
1
.22
Dimethyl Ether
45
.00
5
.40
0
.00
TOTAL
12.
.00
45
.00
5,
.40
55
.00
6~
"60
(Continued)
H-24
-------
TABLE H-13. (Continued)
Average
Product Propellant Other
Product Formula
oz.
%
oz.
%
oz.
Paint - Alkyd - 1 (1)
12.00
Tint Aid (Black WD-2350)
0.00
5.00
0.60
Beckosol 13-400 (75% A.I.)
0.00
13.00
1.56
Ammonium Hydroxide (29% NH3)
0.00
1.15
0.14
Titanium Dioxide Powder (R-940)
0.00
2.00
0.24
Propylene Glycol Monomethyl Ether
0.00
5.00
0.60
Isopropanol
0.00
8.00
0.96
Nonylphenoxy Polyethoxy Ethanol
0.00
0.45
0.05
Fluoroacrylic FC-430 Surfactant
0.00
0.02
0.00
Hi-Sil T-600 (Silica)
0.00
0.14
0.02
Magnesium Aluminum Silicate
0.00
0.12
0.01
Drier: Cobalt Hydro Cure II
0.00
0.10
0.01
Drier: Zirconium Cem
0.00
0.08
0.01
De-ionized Water
0.00
19.94
2.39
Dimethyl Ether
45.00
5.40
0.00
12.00
45.00
5.40
55.00
6.60
Paint - Alkyd - 2 (1)
12.00
Tint Aid (Black UD-2350)
0.00
5.00
0.60
Beckosol 13-400 (75% A.I.)
0.00
13.00
1.56
Ammonium Hydroxide (29% NH3)
0.00
1.15
0.14
Propylene Glycol Monomethyl Ether
0.00
5.00
0.60
Isopropanol
0.00
8.00
0.96
Nonylphenoxy Polyethoxy Ethanol
0.00
0.50
0.06
Fluoroacrylic FC-430 Surfactant
0.00
0.02
0.00
Hi-Sil T-600 (Silica)
0.00
0.14
0.02
Magnesium Aluminum Silicate
0.00
0.15
0.02
De-ionized Water
0.00
22.04
2.64
Dimethyl Ether
45.00
5.40
0.00
TOTAL
12.00 45.00
5.40
55.00
6.60
H- 25
-------
TABLE H-14. SPACE INSECTICIDE FORMULATIONS
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Total Release Insect Fogger - (1) 12.50
Pyrethrum Extract - 20%
0.00
2.00
0.25
Piperonyl Butoxide; Technical
0.00
1.00
0.13
Pertroleum Distillates
0,00
12.00
1.50
1,1,1-Trichloroethane
0.00
55.00
6.88
Propane A-106
30.00
3.75
0.00
TOTAL
12.50
30.00
3.75
70.00
8.75
Insecticide (2) 14.00
Pyrethins
0.00
0.25
0.04
Piperonyl butoxide
0.00
0.80
0.11
Petroleum distillates
0.00
1.04
0.15
Inert ingredients
0.00
0.91
0.13
(Emulsifier/Corrosion Inhib)
Inert ingredients (Water)
0.00
67.00
9.38
Butane/Isobutane
30.00
4.20
0.00
TOTAL
14.00
30.00
4.20
70.00
o
CO
CJ\
H- 26
-------
TABLE H-15. RESIDUAL INSECTICIDE FORMULATIONS
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Insect Repellent (6) 14.00
n,n-dimethyl-m-toluamide
0.00
19.00
2.66
Other isomers
0.00
1.00
0.14
2,3,4,5-bis-(2-butylene)
0.00
1.00
0.14
tetrahydro- 2 -furaldehyde
n-octyl dicycloheptene
0.00
4.00
0.56
dicarboximide
Inerts (alcohol and propellant)
30.00
4.20
45.00
6.30
TOTAL
14.00
30.00
4.20
70.00
9.80
it and Roach Killer (6)
11.00
d-trans-Allethrin
0.00
0.05
0.01
Piperonyl butoxide
0.00
0.10
0.01
N-Octyl dicycloheptene
0.00
0.17
0.02
dicarboximide
0-Isopropoxyphenyl
0.00
0.50
0.06
methyl carbonate
Petroleum distillate
0.00
86.25
9.49
Propellant
12.90
1.42
0.00
TOTAL
11.00
12.90
1.42
87.07
9.58
H-27
-------
TABLE H-16. MAJOR FOOD PRODUCTS FORMULATIONS
Product Formula
Average
Product
Weight
oz.
Propellant
oz.
Other
oz.
Whipped Cream (7)
Synthetic Dairy Cream
Nitrous oxide
TOTAL
11.00
11.00
17.50
0.00
1.93
17.50 1.93
82.50
82.50
9.08
0.00
9.08
Frypan Spray (7)
Corn oil, grain alcohol,
lecithin
Propellant
6.00
0.00
31.00 1.86
69.00
4.1 4
0.00
TOTAL
6.00
31.00 1.86
69.00
4.14
H- 28
-------
TABLE H-17. ANIMAL PRODUCTS FORMULATION
Average
Product Propellant Other
Weight
Product Formula oz. % oz. % oz.
Flea and Tick Spray 7.00
for Dogs - (6)
2-chloro-l(2,3,5-trichlorophenyl)
0.00
0.99
0.07
vinyl dimethyl phosphate
Inerts (incl. propellant)
5.00 0.35
94.01
6.58
TOTAL 7.00
5.00 0.35
95.00
6.65
H- 29
-------
REFERENCES FOR APPENDIX H
1. Nelson, T.P., and S.L. Wevill. Aerosol Industry Success in Reducing CFC
Propellant Usage. EPA-600/2-89-062 (NTIS PB90-143447). U.S.
Environmental Protection Agency, Research Triangle Park, NC, November
1989.
2. Jones, A., H. Rich, G. Sewell, M. Rogozen, and N. Katz. Photochemically
Reactive Organic Compound Emissions (NTIS PB88-216940).* U.S.
Environmental Protection Agency, Region 2, New York, NY, November 26,
1986. (») EPA-902/4-86-001.
3. Examination of brake cleaners at a local auto supply store, Radian
Corporation, Austin, TX, June 1989.
4. Examination of tire sealant at local auto parts store, Radian
Corporation, Austin, TX, September 1988.
5. Uphouse, H.G. Industrial Aerosol Sprays. Aerosol Age, January 1983.
6. Control Techniques for Reducing Emissions of Photochemically Reactive
Organic Compounds from Consumer and Commercial products. B/834-025-
29a/#14, Science Applications International Corporation for the U.S.
Environmental Protection Agency, Region 2, New York, NY, September 30,
1987.
7. Johnsen, Montfort A. The Aerosol Handbook, Second Edition. Dorland
Publishing Company, Mendham, NJ, 1982.
H-30
-------
TECHNICAL REPORT DATA
(Please read Inurvctians on the rcvenc before comptr
1. REPORT NO. 2.
EPA-600/2-91-0 56
3
a. title and subtitle
Manual for Non-CFC Aerosol Packaging: Conversion
from CFC to Hydrocarbon Propellants
5. REPORT DATE
September 1991
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
K.M. Adams, K. E. Hummel, T. P. Nelson, and
S. L. Wevill
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Radian Corporation
P. C. Box 201088
Austin, Texas 78720-1088
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-D0-0125, Task 8
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Air and Energy Engineering Research Laboratory
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 12/90-7/91
14.SPONSORING AGENCY CODE
EPA/600/13
15.supplementary notes AEERL project officer is N. Dean Smith. Mail Drop 62B, 919/541-
2708.
16 ABSTRACT
The report provides technical assistance to aerosol product marketers and
fillers in other nations now faced with eliminating chlorofluorocarbons (CFCs) un-
der the terms of the Montreal Protocol. It addresses the issues of hydrocarbon
propellant supply, product reformulation, equipment conversion, and safety concerns
for both the manufacturing plaints and the aerosol products themselves. Because
stratospheric ozone provides protection from biologically damaging ultraviolet-B
radiation, and because CFCs have been strongly implicated in the thinning of the
Earth's stratospheric ozone layer, there is an urgent need to eliminate production
and use of the CFCs. In the U. S., CFCs were banned for use as propellants from
nearly all aerosol products as early as 1978. In place of the CFC propellants,
liquified hydrocarbons such as propane, n-butane, and isobutane were found to be
acceptable substitutes for most aerosol products.
17. KEY WORDS AND DOCUMENT ANALYSIS
a DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. cosati Field/Group
Pollution Propane
Halocarbons Butanes
Ozone Packaging
Stratosphere
Ultraviolet Radiation
Aerosols
Hydrocarbons
Pollution Control
Stationary Sources
Chlorofluorocarbons
13 B
07 C
07B 13 D
04A
20F
07D
IB. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisRepon)
Unclassified
21 OF PAGES
218
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9 73)
|
------- |