Carefully add solvent to the cleaner to minimize
disturbing the vapor blanket. Solvent should be
pumped into the cleaner through a submerged
- outlet. Makeup solvent should be added to a rinse
compartment, or better yet, to the cleaner’s
condensate collection tank. In either case, it
should be added below the solvent surface. Cold
solvent definitely should not be added to a boiling

sump: it may stop the boiling and cause the vapor

blanket to collapse (see Exhibit 9).

Avoid pouring solvent with buckets or drums into

a open-top degreaser because:

« Soivent falling through air evaporates rapidly,
causing significant losses before entering the
unit; :

,

«The pouring action creates turbulence in the
vapor blanket, leading to convection losses.
This effect will be exacerbated if the cold
solvent causes the vapor blanket to collapse; _

“© Spillage is increased; and |

¢ Increased worker exposure may occur.

Exhibit 9
SOLVENT REFILL PROCEDURE

Equipment Strategies

System optimization will improve the efficiency of
your manufacturing process. as well as reduce
unnecessary emissions. Solvent cleaning units -
should be used to their maximum potential. Cue
large unit costs less than two small units and is
much more efficient. «© - ~

Vapor emissions can be reduced by consolidating

operations of several open-top units into a single,
enclosed unit designed for continuous operation.
Production . scheduling, involving linear
Programming or other methods, can help
Streamline your process and reduce unnecessary

, Steps as well as associated labor and process costs.

Ideally, you should size a machine to your required

| Capacity. But ‘if necessary, you should oversize

your system rather than buy two machines. It is
important to consider the ability of the unit to
accept scale down. System operation at 20-30

| percent of maximum capacity can be important.



CONSERVATION PRACTICES AND
STRATEGIES

. This section of the manual begins by discussing conservation’ Practices in general and then
Presents specifics of different cleaning operations (e.g., batch, in-line, and cold cleaning).
Finally, the section concludes with an overview of reclamation and recycling procedures,
The section is organized in the following manner:

Best practices to operate solvent-cleaning equipment;

Causes of emissions and reduction strategies for batch cleaning operations;
- Emissions during in-line cleaning and techniques to.reduce them;

Cold cleaning practices and emissions reductions; ; ,

Reclamation and recycling Practices;

Other control technologies;

. _A summary of emission‘causes and solutions.



a

slides open to allow.the product to enter into the
vapor zone. ‘When the workload clears the lid on
its downward descent, the lid closes. Subsequent
‘dosses due to the “piston effect” or sprayers
disturbing the vapor blanket are reduced.

Shortly afier vapor condensation ceases, or
spraying is terminated, the workload can be raised
into the cooling coil zone of the degreaser with the
lid still closed to minimize disturbance to the
vapor zone and worklosd dragout losses. When
the solvent has vaporized and the product is free
of liquid solvent (dry), the hoist raises the product
out of the + The lid opens to allow the
product to exit, and then closes.

Such designs can be purchased as an integral part
of many, new degreaser designs. Retrofit kits
consisting of a lid, hoist, or a combination of the
two are also available to convert existing
degreasers. Retrofitting degreasers may require
repermitting.

Start-Up and Shut-Down Procedures

Start-up always results in some loss of solvent
vapor as air fs purged from the system. When the
cleaner is used on an intermittent basis, emissions
caused by frequent start-ups and shut-downs can be
minimized by deferring cleaning until there is a full

day’s worth of work to process. Thus, there will .

only be one start-up of the cleaning equipment. If
such scheduling is impossible, the unit should be
left on with the lid closed when not in use.

Solvent emissions during start-up can be
minimized through the following steps in the order
shown:

« Start up the condenser cooling system and make
sure that it is operating properly;

© Start up any auxiliary emission control
equipment;

e Check and adjust solvent levels in all

compartments;

« Tum on heaters;

«. Start up the spray. pumps once a stable vapor -

blanket is established; and

- not discarded or lost.

« Process work pieces only after the vapor blanket
has been established. In order to determine if
the vapor blanket has been established you must

_ look inside the unit. Best practice is to do this
only once. . Time how long the blanket takes to
form, and’ incorporate that time into the’
procedure.

When shutting down the system, use the following
steps in the sequence shown: .

Stop work.processing and clear the machine of
all work; - oe -

© Close the cover on open-top units;
+ Turn off the:heaters;-

© Activate sump cooling coils where provided;
water-cooled sump cooling coils can be easily
installed in many cases; :

« Allow the vapor blanket to collapse completely.
As before, time this step;

* Turn off the condenser cooling system where
applicable. However, some units do not have
sump cooling coils. In this case, the condenser ~
cooling system should be kept on, on an
intermittent basis.

Note: If cooling condenser is‘ left running for
extended periods after shut-down, it could cause
moisture condensation on the coils from room air.
‘The moisture would drip into the sump and
contaminate the solvent. However, ‘this can be

- prevented with the use of a water separator or
desiccant dryer. :

Idle Time Management |

Simple procedures such as putting the unit on
*cool" mode or turning it off whenever it is not in
use can help reduce losses during idle time.
However, start-up and shut-down losses must be
factored into scheduling decisions. Each
installation may warrant its own, customized plan.

Using rigid covers with tight seals is essential when
a machine is not operating. Make sure covers are



Exhibit 2

CORPORATE POLICIES ON CFC-113 REDUCT 1ON SCHEDULE —

_ Reduction Schedule
Company CFC-113

American Electronics Association Member . ". Phaseout 2000
Companies, U.S. .

AT&T, US. a Phaseout 1994.
Canon, Japan * _ ; _‘Phascout 1994
Digital Equipment Corporation, US. Phaseout 1995
Hitachi Corporation, Japan 7 Phaseout 1993
Honeywell, U.S. . . Phaseout 1997
IBM, US. : Phaseout 1993
Intel Corporation, U.S. ” Phaseout 1992:
Matsushita, Japan . oo ' Phaseout 1995
Motorola, Inc., U.S. ee _ Phaseout 1992 °
Nissan Motor Corp., Japan Co Phaseout 1993
Northern Telecom, Canada ‘Phaseout 1991
Seiko-Epson, Japan . Phaseout 1993
Sharp Corporation, Japan _ *Phaseout 1995
‘Texas Instruments, U.S. . Phaseout 1994 >
‘Toshiba Corporation, Japan Phaseout 1995
Volvo, Sweden ; oe "-Phaseout 1994



CASE STUDY #4: ~ Euwraoe ond es roth, wert ernie os
“ING AND REDUCTION —_ >... antsystem seats were detected and eliminated

on 4.rcgular basis. Solvent usage is tightly
tracked and plotted. Any spikes in the usage

Case Study #4 outlines the 50 percent reduction of level triggers a thorough systems check of all
CFC-113 solvent consumption from a conveyor . seals, . fittings, covers, using a common
degreaser. Motorola accomplished the reduction © refrigerant vapor detector. Note that solvent :
with the following actions: evaporates so quickly that leaks will not appear

as drips. Exhibit 23 depicts a spike caused. by a
seal leak which was detected by close -

© The temperature of-the vapor cooling coils was . monitoring of the solvent usage. UCL and LCL
reduced until water started condensing on the : are the acronyms for upper confidence limit and
coils. This required a system with a closed loop _ lower confidence limit respectively.
cooling unit with a refrigeration system. Water . a —_
condensation initially caused the alcohol in the © Internal baffles were installed to reduce the
solvent to separate into a second phase, disturbance to the vapor blanket caused by
destroying the cleaning effectiveness and © external air currents. ;
creating a fire hazard. To overcome this

Problem, the desiccant must be dried daily. . Vapor leaks were sealed where possible.

—_——$

Exhibit 23

SOLVENT USAGE PROFILE FOR A
CONVEYOR DEGREASER

|

Os

044

Gafone Per Hour
&

Ot

T T

3B 40 42 46 48 48 SO 8242 4 6 8 1 1 1 8 : , .
nes a] .

Week ls

Source: Motorola Likeeasind



-Exhibit 17°

FACILITY CONSIDERATIONS
IN CHOOSING AN OFF-SITE RECYCLER

Types of solvent wastes managed.

Availability of laboratory facilities and suitable analytical procedures.

Ability to meet solvent purity specifications.

Availability of custom recycling services (e.g., vendor-owned recycling units that
can be operated on the generator’s property).

Expertise on in-plant waste mariagement strategies and process controls.

Availability of registered trucks to transport the solvent wastes, a
Distance to the recycling facility and associated transportation costs.
Completeness of recordkeeping. .

Adequacy of permits held by the facility. ;

Sufficiency of insurance for recycling/treatment/disposal operations, |

Adequacy of disposal procedures for still bottoms and other solvent wastes.

Compliance record of the facility.

Reputation of the facility.

Financial stability.

Costs of using service. .



a2

‘The vapor/fliquid equilibrium associated with steam
stripping permits a further separation of volatile
solvent from relatively nonvolatile impurities. ‘This
is doné‘at distillation temperatures lower than
thoes encountered in the one-plate distillation of
a contaminant-rich solvent mixture,

Steam stripping can be carried out either as a
batch process or as a continuous process. Batch
processing is more common, but continuous
Operation offers a number of advantages if the
contaminants are liquids (e.g., lubricating oils) of
low to moderate viscosity and the cleaning fluids
are quickly contaminated.

Batch steam stripping is usually performed in the
Same still as was used for still-heel generation.
However, in some high-volume solvent use
applications, the provision of a separate still
dedicated solely to the processing of heels from
other one-plate stills can offer significant
advantages in maintaining a high level of
productivity in the cleaning system. An example of
& steam stripping system is shown in Exhibit 16.

Off-site Recycling

If recycling of waste solvent on-site is impractical,
Several off-site recycling schemes are available.
When selecting an off-site recycling scheme, one
should consider or investigate all of the items
listed in Exhibit 17. Some viable off-site recycling
arrangements include toll recyclers and waste
exchange/brokerage,

Tell Recyclers. Toll recyclers offer services to
generators by supplying solvent wash equipment
and solvent and waste recycling services. The
solvent wash equipment is maintained by these
companies and the solvent is replaced periodically.
‘The used solvent is recycled at an off-site facility.
Costs for these services range from 50 to 90
percent of new solvent cost.

Waste Exchange and Brokerage. This is not a
technology but an information service. A waste

exchange can match a generator of waste with a
facility that can use the waste as a raw material.
Commercial waste brokerage services are also
available. A waste generator is matched with a
potential waste user who can utilize the waste as a
feedstock. Matching generators and users is based
on the knowledge of raw material inputs and

wastes and 4 product outputs of individual industries
and firms. :

Both before and after recycling, solvent should be ,
Monitored for acceptability, including thermal.
breakdown (acidity) and azeotropic imbalance. It
is important to ensure that solvents are not mixed —
at any time during the recovery process. —

Off-site recycling services are offered by a number
of licensed commercial operators. A partial listing
of these firms is provided later in this document.
After the maximum amount of solvent ‘is
recovered, the still bottoms and other residues
from ‘degreasing operations are destroyed’
thermally, generally through fuel blending.



«s

Thermal Destruction

In a thermal destruction unit, the CFCs and

ns are mixed and ignited and passed
through a hot.ceramic furnace to complete the
destruction. Incineration of the gases is
accomplished at approximately 1,800°F. A thermal
destruction unit consists of two beds and the flame
is altemnated between one bed and the other to
optir=ce efficiency (see Exhibit 20).

Exhibit 20
THERMAL DESTRUCTION FLOW DIAGRAM

Recent developments in catalytic chemistry appear
to make catalytic destruction of halogenated |
hydrocarbons a viable control option. In addition _
to significantly reducing the temperature required,
these new catalysts allow destruction and
have been shown to be resistant to deactivation.

NATURAL GAS

1 Source: Manchester Com.

TO ATMOSPHERE
_@170F
‘SCRUBBING
SYSTEM
1430 °F
K THERMAL 95% | ©)
K OXIDIZER 1500 °F PRIMARY
(1500 °F @ 1.0 SEC.) 11500 F HEAT
K : ; EXCHANGER
J | FROM PROCESS
. CFC 7
SOURCES
¥}) wneee nnn , ROOM AIR





40

Reclamation

External reclamation and recycle services are often
available to purify contaminated solvent and return
it to the original customer or to sell it to other
users. .

Reclamation and recycling can-also be performed
on-site. Several such systems are discussed below.
‘Where recycling solvent waste is viable, the choice
1 between on-site versus off-site recycling must be
made. Major factors that may influence a decision
are shown in Exhibit 15. In addition to these
factors, Title V1 of the Clean Air Act Amendments
of 1990 has imposed recycling requirements. In all
cases, the quality of the reclaimed solvents is an
important consideration. ASTM currently is
feecoping Standards for recycled CFC-113 and

On-site Recycling

On-site recycling is currently.economical if at least
‘approximately 8 gallons of solvent waste are
generated per day. The simplest form of solvent
Teuse is termed “downgrading,” which is using a
solvent that has become contaminated through
initial use for a second cleaning process. For
example, precision bearings need very high purity
solvents for cleaning. The solvent acquires very
little contamination in usage and can be
downgraded for use in less demanding cleaning

operations.

Because more effort is required io recycle solvent
that is heavily contaminated, on-site and off-site
Tecycling or reclamation should be explored. In

vapor degreasing and. cold cleaning, the soil re- ©

+ moved accumulates in the equipment. Eventually,
the solvent still bottoms become too contaminated
for further use and must be reclaimed or disposed

‘through incineration. For on-site recycling, many
different separation technologies are available.
Commonty used separation technologies for
contaminated solvents include gravity separation,

~ filtration, batch distillation, fractional distillation,
evaporation, and steam stripping.

Gravity Separation. The use of settling to separate
solids and water from solvent often permits the

reuse of solvent. For example, paint solvents may
be reused many times if solids are allowed
settle, .

Filtration. Filters can be used 10 remove solids
from many solvents, thus extending solvent life.

Batch Distillation. A batch still vaporizes the used .
solvent and condenses the overhe>= vapors in a”
separate vessel. Solids or high boiling. residues
(>400°F) remain in the still as a residue. Solvent

_ Stills range in size from 5-gallon to 500-gallon .

capacity. A vapor degreaser can be used as a batch
still for recycling solvent by employing proper boil-
down procedures. Detailed discussion of these
procedures is available from -major solvent
suppliers. J

In many applications, it is necessary to keep the
water content of the recovered solvent to less than
100 ppm. This can be accomplished by distilling
the solvent-water azeotrope, decanting the water, —
and then drying the remaining solvent with a
molecular. sieve or other desiccant. The water
Temoved in this operation must then be either
treated or drummed for disposal. :

Fractional Distillation. Fractional distillation is
carried out in a reflux column equipped with either
trays or packing. Heat is supplied by a reboiler
located at the bottom of the column while heat is
Temoved at the top of a column by a condenser.
Fractional distillation allows for separation o!
multi-component mixtures or mixtures of solvent
and oils with similar boiling points.

Evaporation. Evaporation can be employed for
solvent recovery from viscous liquids, sludge, or
still bottoms resulting from distillation. Scraped or
wiped-film evaporators utilize revolving blades, —
which spread the liquid over a heated metal
surface. The vapors are recovered by means of a
condenser. Another type of system, a drum dryer,
employs two heated counter-rotating drums
through which the liquid feed must pass. While
both systems can handle viscous wastes, the drum .
dryer is more tolerant of polymerizable

Steam Stripping. . Steam stripping is a solvent

, Feclamation enhancement process commonly used

for the processing of CFC solvent 'still-heels
generated in one-plate distillations. These still-
heels often can. contain as much as 40 to 50 |
percent (by weight) of solvent. In general, steam

stripping should not be used for MCF. :



12

Exhibit 4

RELATIVE SOLVENT EMISSIONS FROM
REPRESENTATIVE INDUSTRIAL SITUATIONS. |

Emission Factor

BASE | Goop -*- POOR = _—sINDUSTRY
Industrial Practices :

Source: Halogenated Solvents Industry Alliance

_



so

Batch Cleaning Operating
Practices

Process Description

Batch cleaning systems (also called open-top vapor
degreasing) are used primarily.in metal working
operations, and defluxing operations. They can
also be used for maintenance cleaning of electronic
components, small equipment parts, and aircraft
parts where a high degree of cleanliness is needed.

A batch cleaner is a tank with a heat source to boil
solvent and a cooling zone to condense the vapor
in the upper section. ‘The soiled parts are
suspended in an air-free zone of solvent vapor.
The hot vapor condenses onto the cool :parts,
dissolving oils and greases and providing
continuous rinsing with clean solvent. This process
also warms the parts, thus decreasing the rate of
condensation.

As the condensed solvent drains from the part it
carries off the soils and returns to the boiling
liquid reservoir. This vapor treatment is often
augmented by mechanical ‘action such as liquid
immersion, ultrasonic agitation, or spraying the
with quid solvent beneath the vapor level (as
shown in Exhibit 10).

Convection

Because solvent losses result from air currents,

batch cleaners should be placed in an area that is”

as draft-free as possible. Turbulence caused by
drafts from adjacent windows, doors, fans, unit

heaters, ventilators, or spray booths will greatly

increase emissions of solvent vapor.

To avoid excessive air movement, consider.

installing baffles or partitions on the windward side
to divert drafts away from the cleaning unit. You

can reduce the velocity of the air flow over the top ©

of the unit by eliminating dedicated exhaust
ventilation. _ Air velocity over the top of the
machine should not exceed 6 meters per minute
(20 ft/min). However, it should be noted that in
order to minimize worker exposure to high

concentrations of solvent vapor, sufficient ©

ventilation should exist around the vapor degreaser
work areas.

For open-top cavipment. a with drafts can
avoided corrected by using hooded
eaclovures with p automated work. -handling facilities.

Hinged covers, if opened too quickly, tend to drag
some of the solvent vapor with them. Consider an
alternate design such as a cover that slides or rolls

open.

Most machines have covers oF lds to limit solvent
losses and contamination during downtime or idle

* time. Control of the solvent is also provided by

the freeboard; which is part of the tank wall
extending from the top of the vapor zone to the
tank lip. The. freeboard ratio (FBR), or ratio of
freeboard height to machine width, usually ranges

* from -75 0 1.0, depending on the manufacturer's
_ design.

It is sometimes possible to dramatically reduce
convection losses by adding a supplemental water-
cooled or refrigerated freeboard. ‘The original
covers should be abandoned and replaced by
sliding covers on this new freeboard, which should
be as deep as practically possible.

Superheated Vapor Drying

Superheated vapor drying is a relatively new
technology that can be quite effective in
minimizing or eliminating losses from dragout. In
this process, the parts being cleaned come in
contact prior to their withdrawal into the unit's

‘ freeboard zone, with solvent vapor that is

superheated to a temperature above the normal
boiling point of the solvent. The superheated
vapor provides the heat needed to evaporate the
equilibrium film of liquid and any additional
solvent trapped due to work configuration.

The savings associated with superheated vapor .
drying are on par with that of automation. There
are two procedures for effecting the contact of the
work using superheated vapors. In one, the “static”
method, the vapor zone of the degreaser is
superheated using heat exchangers situated at an
elevation below the condenser. In the other, the
“dynamic” method, solvent vapor is recycled by a
blower through a heat exchanger and then
discharged through distributor nozzles onto the
work prior to its withdrawal into the freeboard

zone. -



61°

In replacing the batch cleaning system with an in-
line system and associated still, Northern Telecom
‘encountered a number of problems. Although the
~ new in-line system was more sophisticated, it was
much more expensive (based on per square foot of

boards cleaned) and used a greater amount of .

solvent than the batch machine.

‘The new cleaner was not the best machine for the
specific needs and functions and was not entirely
appropriate for the new product applications. A
financial analysis of the break-even point would
have identified the shortcomings’ of the new

machine and the tikelthood that CFC lepistation

would make the unit obsolete.
To conserve CFC-113, a reduced CFC-113 blend

was used.in this machine. The machine was not ©

compatible with the blend and the ball valves used
in the machine failed.

Besides specific problems related to the equipment
Choice, there were also errors in general handling
of solvents. Throughout this entire process, the
solvent was never treated as a chemical of concern.
Operator awareness was not stressed, and as @
consequence excessive solvent usage continued

*. unabated.

Excessive solvent consumption: was not initially
noticed because of two errors in the procedures
implemented to track solvent usage. First,
Operators were asked to report solvent use on their
respective machines, and who were initially
assumed to be accurate, consistently made mistakes
in reporting solvent use by over 50 percent.
Because the measuring errors were random, several
months were lost. The management group
responsible for tracking the efficiency of the
solvent cleaners from two solvent tracking reports

somehow mishandled the data presented it out of .

context. It was not until all reports were
. Channelled through one individual that confusion

and misunderstanding was replaced by reliable |

reporting of data.





64
4. of product manuf ured: Screw machine parts |
. Previous method of cleanifig: Crossrod vapor degreaser using methylene chloride
Approximate age of old equipment: 15 years
Reason for expenditure: Eliminate solvents or reduce emission
New method of cleaning: Crossrod vapor deégreaser using 2 chloride,
, enclosed, auto hoist, refrigeration chiller, superheat, down
. time chiller
Previous solvent consumption: 750 gal/mo.
New solvent consumption: * 100 gal/mo.
Percent emission reduction: ' 87
Capital investment: $350,000
Hours operated per week: 80
Emission per hour: 33 Ib. smethytene chloride/hr.
Solvent savings per year: $24,900 ‘
5. ‘Type of product manufactured: » Screw machine parts
Previous method of cleaning: Crossrod vapor degreaser using methylene chloride
Approximate age of equipment: 15 years oo .
Reason for expenditure: Eliminate solvents or reduce emissions,
New method of cleaning: Crossrod vapor degreaser using methylene chloride,
enclosed, auto hoist, refrigeration chiller
Previous solvent consumption: © 750 gal/mo.
New solvent consumption: 200 gal/mo.
Percent emission reduction: B :
Capital investment: $80,000
Hours operated per week: 40
Emission per hour: 13.1 Ib. methylene chloride/hr.
Solvent savings per year: $21,050
6. Type of product manufactured: Screw machine parts
Previous method of cleaning: Open-top vapor degreaser using methylene chloride, two
dip ;
Approximate age of equipment: 15 years

Reason for expenditure:
New method of cleaning:

Previous solvent consumption:
New solvent consumption:
Percent emission reduction:
Capital investment:

Hours operated per week:
Emission per hour:

Solvent savings per year:

Eliminate solvents or reduce emissions

Open-top vapor degreaser using methyienc chloride,
enclosed, auto hoist, refrigeration chiller :

350 galfmo.

100 gal/mo.

72

$50,000 .

40

6.5 Ib. methylene chioride/hr
$9,570



t

CASE STUDY #5: HISTORY OF EQUIPMENT
UPGRADES i and '
Case Study #5 presents a history of six solvent users wi switched from old to new systems to reduce solvent

emissions. The case study was provided by the Halogenated Solvents Indust’, Alliance. Each example
describes specific equipment and operating characteristics and the systems which repiaced them.

1 ‘Type of product manufactured: Cosmetic packaging |

Previous method of cleaning: a Crossrod in-line vapor degreaser using trichloroethylene
Approximate age of equipment: » 20 years. ! L ,
Reason for expenditure: Regulation of trichloroethylene as an oxidant
New method of cleaning: Crossrod in-line vapor degreaser using trich loroethylene,
_» Refrigeration chiller, carbon adsorber, Negative pressure.
Previous solvent consumption: 1,250 gai/mo.- :
New solvent consumption: -  t 450 gal/mo. i
- Percent emission reduction: 64 |
Capital investment: $400,000 ‘
Hours operated per week: 120 co
Emission per hour: : 1.8 Ib. trichloroethyiene/hr.
Solvent savings per year: $44,160 : .

2 ‘Type of product manufactured: Cosmetic. packaging : : :
Previous method of cleaning: Crossrod in-line vapor degreaser using methyl chloroform
Approximate age of equipment: 15 years ; ho. . .
Reason for expenditure: Obtain better cleaning ' : :

” New method of cleaning: .  Crossrod in-line vapor degreaser using methyl chloroform,
, enclosed, superheat, no refrigeration, river water for
cooling ;
Previous solvent consumption: 1,050 gal/mo.
New solvent consumption: 105 gal/mo.
Percent emission reduction: 90 : i
Capital investment: . $270,000 (includes new boiler)
Hours operated pe: week: so: . :
Emission per hour: 3.4 Ib. MCF/hr. !
Solvent savings per year: $49,900 : ‘
3. ‘Type of product manufactured: Small household appliances :
. Previous method of cleaning: . : Crossrod vapor degreaser using trichloroethylene

Approximate age of old equipment: 20 years | :

Reason for expenditure: ‘Automate handling and reduce emission - .

New method of cleaning: Crossrod vapor degreaser using trichloroethylene, enclosed

cooling tower, primary cold trap, negative pressure, and"

. ‘carbon adsorber So

Previous solvent consumption: 2,500 gal/mio. !

New solvent consumption: 250 gal/mo. |

Percent emission reduction: 90 ' !

Capital investment: 7 ~ $500,000

Hours operated per week: 120 :

Emission per hour: 6.0 Ib. trichloroethylene/hr.

Solvent savings per year: $124,200





RECAP ON | PROGRAM TO THIS POINT |

If the recommendations presented above are followed, the program will have laid the
groundwork for reducing solvent emissions, including: .

Commitment by management.and workers to reduce emissions; ,
Better understanding of the costs and benefits of reducing emissions;

Recognition of CFC-113 and MCF under their various trade names and | chemical
names; coos ' .

Characterization of cleaning processes to identify the extent of usage and the
need for a conservation and recycling program; .

Identification of the. primary sources of emissions and means of reducing them.



STRUCTURE OF THE MANUAL
This manual is divided into four sections:

CONSERVATION ‘AND RECYCLING ADVANTAGES _

This section outlines some of the advantages of conservation and recycling
practices. . .

_ PROCESS CHARACTERIZATION

This section helps to assess and understand the use of solvents i in manufacturing
- processes. . !
CONSERVATION PRACTICES AND STRATEGIES
In this section, conservation practices specific to batch cleaning, in-line cleaning,
-and cold cleaning are discussed with examples and ideas for reducing losses from
these systems. Reclamation and recycling processes are also discussed.

CASE STUDIES OF INDUSTRIAL PRACTICES

This section presents case . studies of several companies that implemented
conservation and recycling programs. i .



PROCESS CHARACTERIZATION

The first step in reducing use and emission of
ozone-depleting chemicals is identifying them in
your processes. CFC-113 and MCF are marketed
as cleaning Solvents under a variety of names and
labels. ‘They. are also found in smaller concen-

trations in a variety of mixtures. The following is _
@ partial list of these solvents by their trade names,

and the companies that manufacture them:

; CFC-13

Trade Name Manufacturer
Algofrane 113 Montecatini
Arklone P Ici
Assahifron 113 Asahi Glass
‘Daiflon 113 “- Daikin
Daifion S3 Daikin
Flugen 113 Atochem
Freon PCA DuPont
Freon TMS (94%) DuPont
Freon 113 DuPont
Freon TF " DuPont
Frigen 113 Hoechst
_-Frigen 113A Hoechst

* .” Frigen TR Hoechst
Genetron 113. Allied Signal
Genesolv D Allied Signal

Nomenclature/Chemical Names
1,1,2-Trifluorotrichioroethane
R113
F113

Methyl Chloroform: :
» ‘Trade Name ’
Genklene
Propaklone
Aecrothene TT
Chlorothene SM
Dowclene EC
Dowclene LS
Proact

Prelete
_ Solvent 1,1,1

1.1,1-Trichloroethane
. MCF
_TCA

enclosing them can reduce emissions from 50 to 80.

"Sources of Potential
' Savings —

There are five steps involved in reducing emission
_ Of solvents. Incorporating these five steps in your
evaluation process will significantly reduce
emissions. ‘The savings associated with each step
_ can vary widely; a representative range is presented

| im the discussion below.

"These five steps can be summarized'as the
following actions: . .

Eliminate

Isolate
Automate
Educate

Maintain. |

Eliminate. Eliminating solvents results in a 100
Percent reduction in emissions. The first step in
reducing the use and emission of solvents is to’
‘assess the need to employ solvent cleaning at each
. existing stage in the ‘manufacturing process.
‘Redundant or unnecessary cleaning of parts is
‘common in manufacturing systems. Any Stage in
‘@ process where cleaning can be ¢liminated will
automatically reduce emission of the chemicals,
while saving money. i : .
If parts are cleaned a umber of times before final
assembly, consolidation (or centralizing) of
cleaning processes and equipment will reduce
unnecessary steps in the manufacturing process. It
also concentrates activities to fewer machines ~ an
advantage in both maintenance and operating
costs. :

Isolate. Isolating open sources of emission and



41

ADVANTAGES

There are a number of compelling reasons to
‘conserve and recycle CFC-113 and MCF solvents.

degreasers has been . important to reducing
occupational exposure and. minimizing solvent’
losses. With the added incentive of protecting the

_Stratospheric. ozone layer and mitigating the .

greenhouse effect, it is now imperative that your
company reduce emissions of these chemicals
through conservation and recycling.

Solvent conservation and recycling
protects worker health and Protects
, the local environment.

Solvent conservation and recycling
improves operating practices.

Understanding and controlling
emissions of cleaning solvents
, Supports’ the optimization of -
manufacturing processes.
Reducing waste streams and chemical
losses during operation saves money
and can help your company comply.
with environmental requirements.

In all bot the most efficient systems, vapor
ing and cold cleaning systems emit

relatively high amounts of solvents when compared -

to solvent emissions when proper engineering
controls are implemented. Exhibit 4 shows typical

emission factors in industrial practices. The results .

are based on a standard load, keeping variables
such as thermal mass. constant for the different

« operating settings. .

In Exhibit 4, "base" represents the minimal amount
of solvent emissions from a process unit that is

emissions from vapor .

CONSERVATION AND RECYCLING

idling with its cover on. The amount of solvent

loss during this idling period is arbitrarily given an

, emission factor of 1.0.

.. "Good" Tepresents solvent loss rates for a properly
' operated unit with a representative load. The
- generat procedure is a 30-second vapor rinse, 30-
{ second ultrasonic immersion, 60-second vapor dry,
: and a 30-second residence in the freeboard zone .

(just above the vapor zone but still within the

" eooling coils). This emission factor represents a
< high level of conservation of emissions through ‘

strict adherence to proper procedure.

: "Poor" represents solvent loss rates when some
» common shortcuts are taken in violation of “good”

procedure. For example, when no freeboard
residence is used andthe vapor dry is reduced
from 60 seconds to 30 seconds. As shown in

: Exhibit 4, these seemingly minor violations in
procedure dramatically increase emissions by a
, | factor of five compared to the “Base” case.

“Industry” represents a value that is representative
of what is commonly found in industry. This value
| incorporates losses associated with liquid dragout, _
_ Grafts, rapid entranc: and exit speeds, uncontrolled
| sprays, and other procedural violations. This case
i Tepresents an increase in emissions by a factor of

eight compared to the . “Base” case. This

: Consumption level. is generally found in high
.. production situations where throughput iss

emphasized over solvent savings.

Identifying the sources of emissions is the first step
in reducing emissions. In our discussions of the .
various technologies, we examine specific sources
of emissions and cite actions which will help to
reduce these losses. :





Excise Tax

Congress has also placed an excise tax on ozone-
depleting chemicals manufactured or imported for
use in the United States. This tax provides a

further incentive to use alternatives and substitutes -
to CFC-113 and MCF. The tax amounts are based _

on each solvent’s ozone depleting potential.

Tax Amount
Calendar Year

——Per Pound _
CFC-113 MCF

1991 $1096  $0.137
1992 $1336 $0.167
1993 $2120 $0265
1994 _ $2120 $0.265
1995 $2.480' $0310

The tax will increase by $0.310 per pound
for CFC-113 and $0.045 per pound
MCF each year after 1995. .

Other International Phaseout
Schedules

European Community Directive _

Under the Single European Act of 1987, the twelve

members of the European Community (EC) are
now subject to various environmental directives.

The members of the EC are Belgium, Denmark,

Germany, France, Greece, Great Britain, Ireland, ©

Italy, Luxembourg, the Netherlands, Portugal, and
Spain. Council Regulation number 594/91 of
March 4, 1991 provides regulatory provisions for
the production of substances that deplete the
ozone layer. The EC phaseout schedule for CFC-
113 production is more stringent than the
Montreal Protocol. It calls for a 50 percent
reduction of CFC-113 by the end of 1993, a 67.5
percent reduction by the end of 1995, an 85
percent reduction by the end of 1996, and
complete phaseout by June 30, 1997. For MCF,
the production phaseout schedule is as follows: 30

percent reduction by the end of 1995, 70 percent
by the end of 2000, and a complete phaseout by
the end of 2004. While all members must abide by.
these dates, Council Regulation number 3322/88 of
October 31, 1988 states that EC members may take
even more extensive measures to protect the ozone
layer. :

Other Legistation,

Several other countries have adopted legislation
that is more stringent than the terms of the
Montreal Protocol. Environment Canada, ‘the
federal environmental agency responsible for
environmental. protection in Canada, also has a
reduction program in place that is more stringent
than the Montreal Protocol. All production and
import of CFCs, for use in Canada, must be
eliminated by no later than 1997. Environment -
Canada has also announced 2 series of target dates
for the phaseout of CFCs in specific end uses. For
solvent cleaning applications, such as metal and
precision cleaning, it mandates a phaseout of CFC-
113. by the end of .1994,. Pending’ final
consultations with end-users and producers. of
MCF, the target date for the phaseout of MCF will
be 2000. .

, Japan has ratified the revised Montreal Protocol.

The recent Ozone Layer Protection Act gives the
Ministry of International Trade. and Industry ~
(MITI) the authorization to promulgate ordinances
governing the use of ozone-depleting compounds.
MITI and the Environmental Agency have -
established the ‘Guidelines for Discharge
Reduction and Use Rationalization." Based upon
these guidelines, various government agencies
provide administrative guidance and advice to the
industries under their respective jurisdictions.
Specifically, MITI, the ministry overseeing several
aspects of Japanese industry including the .
production and trade of controlled’ substances,
Prepares and distributes manuals, and encourages
industry to reduce ozone-depleting compounds
consumption through economic measures such as -
tax incentives to promote the use of equipment to
recover and reuse solvents.

_The EFTA (European Free Trade Agreement)

countries (ie., Austria, Finland, Iceland, Norway,
Sweden, and Switzerland) have each adopted
measures to completely phaseout fully

ozone-depleting compounds. Some of the EFTA



7 7 ees

means of creating, gathering, and distributing

information on alternatives.

One example of ICOLP's. activities is the
development and support of an alternative
technologies electronic database “OZONET."
OZONET is accessible worldwide and has relevant
information on the alternatives to ozone-depleting
solvents. OZONET not only contains technical
publications, conference papers, and reports on the
most recent developments of alternatives to the .
current uses of ozone-depleting solvents, but it also
contains: .

« Information on the health, safety and .
environmental effects of alternative chemicals ‘

and processes;

. Information supplied by companies developing
alternative chemicals and technologies;

© Names, addresses, and telephone numbers for
technical experts, government contacts,
institutions and associations, and other key \
contributors to the selection of alternatives; :

« Dates and places of forthcoming ‘conferences,
seminars, and workshops;

© Legislation that has been enacted or is in place
internationally, nationally, and locally.

Information about ICOLP can be obtained from:

Mr. Steven B. Hellem
Executive Director

ICOLP

1440 New York Avenue, N.W.
Suite 300

‘Washington, D.C. 20005

Tel: (202) 737-1419

Fax: (202) 639-8685



65.

-CASE STUDY #6:
SOLVENT CONSERVA-
TION AND RECYCLING

Case Study #6 presents a solvent conservation and
recycling project undertaken at Royal. Ordnance
Blackbtimn, United Kingdom. Royal Ordnance
Blackburn was originally established to produce
artillery fuzes, and continues to do so today
although these are now electronic based as distinct
from being purely mechanical. Additional
expansion and diversification over the years into

electronic control and communication systems of .

various kinds has seen the work pattern

but essentially Royal Ordnance Blackburn still
manufactures large numbers of small precision
engineered components in brass, steel, “and
aluminum.

, Royal Ordnance Blackburn's usage of CFO: is of
three types:

* De-fluxing of printed circuit boards;
* Precision cleaning of assemblies/sub-assemblies;
and

‘© Stain-free drying of components after

processing.

: In order to meet the requirements of the Montreal
Protocol, a program of control and récycling was
introduced. This program included surveying the
usage of CFCs, and how individual plants operated.
This survey showed that in some instances CFCs
were being used (often in- open containers) for
general cleaning purposes when other solvents

would have been more appropriate. Some working -

Practices were also identified as being wasteful-of
solvent. An in-house training program which
explained the problem and consequences of ozone
layer destruction was instituted. This program was
aimed at all levels of shop-floor staff. As a result
of this program, a reduction in usage of CFCs
coupied with improved methods of. ‘working were
achieved.

A second phase was to ‘examine reoycling of

solvents for reuse in the factory. All departments
were required to drum their waste solvents

separately and return them to.a central collection
point, correctly identified and labelled. A solvent
' distillation plant was purchased and installed. The
‘plant was designed to meet all present and ~

_ foreseeable safety and. legislative requirements and

was to be capable of re-distilling most solvents
‘used in the factory, ¢.g.,, trichloroethylene; in
addition to CFCs. The’ plant, including some
| Necessary conversion work on the building housing
the plant cost some U.S. $79,500. The solvent
. feclaimed over approximately six months indicates
that the plant will pay for itself in 12-15 months.
| The plant is capable of distilling up to 500 liters
per hour, depending on the solvent and operating
: parameters. Ithas considerable spare capacity, and .
is capable of meeting all future requirements. The

‘quality .of solvent obtained from the distillation
‘process is of an acceptable quality for normal



’ Exhibit 21

EMISSIONS REDUCTIONS:
PROBLEMS AND SOLUTIONS CHECKLIST

Possible Problems - Possible Solutions

Improper degreaser placement Cleaning system should be placed to avoid cross
. drafts from open doors, windows, fans, and air
conditioning vents. If possible, enclose the unit.

Remove or reduce dedicated vents.

Degreasers should be covered when not in use. A
tight sliding cover, is best. A rolling cover is |
acceptable.

Clean-out doors, piping, pumps, and filter housings
should be checked weekly for leaks.

Chiller package should be maintained regularly.
Spraying above the vapor zone Spraying should always be. conducted at least 6
: + inches below the vapor line. Sprays should be

Excessive solvent dragout , Work should be oriented and rotated to allow
maximum solvent drainage.

Immersion and withdrawal rates should be less
than 10'fpm for open top units. -

Speeds should be approximately 3-5 fpm
for in-line belt units. :

Work should remain in vapor zone ‘until
condensation stops.

Product is too large for machine ‘The area of the basket or work load should not
exceed 50 percent of the area of the boil sump.

‘The. mass (weight) of the workload processes
should not exceed the machine's rated capacity.



vi 1
: Table of Contents (Continued)
Maintenance .......2eeeeeeeeceeeeeenee
Superheated Vapor Drying .<.----+----
Start-Up and Shut-Down Procedures .....-.+-++¢+++++ ;
Idle Time Management ......-...secee eee eeee ccc eeeenccceee 3B
Cold Cleaning ve cceeeccccesceceeeeesesensesaseterenes ceeee ee 39
Cleaning Methods and Emission Reduction cen eeenee ateceweecees 39
Other Control Technologies ......-
Carbon Adsorption .......-
MCF and Carbon Adsorption
Air Stripping ....... sees
Thermal Destruction sence
Recap of the Manual ........---- be ecececeeeseeeceees vevepeeees ee
Case Studies of Industrial Fractices........--.----e0--e05 cece eeececeeeees ID
Case Study #1 - CFC Reduction/Elimination in Electronics Cleaning, ....... 55
Case Study #2 - Using Industrial Hygiene Techniques to Monitor
and Reduce Solvent Losses ....-..-+-eeseeeecceee se ececeeceeeee ee ID
Case Study #3 - Solvent Equipment Selection - A Case Study of Errors - 60
Case Study #4 - Emissions Monitoring and Reduction .....------ . - 62
Case Study #5 - History of Equipment Upgrades ......- seeeeee : -. 63
, Case Study #6 - Solvent Conservation and Recycling ..-.-.-- ra >)
References .......ee cece cere eeeeees scene cece cence ence ee eeteeees cee 67
List of Solvent Recyclers and Equipment Manufacturers Leveeeeeee eewcees ‘wees 69

Appendix A - Industry Cooperative for Ozone Layer Protection Weedeeeeten seeee 77



SOLVENT LOSSES IN A TYPICAL PRINTED WIRING
- ASSEMBLY PLANT

I ‘3% 1
| Spllis, Leaks Recycle

: : 15% Evaporative Losses
: ‘Hand :
= Cleani .
_ 1% vsanne .
' Leaks .

Source: Northem Telecom ue ; : : renee



_ Exhibit 22 — ;
SOLVENT USAGE REDUCTION PROGRAM

THOUSANDS

140 . — aEEeanmeemen! ——

SOLVENT USE IN Ibs

YEARS

Source: Digital Equipment Corp. . : . . ° Frece-11



CASE STUDY #2:.
USING INDUSTRIAL.
HYGIENE TECHNIQUES
TO MONITOR: AND :
~REDUCE SOLVENT
LOSSES

Case Study #2 shows how monitoring solvent —

emissions can identify ways to reduce solvent
consumption and protect worker health

A Problem with Excessive
Emissions

‘At Honeywell a MCF vapor degreaser was losing
large quantities of solvent and employees were
complaining about strong solvent odors. The
_ Gegreaser is an open top degreaser with no hoist.
The maintenance departments showed through
inspection of the heat and.cooling systems that all
systems were operating properly. within the
designated temperatures | ‘and there were no
identifiable leaks. :

Taking Action to Solve the
Problem

- Ar. investigation was as completed by the Industrial

_ Hygiene staff to identify employee, solvent
exposures. During the investigation, air samples

Steady

Air Conditioning on
Elevator Door Open
-Partitioning in Place -

were collected in operator breathing zones with

length-of-stain calorimetric . detection _ tubes.
Readings were found to vary greatly between 50
and 300 ppm MCF. The current threshold limit
value is 350 ppm. Further monitoring found a
correlation between air monitoring results and air
conditioner and elevator operations. Smoke
‘testing. of air ‘currents’ and vapor blanket

..disturbances indicated that’ increased velocities

across the top of the vapor degreaser, caused by air
conditioning and elevator shaft drafts, broke down
‘the vapor blanket. Detector tube readings in
stable conditions were 50 ppm compared to
turbulent conditions of 300 ppm solvent. .

‘Partitioning. the work -area stopped air currents
from passing across the vapor degreaser. To allow
some air movement and reduce the chance of
vapor buildup in the work area, the partitioning

did not extend to the ceiling. Follow-up personal

‘monitoring of the operon confirmed these levels.

Results

‘Worker exposures and solvent losses were reduced

greatly, An immediate reduction in work area

concentration was achieved with solvent levels

Gropping to. between 25 and SO ppm MCF.

\Improvements from the program are presented in

‘the table below. The overall solvent losses were:

reduced by 75 percent. This easy-to-perform

monitoring can be completed at a.cost of less ‘than .
$100 per investigation and an initial equipment —
‘investment of approximately $300. In this case
Study, the value of the MCF saved in one month

‘exceeds the $300 investment in equipment, and

|contributed to employee satisfaction. .
I



—

CASE STUDY #3:
SOLVENT EQUIPMENT ~
SELECTION -A =
CASE STUDY OF
ERRORS

Case Study #3 illustrates errors that can be

avoided during planning and implementation of 2

CEC reduction program.

‘With the growing concerns associated with CFC
solvent usage, Northern Telecom, a large,

multinational supplier of telecommunications _

electronics, began an aggressive campaign to
climinate the materials. While the conservation
portion of this program was successful in reducing
CFC emissions by about 50 percent, there are
lessons from the experiences that will help others
avoid investment mistakes.

Errors resulted in several areas:
Ineffective use of an automated hoist
Poor education of operators ©

Incorrect equipment selection

Improper equipment operations

Poor control over use and handling of
solvents.

Norther Telecom was using CFC-113 in an open-

top batch cleaner for cleaning printed circuit board
assemblies. The open-top unit had the following

specifications:

« At 50 percent utilization, the unit cleaned
30,000 square feet of boards;

« The unit consumed 80 gallons of solvent per
month;

Energy costs were insignificant;

«Labor costs-were $12,500/yr;

© Total operating costs (labor + ‘solvent) was
$45,000/yr.

Shortly after ‘the open-top unit was, installed, an
automatic hoist was added for better process
control and to conserve solvent. However, the
hoist system was removed within six months of
installation because operators complained of

_ inefficiencies associated with its use. Failure to.

utilize the hoist. represented management's
reluctance to support a conservation process that
would have: reduced solvent use, Operators had
not been educated about the importance of solvent
conservation. .

- After two years of. operation, Northern Telecom

introduced a new product line. As part of this
product line, the company it
solvent cleaning machine. The batch cleaner was

._ replaced by an in-line cleaner and still. The in-line

system was being used in other high volume
corporate facilities, and was therefore was assumed

" to be appropriate.

‘The operating characteristics Of the in-line unit”

_ © Capital costs $90,000 (with still);

Capacity of 200 gallons of solvent,

© At idle the unit consumed 0.75 Ibs of solvent,
‘ per hour, .

. Operating at 4 fpm, the unit consumed 143
Ibs/hr of solvent; a

_ Average production was near 36,000 square feet

_Of product per years

. ‘Average solvent use was 3 to 4 barrels per
month. Solvent costs were $78,000 per year,

© The unit required a part-time operator (25
percent of the time), even though at the time of
it was assumed to need no operator.

Labor costs were $6,250 per year; .

e Annual utility costs were $25,000,

° Total operating costs (labor, utilities, and
’ solvent): $109,250/yr, or over $3.00/board.



Exhibit 6(a)

AN EXAMPLE OF A PRINTED CIRCUIT BOARD
_ CLEANING EQUIPMENT PROFILE

4, Identification
‘Equipment Name:
Model Number:
Manufacturer:
‘Year Purchased: -
‘Trade Name of

Chemicals Used:

Annual Quantity of CFC or MCF
Purchased for Use in this
Equipment (specify units):

Annual Quantity of CFC or MCE Waste
Requiring Disposal or Off-site
Recycling:

“Annual Board Production
(specify units):

Average Board Area:
(specify units):
Check appropriate blanks:
Single sided
Malulyered |
ul
Number of layers

Average Number of Solder
Connections per Board:

C. Emission Controls
Do you practice the following? If you do, briefly describe the procedures:
Leak Testing: _
Alternate Testing Methods: .
On-site Recovery/Recycling:
Improved Loss Control Procedures:
Operator Awareness/Guidelines:

Source: U.S. EPA 1990



a

70

Hydrocarbon Recyclers . Industrial Solvents & Chemical

5354-West 46th Street South . : P.O. Box'158
P.O. Box 9557 Emigsville, PA 17318
‘Tulsa, OK 74157 ; . (717) 938-4621
(918) 446-7434 : .
International Solvent Corporation KDM Company .
$800 190th Street . . 4303 Profit Drive
Surrey, Vancouver, CN V3T 4W2 . San Antonio, TX 78219
(604) 888-4653 (512) 333-4011
‘Liberty Solvents and Chemical M & J Solvents Company
9429 Ravena Road . 1577 Marietta Road, N.W.
‘Twinsburg, OH 44087 P.O. Box 19703 .
(216) 425-4484 : Atlanta, GA 30325
; (404) 355-8240”
Marisol, Inc. : Michigan Recovery Systems -
125 Factory Lane” 36345 Van Born Road
Middlesex, NJ 08846 . , Romulus, MI 41874
(201) 469-5100 (B13) 326-3100
Milsolv Company North East Chemical Corporation
P.O. Box 444 3645 Warrensville Center Road
Butler, WI 53007 Cleveland, OH 44122 .
(414) 252-3550 (216) 961-8618
Nortry, Inc. - * Qil and Solvent Process Company
515 Lycaste ‘ ' : P.O. Box 907
Detroit, MI 48214 | Azusa, CA 91702
(313) 824-5850 | (818) 334-5117
Omega Recovery Services . Pride Solvents & Chemical Company
12504 East Whittier Blvd. ’ 88 Lamar Street
Whittier, CA 90602 ‘Wast Babylon, NY: 11704
(213) 698-0991 : (516) 643-4800 :
Prillaman Chemical Corporation . Reclaimed Energy Company, Inc.
P.O. Box 4024 P.O. Box 418111
Martinsville, VA 24112 , Indianapolis, IN 46241 -
(713) 638-8829 (317) 241-9021
Rho-Chem Corporation Rinchem Company
425 Isis Avenue 4115 West Turney Avenue
Inglewood, CA 90301 ’ Phoenix, AZ 85019
(213) 776-6233 (602) 233-2000
Romic Chemical Corporation * Safety Kleen Corporation’
2081 Bay Road . 777 Big Timber Road
Palo Alto, CA 94303 Elgin, IL 60120

(415) 324-1638 (B12) 697-8460



Disclaimer

The US. Environmental Protection Agency (EPA), the Industry Cooperative for Ozone Layer :
Protection (ICOLP), the ICOLP committee members, and the companies that employ the
ICOLP committee members do not endorse the cleaning performance, worker safety, or
environmental. acceptability of any of the technical options discussed. Every cleaning
operation requires consideration of worker safety.and proper disposal of contaminants and
waste products generated from cleaning processes. Moreover, as work continues, including
additional toxicity testing and evaluation under Section 612 (Safe Alternatives Policy) of the
Clean Air Act Amendments of 1900 and elsewhere, more information on the health,
environmental and safety effects of alternatives will become available for. use in selecting
among alternatives discussed in this document. i

EPA and ICOLP, in furnishing or distributing this information, do not make any warranty
or representation, ¢ither express or implied, with respect to its accuracy, completeness or
utility; nor do EPA and ICOLP assume any liability of any kind whatsoever resulting from

- the use of,'or reliance upon, any: information, material, or procedure contained herein,
including but not limited to any claims regarding health, safety, environmental effects or fate,
efficacy, or performance, made by the source of thé information. :

Mention of any company or product in this document is for informational Purposes only, and _
does not constitute a recommendation of any such company or product, either express or
implied by EPA, ICOLP, ICOLP committee members, or the companies that employ the
ICOLP committee members. fy Cos

4





. 2 oF

- countries have Sector-specific interim phaseout

dates for certain solvent uses. Norway and Sweden.

will phaseout their use of CFC-113. in all
applications except textile dry cleaning by Juty 1
and January 1, 1991, Tespectively. Furthermore,
Austria will phaseout CFC-113 in some solvent
cleaning applications by January 1, 1992 and 1994.
Austria, Finland, Norway, and- Sweden will
completely. phaseout their use of CFC-113 in all
applications by January 1, 1995. Sweden also plans
an aggressive phaseout date of 1995 for MCF.

" Cooperative Efforts

‘The U.S. Environmental Protection Agency (EPA)

has been working with industry to disseminate
information on technically feasible, cost effective,
and environmentally sound alternatives for ozone-
depleting substances. As part of this effort, the
US. EPA is working with the Industry Cooperative
for Ozone Layer Protection (ICOLP*) to prepare
@ Series of manuals to provide technical infor-
mation on alternatives to CFC-113 and MCF.. The
manuals are based on actual industrial

that will serve as a guide to users of CFC-113 and
MCF worldwide. These manuals will be updated

. periodically as technical developments occur.

The first manuals in the series are:

"Conservation and Recycling Practices for CFC-
113 and Methyl Chloroform.

. © Aqueous and Semi-Aqueous Alternatives 19
CFC-113 and Methyl Chloroform Cleaning of
Printed Circuit Board Assemblies. :

* Inert Gas Soldering/Low ‘Residue Flux and
“. Paste Alternatives to. CFC-113 and Methyl
Chloroform.

* Alternatives for CFC-113 and Methyl Chloro-
’ form in Metal Cleaning.

. Eliminating CFC-113 and Methyl Chloroform in

Precision Cleaning Operations.

* Appendix A presents more detailed information
about ICOLP. © .

e Riveting Without ores and Methyl Chioro- -

form. .
This particular manual presents a sa simple sirictured
to help you reduce use and emissions of
CFC-113 and/or MCF. The manual:

(© Guides you through a characierzation of your
existing process; .

‘e Helps you identity sources of emissions from
| your process;

‘© Outlines the selection criteria for appropriate
conservation and recycling measures for your

« Introduces several Conservation and recycling
|. technologies;

Presents detailed case studies of solvent
conservation and recycling measures.

‘The conservation measures for CFC-113 and McF
cleaning will help to reduce losses from:

¢ Convection and diffusion
‘© Dragout

° Maintenance

° Miscellaneous ‘sources.
This manual will be helpful to all users of CFC-

113 and MCF in solvent cleaning. However, the.
success of your CFC-113 and MCF reduction

‘strategies will depend upon how effectively you can -

coordinate your conservation and

h recycling
. ‘programs. The reduction of CFC-113 and MCF in,

‘solvent cleaning presents a demanding challenge
‘for your organization. The rewards for success are
the contribution to global environmental

- protection and the increase in your company’s

industrial efficiency.
; i



Oter International Phase Sihedics eee eceee see e eee ec ccc ceeeee es 6
Cooperative Efforts ......... 0.20.0 ,

iy

Structure of the Manual... 2.20 2e20sceseteeeeeeseteeatseseeeaenees 0 9

Conservation and Recycling Advantage - ‘eae

weeeeee weet teteteeeeeeeeee HT

Sources of Potential Savings ....... :
' Extent of Usage ....... .. . :
Solvent Loss Mechanisms ...........

Measurement and Monitoring .......

Recap on Program to this Point ..........:...¢...

. Conservation Practices and Strategies. .

_Best Practices in Operation

Operator Training Curriculum . Sales cccecccces
Handling Practices for CFC-113 and MCF sa vees
. Pumping Practices ......5.5.. .

Equipment Strategies nan seen ees,

Batch Cleaning Operating Practices... .i.....
Process Description see
Superheated Vapor Drying - See e nee e eee eeceeeeeee
Dragout ......0.......0. eats eee
Maintenance .............

~. Piston Effect ..........
Vapor Blanket Collapse . :
" Programmable Hoists ......... cence
Start-Up and Shut-Down Procedures
Idle Time Management . .



‘Vara International, Inc.
1201 19th Place

‘Vero Beach, FL 32690
(407) 567-1320

v2
Phillips Manufacturing Company : Rekuperator KG . :
7334 North Clark Street , Dr Ing Schack & Co. . -
Chicago, TL 60626 Sternstrasse 9-11 . -
(G12) 338-6200 Postfach 320960 fe

D-4000 Dusseldorf 1 ©

Germany

* Tel: 0211-490055

Telex: 8584894
Rotamil Maschinenbar GmbH Sutcliffe Croftshaw Limited
Postfach 12053 . _Neills Road

«5900 Siegen Bold

Eisenhuttenstrasse 26 ” St. Helens .
0271 6711 Merseyside WAS 4TH
Germany England -
Telex: 872352 Tel: 0744-810107
Sutcliffe Croftshaw Limited Vic Manufacturing Company.
P.O. Box 2526 1620 Central Avenue, N.E.
Columbus, OH 43216 Minneapolis, MN 55413
Tel: (614) 258-9501 (612) 781-6601

Equipment Suppliers - Vapor Degreasing Equipment

Baron-Blakeslee, Inc.
2001 North Janice Avenue
Melrose Park, IL 60160
(312) 450-3900

Corpane Industries
10106 Bluegrass Parkway
Louisville, KY 40299
(502) 491-4433

Delta Industries

8137 Allport Avenue

Santa Fe Springs, CA 90670
(213) 945-1067

Electrovert Corp.
4330 Beltway Place
Suite 350

Arlington, TX 76017
(817) 468-5171

Branson Ultrasonics Corporation

Eagle Road

Danbury, CT 06484

(203) 769-0400

Crest, Ultrasonics Corporation
Scotch Road - Mercer County Airport
P.O. Box 7266

Trenton, NJ 08628

(609) 883-4000

Detrex Corporation
it Division —
P.O. Box 5111
Southfield, MI 48086-5111

G13) 358-5800. - !
~ Finishing Equipment, inc:

3640 Kennebec Drive

St. Paul, MN 55122

(612) 452-1860,



ve

Glossary,

: oa
Carbon Adsorption — A recovery process that captures solvent vapors from air on activated carbon. The .'
solvent is recovered (by desorption) from the carbon by injecting stcam into the carbon bed and condensing .
the resultant solvent and water vapor.

CFC — An abbreviation for chiorofluorncarbon. : Tos i

Chiorofiuorocarbon — An organic chemical composed of. chlorine, fluorine and carbon atoms, usually
characterized by high stability contributing to a high ODP.

Condensate -- ~ Liquid solvent resulting from cooling solvent “apors. It is the clean solvent that condenses on
the cooling coils of a vapor degreaser or still. ;

; Desiccant Dryer —- {A means of femoving water from a solvent by adsorption with desiccant sich a sta :
gel or molecular sieve. ' . i

’ Desorption — — The process of regenernting «carbon adsorption unit by treating the carbon with steam to
rTemave the adsorbed solvent. :

Distillation — ~ A proces of puriying solvent by boiling condensing the vapor and collecting the condensate.

Dragoat = Solent that i cased out of wapor degreasing operations: ligud tapped in or onthe pan
being processed, and a micro-layer of solvent on part surfaces.

Freeboard — ~ Distance from the top of the vapor level tothe 1 of the degreasing tank.

Freeboard Ratio —- The ratio ‘of freeboard height to width of the machine opening. It should be between 75
and 1.0 for reduced emissions. — . i

t

t Greenhouse Effect ~ A thermodynamic effect whereby energy absorbed at the earth's surface, which is
normally able to radiate back out to space in the form of long-wave infrared radiation, is retained by gases in
the atmosphere, causing a rise in temperature. The gases in question are partially natural, but manmade
pollution is thought to increasingly contribute to the effect. The same CFCs that cause ozone depletion are
known to be “greenhouse gases," witha single CFC molecule having the same estimated effect as 10,U00 carbon
dioxide molecules.

Halogenated Solvents -- Liquid substances that contain carbon, halogen or carbon tiydrogen, and halogen (such

- as fluorine or chlorine) atoms. In this text, the term refers to the commercial solvents, methylene chloride,

perchloroethyicne, 1,1,1-trichloroethane (MCF), trichloroethylene, and trichlorotrifluoroethane (CPO-S). .

“Halons -- Fire-extinguishing agents with high ODPs. Y m
HCFC — An abbreviation for hydrochlorofluorocarbon.

HFC — An abbreviation for hydrofluorocarbon. i

ODP -- An abbreviation for ozone depletion potential. |

i a 1, .
Ozone -- A gas formed when oxygen is ionized by, for example, the. action of ultraviolet light or a strong <
electric field. It has the property of blocking the passage of dangerous wavelengths of ultraviolet light.
Whereas it is a desirable gas in the Stratosphere, it is toxic to living organisms at ground level (see volatile

organic compound). i



a oe en)

: ‘The three main sources of emissions are: :

¢ Diffusive and convective losses , of
solvent vapor from the equipment;

_ Leakage from the equipment and its:
associated piping; ~

" Liquid and vapor dragout on the work
being processed. :

Economic Benefits

The. U.S. tax on CFCs and MCF, and product
shortages, will.continue to improve the economics
Of recycling and conservation. As production cuts
80 into effect and prices continue to rise, the
efficient use of solvents will. become more

profitable.
The elimination of waste streams in a

manufacturing process increases the efficiency of .

the process and réduces costs associated with
complying with state and local regulations on
hazardous waste minimization and auditing
requirements. Reclaiming and recycling solvents is
,One way to reduce both waste streams and the
virgin use of expensive ozone-depleting solvents.

- It is important, however, to avoid mixing solvents
in the recovery process. The quality of recovered
solvents should be examined for sukability for
intended future uses. ©

Solvent recycling can occur both on-site and off-
site. While the magnitude of on-site recycling is
difficult to quantify, it has been a significant

it in the increased solvent efficiencies
that have been achieved in recent years. Over 100
‘off-site solvent recycling organizations exist in the
USS. and Europe. Over the last several years these
companies have proven that recycling is
economical for both themselves and those who use

solvents. As more companies perform solvent:

Tecovery, the recycling organizations are now

i to serve the needs of the industry. A
partial list of solvent recyclers appears at the end
of this manual. :

Older equipment is generally less efficient and
more likely to emit sdlvents than new equipment.

Recent improvements in machine designs address
: the main sources of emissions. Solvent losses can
be reduced either by replacing old machines with
: Mew equipment or retrofitting older machines with .
| improvements. A partial list of vendors of
| equipment appears at the end of this manual.

| Occupational Safety.and Health regulations which

- are in place in the U.S. and Europe also motivate

companies to reduce emissions of solvents.
| Permissible exposure: limits require companies 10
‘ monitor and contro! emission of certain solvents.



OD

 Unkad States Ne and : EPAM00/1-01017

eee
Conservation And Recycling

Practices For CFC-113 And
Methy! Chloroforn -

S(O

- | "Printed on Recycled Paper 7



76

Onone depletion -- Accelerated chemical destruction of the stratospheric ozone layer by the presence of
substances produced, for the most part, by. human activities. The most depleting species for the ozone layer
‘are the chlorine and bromine free radicals generated from felatively stable chlorinated, fluorinated, and
brominated products by ultraviolet radiation. . :

Ozone depletion potential -- A relative index indicating the extent to which a chemical produ~. ‘may cause |
ozone depletion. ‘The reference level of 1 is the potential of CFC-11 and CFC-12 to cause ozone depletion.
Ifa product has an ozone ‘depletion potential of 0:5, a given weight of the product in the atmosphere would,
in time, deplete half the ozone that the same weight of ‘CFC-11 would deplete. The ozone depletion potentials
are calculated from mathematical models which take into account factors such as the stability of the product,
the rate of diffusion, the quantity of depleting atoms per molecule, and the effect of ultraviolet light and other
radiation on the molecules. . .

Oxone Layer — A layer in the stratosphere, at an altitude of approximately 10-50 km, where a relatively strong
concentration of ozone shields the earth from excessive ultraviolet tadiation. .
Piston Effect Displacement of solvent vapors due to entry and exit of basket or part that is too large.
Refrigerated Freeboard Device — A low-temperature heat exchange coil located in the degreaser freeboard
zone, immediately above the water-cooled condensers. ‘The freeboard chiller lowers the partial pressure of the
solvent in the freeboard zone which results in a reduction in the solvent diffusion rate. , .

‘Shock Load — A large part or load of parts which cause the solvent vapor level to drop substantially below
the normal operating level. . 7 tO

Steam Distillation -- The practice of injecting steam directly into the still after normal distillation has ceased
to recover more solvent from the residue. ‘

Stl — A unit employed to purify solvent by distillation. .

‘Vapor Line -- The line or level of the solvent vapor-air interface in the vapor degreasing unit.

Volatile organic compound (VOC) — These are constituents that will evaporate at their temperature of use
and which, by a photochemical reaction, will cause atmospheric oxygen to be converted into potential smog-
promoting tropospheric ozone under favorable climatic conditions. | _
Water Separator — A device designed to remove water from the solvent by flotation,

‘Work Capacity ~The load a degreaser is designed to process efficiently while maintaining a steady vapor level



; Exhibit 13 a:
IN - LINE CLEANING SYSTEM

| Degreased
—_ Part
f Condensing
Board Coil
—_f[ Water
Jacket

\ aa vent
Boiling Sump _/ Heat Solvent Spray

Source: Halogenated Solvents Industry Alliance Frees |





Exhibit 1.
Exhibit 2
Exhibit 3 -

Exhibit 4

Exhibit 5.
Exhibit 6(a)

Exhibit 6(b)
_ Exhibit 7
Exhibit 8
Exhibit 9
Exhibit 10
Exhibit 11
Exhibit 12
Exhibit 13
Exhibit 14
Exhibit 15 .

Exhibit 16
‘Exhibit 17
Exhibit 18
Exhibit 19
Exhibit 20
Exhibit 21
Exhibit 22
Exhibit 23

List of Exhibits

Montreal Protocol Participants ................. se ee swears seeeee l
Corporate Policies on CFC-113 Reduction Schedule wee e cece eee cene 2
Phaseout Dates for CFC-113 and Methyl Chloroform Under the -

US. Clean Air Act and the Montreal Protocol ........... 0000000 1 4

Relative Solvent Emissions From: _ Representative Industrial
Situations .......... 0. cece eee cence
CFC-113 and Methyl: Chloroform Usage Profile .
An Example of a Printec Circuit Board-Cleaning Equipment

Profile .............4. See emcee cere c nec enecae ee eceaeee 18
An Example of a Metal Cleaning Equipment Profile. peeseceweccees 19

. Solvent Losses in a Typical Printed Wiring Assembly Plant ........:.. 21

Training Curriculum for Solvent Reduction Program ..... sees
Solvent Refill Procedure ........:... eae

Basic Vapor Degreaser-Batch Cleaning .......... be eee tees - 31
Schematic of Piston Effect ...... tee e eens act eeeceee sees 33
Schematic of Vapor Blanket Collapse ..... eveweepene - 33
In-Line Solvent Cleaning System .............0006 - 36
Orientation of Parts for Maximum Drainage wee eevee eneceecages 37
Factors Influencing the Decision to Recycle Solvent Wastes On-

ESS +. 41

Continuous Steam Stripping 6... 6) se eee eee reece eee eee - 43
Facility Considerations in Choosing an OFF Site Recycler sense eeees 44
Point-Of-Use Carbon Adsorption Process Schematic. ....... wee 46 -
Rotary Carbon Adsorption System ...:°. sence ase - 47
Thermal Destruction Flow Diagram... . rca deeee -« &
Emissions Reductions: Problems and Solutions Checklist seeeee -. 50

Solvent Usage Reduction Program ..............6. .. 57

Solvent Usage Profile for'a Conveyor Degreaser . reve eee eee eee 62. ;



_ RECAP OF THE MANUAL |

Previous sections of this manual have proviced information on:

Stratospheric ozone depletion and restrictions on the use of CFC-113 and MCF.

Steps to characterize a process to determine solvent use and emissions.

‘Conservation practices and strategies specific to batch cleaning, in-line cleaning, :

and cold cleaning.
Rationale for conserving and recycling solvents in cleaning processes.

¢ Reclamation and recycling systems and services.

A summary of problems and solutions for solvent emission is presented in Exhibit 21.



32

eee

Dragout

Dragout is primarily a function of the geometry of
the part being cleaned and the type of basket being
used. You can reduce dragout losses if the work
being cleaned is always positioned in baskets or on
hooks, racks, or conveyor belts to permit maximum
liquid drainage. Solvent trapped in pockets and
recesses results in excessive dragout ” losses.
Baskets containing a random fill of parts should be
rotated during cleaning to facilitate drainage.

If possible, hold the workload in the vapor zone
after the final cleaning step until its temperature
equals that of the vapor zone and vapor stops
condensing on the part. Work taken out earlier
will emerge wet with solvent condensate. Ten feet
per minute is an effective maximum speed for work
entering/leaving a degreaser in batch operations.

Dwell times — the time spent in the vapor zone —
that are too short are most often seen in open-top,
units where the work is manually moved in and out
of the unit. A freeboard dwell of the workpart just
above the vapor line is suggested until all solvent
on the workpart has flashed off. Automatic hoists

can help reduce excessive dragout due to

insufficient dwell time. They can also reduce the
piston effect and free the operator to perform
other tasks.

Maintenance

Solvent losses during maintenance are common
and can be remedied relatively easily. Training
maintenance personnel is critical." Although the
design of vapor degreaser units can vary greatly,
some problems are common to all systems.

Leakage losses are a reflection of the
quality of construction of the cleaning unit and of
the attention paid to its subsequent maintenance.

Pump seals deteriorate when not in contact with
solvent. A ‘running dry" condition erodes the seal
surface and the seal prematurely fails. Systems
should be equipped with gaskets that are suitable
for contact with the solvent and mechanical burden
they face. Note that CFC-113 and MCF may
require different materials.

‘The design and maintenance of cleaners and stills
requires special attention to the seals and gaskets
on covers, lids, and panels. High volume leaks

often occur around corners and joints. where two
seals meet. .

Equipment should be fabricated from materials
that are chemically compatible with the solvent
employed. Aluminum should never be used as a ”
material. of construction for storage and use
equipment with halogenated solvents. Type 300
stainless steels are the materials of
construction for vapor degreasers and defluxers
employing CFC-113 and MCF. They are also the
materials of construction for use with the

new HCFC solvents. It is difficult to obtain leak.

free joints in threaded stainless steel piping.
Welded or soldered joint piping with flanged

. connections for removal of accessories (pumps,

filters, dryers; etc.) is recommended to minimize,
leakages. .

Without an effective cooling system, more solvent
would escape, and these systems would evaporate
Gry. This is another maintenance area requirement.

When possible take advantage of services offered
by the machine manufacturers; they have
experience in fine tuning the cleaner to minimize
losses. You may wish to supplement this
assistance with services offered by solvent suppliers
who often have programs and information that can
heip operators manage the process better. ~

Piston Effect

‘The loss of solvent vapor can be decreased’ by

. avoiding the processing of workloads that exceed

the cleaning system's design capacities.

‘A workload that is too large in physical size can
displace vapor from the vapor degreaser by the
piston effect.” Such losses can be minimized by
making sure that the workload area is not greater
than SO percent of the horizontal cross-sectional
area of the sump into which it is being introduced.
You should also use baskets which minimize the
area of the workload i 7 to the surface
of the solvent baths (see Exhibit 11).

Proper placement of baffles to contain the vapor as
well as an increase in the freeboard ratio within
the tank reduces losses from the piston effect.



Kerry Ultrasonics, Ltd.

Hunting Gate, Wilbury Way; Hitchin
England .

Herts SG4 OTQ
Tel: 0462-50761-5
Fax: 0462-420712

Phillips Manufacturing
7334 North Clark Sireet
Chicago, IL 60626
12) 338-6200

ICI Chemical & Polymers Ltd.
P.O. Box 19
Runcorn

. Cheschire, WA7 «Lw

Tel: 0928 514444 !
Fax 0928 580742

Ohtsuka Technical Industry Co., Ltd
3-32 3 Chome, Kigawahigashi

 Yodogawa-Ku, Osaka, Japan
Tek: 096-304-7963.

Unique Industries
11544 Sheldon Street .

- Sun Valley; CA 91352.

(213) 875-3810

Equipment Suppliers ~ Montoring Equipment |

Foxboro Co. .

151 Woodward Ave.
Box 5449

S. Norwalk, CT 06856

’. Mine Safety Appliances
Box 427
Pittsburgh, PA 15230

12345 Starkey Rd.
Largo, FL 33543

Other Resources

Center for Emissions Control
1225 19th Street, N.W.-
-Suite 300

Washington, DC 20036

(202) 785-4374

Gastech
8445 Central Ave.
Newark, CA 94560

TIF , i
3661 NW 74 St.
Miami, FL 33147



‘the following two steps should be

followed for printed circuit: board ©
7 .

Determine total production of boards

in square meters of surface area for a

given time period (year, quarter,
month). Only measure. the area of

one side of the board regardless of
whether it is single sided, two sided,
or multiple layer in configuration and
regardless of whether any components
are mounted on it.

Divide total quantity of CFC-113 or -
MCF purchased by total manufactured

board area for the same period to

determine the ratio of pounds solvent

used per square feet of board

produced, expressed as Ibs/ft”.

In North American industry, this ratio is on the
order of 0.41 Ibs/ft? (2.0 kg/m?) for a production ,
facility operated with today’s technology and with
minimal attention to chemical handling.
Determine your use ratio before beginning your
conservation and elimination programs.

For metal cleaning, this ratio can be H
determined by the following step: .

e Divide total quantity of solvent
purchased by total units or weight of

parts cleaned for a given time period.

, Regardless of the cleaning process used, calculate ,

this ratio and report it on a. regular basis ~
monthly is recommended. ‘This step is important
because it enables you to monitor success as your
conservation. programs go into effect. It will also
stimulate your employees to take an interest and
participate in the drive to reduce solvent use.

Keep a log book for solvents used in each of your
machines. The log tracks the amount of solvent

._ success.

used and product cleaned and « gives you

information to compare machines. Log books will

add incentive and a feeling of ownership to
operators of the machines. - - os

At this point, you -have to make the following

decision: .

If you have. already reduced use by 75 percent,
you probably have good conservation practices
in place and will be ready to focus more time
and effort on exploring alternate processes and
technologies. ° .

If your usage has reduced by less than 75

percent of original, you can probably benefit
_ from additional conservation programs.

Next, do an assessment of where you are losing
solvents. Do this for the whole plant beginning
with the delivery of solvent. You may wish to

* develop a simple flow diagram as.in Exhibit 7.

This will give your project manager and your
technical staff an understanding of the areas to
focus on first. If you have more than one cleaning
machine, you should do an analysis of each, since
solvent losses may vary significantly from machine
to machine. :

With knowledge of solvent use and where losses
are occurring, you can now select the appropriate
conservation programs described in the next
section. ~ ‘

Solvent Loss Mechanisms

Losses from convection, diffusion, dragout,
maintenance, and spills occur in all solvent —
‘cleaning systems. Knowing-which losses are the
most significant in your operation and which can
most easily be reduced will help improve your

In a vapor degreaser, there is a layer of relatively
stagnant gas in the freeboard zone of the machine
that. is ‘sandwiched between the layer of 100
percent solvent vapor at the bottom of the
condenser and the layer of 100 percent air exiting
at the top lip of the machine.



37

Dragout -

Orientation of the part and part design plays a key
role in the volume of solvent dragged out of the
- cleaners. For example, in many instances in the
electronics industry, it has been found that solvent
adheres to the underside of components and

. collects in pools in connectors. This could be -

minimized through reorientation (see Exhibit 14).

Exhibis 14 7
ORIENTATION FOR
MAXIMUM DRAINAGE _

Reorientation can be as simple as changing the
method by which the parts are processed. ‘This
may require an intelligent controller interfaced
with a turntable located after the wave solder
machine. The turntable may require a faster cycle
time to reduce the adverse effects on production.
In a less sophisticated operation, the operator can
load the parts to optimize cleaning. _.

In optimizing the machine, examine the potential
for reducing the conveyor belt speed. This keeps
the board in the vapor zone longer for more
complete evaporation of solvent, thus reducing
dragout to a minimum. A recommended maximum
speed for work entering and leaving an open-top
cleaner is 3 meters/min (10 ft/min). For
conveyorized belt in-line systems,.consider 3 to 5

—

fmin conveyor speed. Higher throughput rates
can cause disturbances at the vapor/air interface
_ that resuit in high vapor losses.

Maintenance

UA bulk solvent handling system reduces solvent
“esses duc to drum handling, transferring to small
containers, and filling the cleaners. With
appropriate real time alarms, aan are alerted
to possible leak conditions by. monitoring
consumption or loss in each cleaner as solvent is

* supplied. Careful ‘visual inspection should _

supplement the use of alarm systems.

, Solvent is delivered by bulk tanker and is then

pumped into a bulk storage tank where it is held
until needed. The tank is not pressurized and is

| commonly placed within the plant. Distribution to

the Cleaners is provided through a series of pumps

' and pipes. These pipes, vaives, etc, should be

‘| become excessive in the case of a leak.

made of appropriate materials. Therefore, the
system eliminates all manual handling of solvents
and minimizes losses. Control is provided by float. -
| Switches within individual washer units. .

: A microprocessor cin be used to monitor solvent
: consumption. This provides consumption data and
’ activates an alarm in case levels

‘Pump seals deteriorate when not in contact with
solvent. A “running dry* condition erodes the seal
surface and the seals fail prematurely. Pumps and
» Seals are typical sites for leaks. -

‘The design and mairtenance of cieaners and stills
| Tequire attention to the seals and gaskets on
, Covers, lids, and panels. High volume leaks often
, Occur around corners and joints where two seais
| Meet. Check that new and replacement materials
| are compatible with the solvents in use.

| Takeadvantage of services offered by the machine
manufacturers; they have experience in fine tuning
_ the cleaner to minimize losses. This can be a
: supplement ° to the services offered by solvent

: suppliers who often. have programs . and
) information that can nelp Operators better manage
_ the process. .

| Check all temperature-measuring devices and
‘controls. Correctly calibrated instruments will ~



Exhibit 6(b). 7

AN EXAMPLE OF A METAL CLEANING EQUIPMENT PROFILE
4, Identification ‘ !
Equipment Name: __ : :
Model Number:
Manufactorer:
“Year Purchased:

Trade Name of
Chemicals Used:

Annual Quantity of CFC or MCF
Purchased for Use in this

| Equipment (specify units):
of ‘anual Quant of Cr eT MCF ‘Waste
. Requ isposal or Ie
Recycling:

B. Equipment Usage Pattern

Annual Quantity of Parts Cleaned !
(specify. units):

‘Type of Part Cleaned:

‘Type of Cleaning Equipment:

Cold cleaner/dip tank .
Irvine vapor Gegresser

C. Emission Controls’

Do you practice the following? If you do, briefly describe the procedures: :
Leak Testing: : , : :
Alternate Testing Methods: Zz
On-site Recovery/Recycling:

Improved Loss Control Procedures:
Operator Awareness/Guidelines:

Source: U.S. EPA 1990


sé

Carbon Adsorption

Carbon adsorption, a good means of recovering
amd reusing solvents, is accomplished by adsorbing
the solvent in a bed of carbon and later steam
stripping for reuse. This technique was chosen
because it is the best available technology known
at this time, has a relatively low cost, and is proven
in many actual installations.

The basic steps are:

« Solvent Jaden air is drawn from an enclosure
built around the 5-sump, open-top degreaser to
capture fugitive emissions. Solvent vapors are
collected at the bottom and top of the enclosure
(designed to minimize any drafts across the
degreasers) and ducted to carbon adsorbers
through a particulate filter to catch any
particles. Air is collected by lip vents at the
base of the cleaning chamber access door of the
shear stress machine. ’

¢ At the carbon adsorber, the solvent laden air is

drawn through the carbon beds by a process -

blower at 800 to 1,200 cfm. Blowers pull the air
through one or two carbon adsorption beds,
each bed filled with 600 Ibs. of carbon leaving

the solvent deposited on the carbon (coconut).

© Two or three carbon beds (depending on the
solvent loading and cfm required) are installed
in parallel. One or two beds are adsorbing CFC
while one is de-sorbing and drying CFC for re-
use. The beds are switched by either the stack
analyzer (typically set at 5 ppm) or a timer asa
back-up to the analyzers.

© Upon completion Of this phase of the process,
steam is used to remove trapped solvent from.
the carbon pores by pushing steam in a reverse
flow through the beds. A water/solvent mixture
is created when the steam is passed through a
condenser. From this condenser, the water/
solvent mixture is sent to a separator tank
where the water and solvent are separated by
gravity with the water going out the top and the
solvent out the bottom.

¢ Thesolvent then goes to a solvent holding tank.
The solvent is pumped to a still where it is
further refined and then transferred to another
holding tank where the technician pumps it on

demand to the still on the open top or the

. . Solvent tank in the shear stress machines.

The carbon adsorbers are designed to”
meet the following specifications: -

© 10 and 16 Ibs per hour of CFC-113
loading for recovery;

200 and 1200 cf blower for solvent
air stream;

Stainless steel recovery my vl

for CFC-113 recovery (charred
coconut husk);

Stack analyzer for bed switching when
saturated with hour time as backup.

The project cost of the carbon adsorbers was:

« For a 2 bed, 10 Ibs per hour, 800 cfm unit:
$62,000

. For 23 ted, 16 he, per hour, 1200 cfm unit:
$73,000

+ Automated material handling unit: $45,000
e Facility fit-up and miscellaneous: $187,000

‘Total project cost, including start-up and operator
training was $380,000.

Carrenty there are ns catbon adeorbees operating
at Digital. Based on actual usage numbers for
1990, solvent emissions are projected to be reduced
by 69 percent (see Exhibit 22). -





10



74



47

"Exhibit 1 9

‘ROTARY CARBON ADSORPTION ‘SYSTEM

Flow Chart ° : 7
az _

~ ;

RA Rotary Adsorbers

CC Crude Gas Conditioner
AH Air Heater

HP Heating Pipe

Source: Bowe

AG Air Cooler ©

WS Water Separator

ST. Solvent Tank ;

PP. Processing Water Purification

Frece08



“74

Sol-Pro, Inc. Southeastern Chemical & Solvent .
P.O. Box 1781 170 South’ Lafayette Boulevard
Tacoma, WA 98401 Sumter, SC 29150
(206) 627-4822 (803) 773-7387
Spartan Chemical Compar~ | Tricil Recovery Services, Inc,
2538 28th Street, S.W. | Bartow Municipal Airport _
‘Wyoming, MI 49509 . Route 3, P.O. Box 249

| Bartow, FL 33830-9504

(616) 534-4921

US. Chemical Company
29163 Calahan

Roseville, MI 48066
G13) 778-1414

Equipment Suppliers - Carbon ‘Adsorption Equipment

-Baron-] -Blakeslee, Inc.
"2001 North Janice Avenue
‘Melrose Park, IL 60160

"amdsipes mb#t 7 Co. KG
28 Bremen 66 .
Postfach 66032
Knechtsand 4

Germany :
Tel: 0421-580038
Telex: 245445

BOWE Reinigungstechnik GmbH
Haunstetter Str. 112
D-8900 Augsburg

Tel: (0821) 57021

Ceilcote Company
140 Sheldon Road
Berea,-OH 44017
(216) 243-0700

Detrex Corporation
‘Equipment Division
"P.O. Box 5111
Southfield, MI 48086-5111
” (313) 358-5800

Otto Dirr AG:
“Werk Bernhausen
Postfach 1260 .
7024 Filderstradt 1

.Germany
Tel: 0711-790281
Telex: 7255850 °

‘ 613) 933-6111

' Waste Research & Reclamation
‘Route No. 7
: Eau Claire, WI.54701

(715) 834-9624.

(312) 450-3900

Brechbuhl AG
Sihiquai 244

"* CH8031 Zurich

Switzerland

Tel: 01-448950

Telex: 54195 PLAZU CH
‘DCI International - |
1229 Country Club Road
Indianapolis, IN 46234
cu) 271-4001

Hoyt Manufacturing Company
251 Forge Road

‘Westport, MA 02790’ -'

(617) 636-8811 :

Omniatex

40013 Castel Maggiore.
Via Andrea Costa 4
Bologna i
Ialy : :
Tel: _051-70034

* Telex. 213418 OTEX-1



APPENDIX A
INDUSTRY COOPERATIVE

_ FOR OZONE LAYER PROTECTION |

‘The Industry © Cooperative for. Ozone Layer
Protection (ICOLP) was formed by a group of
industries to the ozone layer. The primary
role of ICOLP is to coordinate the exchange of
non-proprietary information on alternative
technologies, substances, and processes to
eliminate ozone-depleting solvents. By working
closely with solvent users, suppliers, and other
. interested organizations worldwide, ICOLP seeks
the widest and most effective dissemination of

ICOLP corporate members include:

AT&T

Boeing Company

British Aerospace

Compaq Computer Corporation
. Digital Equipment Corporation

Ford Motor Company

‘Texas Instruments
‘Toshiba Corporation

In addition, ICOLP has a number of industry

" association and government organization affiliates.

Industry association affiliates include American
Electronics Association (AEA), Electronic
Industries’ Association, Japan Electrical
Manufacturers Association and Halogenated
Solvents Industry Alliance (U.S.). Government”
organization affiliates include the City of Irvine,
California, the State Institute of Applied Chemistry

(USSR), the US. Air Force, and the US.

Environmental Protection Agency (EPA). The
American Electronics Association, the Electronic
Industries Association, the City of Irvine,

- California, the Japan [Electrical Manufacturers -

Association, the Swedish National Environmental
Protection , the U.S. Air Force, the U.S.
EPA, and the USS.R. Suste Institute or Applied
Chemistry have signed formal Memorandums of

" Understanding. with ICOLP. ICOLP will work

with the U.S. EPA to disseminate information on.
technically feasible, cost effective, . “and
environmentally sound alternatives for ozone
depleting solvents. ! ;

i} - ot

ICOL? is also working with the National Aca¢emy

_ Of Engineering to hold 2 series of workshops to

identify promising research directions and to make
most efficient use of rescarch Funding.

The goals of ICOLP are to:

«Encourage the prompt. adoption. of ‘safe,
_ \¢avironmentally acceptable, non-proprietary
valternative substances, processes, and ©
"technologies to replace current ozone-depleting
‘solvents; © ,

* Act. as an international clearinghouse for
, information on alternatives;
re

«| Work with existing private, national, and
, international trade groups, organizations, and
"government bodies to develop the most efficient





; Exhibit 8 .
TRAINING CURRICULUM FOR SOLVENT REDUCTION PROGRAM -

1. OWNERSHIP

e Encourage operator “ownership” of environmental concerns -

¢ . Operator tracking mechanism .
~- Meter with calibrated:solvent dispensing pump
= Solvent log book H
~- Solvent usage graph
-- Volume/area of work run
-- Report usage to management

. Understanding degreasing process H
— Condensing of solvent on cold part :
~ Evaporation of solvent from warm part

¢ Introduction to types of losses
+ Evaporative ,
— Vapor blanket collapse ‘
-. Dragout

¢ Demonstration of vapor degreaser in operation
~- Start up and shutdown procedures *
= Condensing coil/distillation St
- Vapor blanket smoke tube highlighting

Il. MANAGERISUPERVISORY SUPPORT

¢ Training all operators

«Control of operators
+- Reduce number of operators
-- Reward mechanism
+ Monitor performance

¢ Provide sufficient equipment °

= Stills, filters

— Hoists

~ Properly designed parts basket
© Degreaser placement

Controlled ventilation



References 7

American Society for Testing and Materials. 1976 cape. Handbook of vapor degreasing Sprit technicai
publication 310A. Philadelphia, PA.

Andell, J.L. and RB. Flegel. "1989, Optimizing C CFC-113 conservation in batch vapor Gepreascrs. ‘Presented
at NEPCON East Conference.

Andell, J.L. Solvent conservation in batch degreasers. Pant2: CFC113 meh chrtom ovens From
. the proceedings of the 1989 International Conference on CFC Alternatives. to.

; Anonymous. 1986 June). Solvent vapor recovery and VOC emission contol PoliionEnginaing
Anonymous. 1984 (August 24). Activated carbon fiber ads in solvent recovery Chemical Engineering: 63-64.
‘Anonymous. 1982' (November 19). Vacuum rotary dryer recovers solvent. Chemical Processing: 36. :
Anonymous, 1980 (March 10). Solvent reqeling tem saves costs and cleans ar. Chemical Engering 9.

i

Clement, RW., J. Rains, R. Simmons, and K. Suprenant. andated. Solvent cleaning. ASM Committee on
Solvent Cleaning. Hl .

Dow Chemical Corporation. 1985. Eni nie pr ewig i a shes fo
Dow. FORM No. 100-6096-485. Midland, ML L

Dow Chemical Corporation. Product stewardship manual - -spedaly chlorinated solvents. 1988/1989 edition.
DuPont de Nemours & Co. 1982. Performance guide for freon solvent systems. |

DuPont de Nemours & Co. 1987. Freon cleaning agents - Cleaning system design. FS-30A (product
literature) Wilmington, DE. _ - ! , :

DuPont de Nemours & Co. 1987, Freon cleaning | agents - recommended work Practices. FS-30B (product
literature) Wilmington, DE. ' .

"Halogenated Solvents * Industry Alliance. 1989. Moora om por Socaig ASTM Mangal Sei MOL,

- ICI Chior-Chemicals. 1990 (January). Activated carbon recovery of solvent from air streams. Runcorn, UK

ICI Chior-Chemicals. 1989. Genklene fact sheets. Runcorn, UK

Joshi, SB. 1988 (August 15-18). Use of solvent test kits to monitor solvent condition and maximize solvent
utilization. Symposium proceedings of Process Technology "88: The Key to Hazardous Waste Minimization.
Sacramento, CA. Sponsored by Air Force Logistics Command.

Kenson, R.E. 1985 (August). Recovery and reuse of solvents from voc air emissions Environmental
Progress: 161-165.

[. !



Exhibit 8 (continued)

«Maintenance program
= Chiller package
~ Leaks
-- Cleaning

© Demonstration
= Ventilation disturbances
- Basket design
— Insufficient cooling

Ill, VAPOR DEGREASER OPERATIONS

e Part racking
= Part cupping
- Cohesion of solvents between parts
-- Part/basket mass -- vapor blanket collapse

Stow part submersion and withdrawal
~ Piston effect
= Vertical rate less than 10 ft/min
= Drying in condensing zone

Spraying techniques
~ Low pressure
-— Below condenser area
- Fixed spraying zone

Solvent addition/removal a
- Utilization of open-top unit as a still
Add below vapor and liquid levels
No removal for hand or cold cleaning
Disposition of still bottoms, handling empty drums

Demonstrations* .
= Vapor blanket collapse due to mass
— Piston effect .
~- Insufficient drying time
— Solvent addition

* Demonstrations are an important tool in training. Artificial smoke from smoke-generating tubes
can provide an excellent media for observing air currents and vapor blankets. Dry ice can also be used
in a container to provide a nonsolvent demonstration. To minimize exposures to trainees and to limit
sofvent emissions, dry ice may be preferred. Either method provides a hands-on demonstration of -
operator control. . .



One-plate

Exhibit 16

CONTINUOUS STEAM STRIPPING

|}
, ~ , * Cooler |
Waste | '

Separator.

Stripping
Coke —~Na|

Superheater

Steam —se|

Condensor

=| Water
Separator

m1 : Oil
Filter
Steam |
Condensate <-————
Recovered =
Solvent , :
Pump ~
[ Source: DuPont __ _ ed



16

percent. Open-top vapor degreasers can be
retrofitted easily to include a shroud or cover.
Sealed doors and covers should be added where
‘access is necessary but where emissions Occur.
Dedicated vents that can account for up to 15
percent of emissions should be turned down or off,
if other measures can be taken to limit worker

exposure.

Amomate. Automating a vapor degreasing process
can reduce emissions by 40 to 60 percent. Manual
operation of vapor degreasing equipment often
leads to unwanted emissions. Opening and closing

covers, lids, and doors as well as moving the work :

pieces in and out of the solvent can cause
emissions. Employing automatic hoists and
transport systems will reduce operation emissions.

Automated operation also minimizes operator —

error. Manufacturers should consider retiring
older equipment and replacing it with modern
systems which have been designed with emission
reductions features. It is important to note that
retrofitting a degreaser may require a permit
modification. Replacing an old degreaser ‘with a
new one will likely require repermitting. A
sigcificant cost savings can be achieved with such
investments, but plan ahead by purchasing
equipment that can use the new solvents that are
replacing CFC-113 and MCF. In many cases,
however, different equipment designs will be
required to use alternative solvents. .

Educate. Education programs can lead to
procedure changes, which in turn can Teduce
emissions by 20 to 30 percent. ‘Training workers to
be aware of the need to’ reduce. emissions will
ensure that programs are instituted correctly and
that accidental emissions are reduced. Information
sessions addressing emission issues of start-up, Shut
down, and idle time procedures should be included
in basic operator training. Incentives for
conservation should also be explained to the
. workers, including their own health and safety,
environmental concerns, and company benefits.

Maintain. Improved maintenance procedures can
‘result. in 20 percent reduction in emissions.
Maintenance of vapor degreasing equipment is
essential to preventing potential emissi Leak
testing and usage logs can be used to track the use
and emissions of solvents. Improving solvent
change and boil down procedures will also reduce
emissions. General equipment maintenance is

important for proper operation. A critical

. maintenance issue is the associated chiller package, ‘

‘where failures can result in the loss of excessive
amounts of solvent overnight. .

Extent of Usage

‘An effective program to reduce CFC-113 and MCF
use requires a good knowledge of your plant
operations, including quantities of solvents used
for each process and areas-where losses occur.
‘The following questions will help you understand
your plant operations: ‘

. ‘Who purchases CFC-113 and MCF?

. Who takes delivery?

. How is ihe CFC-113 or MCF handled from
arrival to ultimate use? .

¢ How is CFC-113 or MCF used?
* -@ Where do losses take place?

Have the manager of your solvents elimination

program start with a survey. A copy of
questionnaires that can be’ used are shown in
Exhibits 5 and 6. ‘This survey form should be sent
to individuals in each plant location who are
responsible for Material Safety. Data Sheets
(MSDS). All MSDS should be checked for 1,1,2-
trichloro-1,2.2-trifluoroethane (CFC-113) and.
1,1,1-trichloroethane (methyl chloroform) to help
identify the trade name. The MSDS sheets should

be cross-checked with the trade names listed

previousty in this section. Identify the quantities
bought in the calendar year and start
reporting ona regular basis (monthly or quarterly).

Some solvent losses will inevitably occur during
operation. However, it is impossible to determine
the extent of your emissions and potential
reductions until a process assessment is performed.
Monitoring your operations is also the best way to
determine the success of your conservation
programs.



Exhibit 18
POINT-OF-USE CARBON ADSORPTION
” PROCESS SCHEMATIC - .
Drying Air -
proces i

Steam

Seoing Water

Vent

Sewer

——t
Recovered Solvent

Source: Digital Equipment Corporation

Water Sep 1

rocee-s



5S

CASE STUDY #1:
CFC REDUCTION/
ELIMINATION IN.
ELECTRONICS
CLEANING

Case Study #1 describes the steps taken by Digital

- Equipment Corporation to reduce CFC emissions —

and.to select an alternative cleaning method.

Digital has-used CFC-113 to clean many different
parts and sub-assemblies in the scent and
testing of disk drives (a storage device for

computers).

‘The equipment is a S-sump, open-top vapor
degreaser that was emitting 124,000 Ibs of CFC-113
“fugitive emissions each year before reduction steps
were taken.

Selecting a Téchnology to
Reduce Emissions

Digital commissioned a study to investigate several
technologies for reduction and/or elimination of
CFC-113.. The following summarizes each of the
technologies and recommendations that came from
the study.

Incineration

‘Therma! oxidation is a choice of last resort for:

~ CFC-113. Oxidized CFC-113 creates by-products
of hydrochloric acid and hydrofluoric acid which
feact with the insulating materials used on
commercial oxidizers. The acid vapors must also
be scrubbed in a caustic scrubber. Thermal
oxidation has no solvent recovery. It is, however,

an effective means of reducing volatile organic ,

compounds (VOCs).

Water scrubbing

” Water scrubbing extracts solvent from the process

air stream and, consequently, is most effective in

‘removing solvents that require one scrubbing.
These solvents generally have high solubility in
,water. When this method is used to remove CFC-
113, a solvent that has low solubility in water, the
‘water after one scrubbing is so saturated with
solvent that it loses’ its ability to remove any
additional CFC-113 from the air stream. Two
‘other factors also make this process questionable
‘for removing CFC-113: Not only must the water
coming out of the scrubber be air stripped before
it ‘can be reused or drained, but the exhausted air |
must also be treated to capture the solvent.

Ol serubbing

‘Under certain conditions ‘oil scrubbing has been
‘demonstrated as an effective means of extracting
solvent from the process air stream. However,
there are no known installations for capture and
“recovery of CFC-113. The process air enters a 7”
diameter column approximately 30’ tall, while a
low viscosity, high boiling point petroleum-based

Oil is sprayed: downward from the top of the
‘column over a 20° long mesh packed at intervals
‘against the airflow. The solvent dissolves into the
‘oil and collects at the base of the column. The
| Scrubbed air exits the top of the column into the
atmosphere. The oil/solvent mixture at the base of

~ithe column is pumped to a holding tank.’ The
‘mixture then moves to a recirculating evaporator

‘where the oil is heated to distill the solvent from
the mixture. The solvent vapors and oil are sent

. ‘to a cyclone separator. In the separator, the oil is

‘captured and sent to'a holding tank where it is
pumped back up to the scrubber distributor. The
‘solvent vapor is vented out the top of the cyclone
| separator, condensed, and gravity fed to a

° |Fecovered solvent tanic

etigoraton

' Refrigeration is a means of recovering ‘VOCs by
| condensation of the airborne solvent. Extremely
‘low temperatures for first droplets are required to
| reduce the solvent vapor pressure to a point where
‘90 percent recovery by condensation can be
‘achieved. Refrigeration recovery is best suited for _
‘ applications where airflow is low and solvent

concentrations high. ‘This technique is widely used _

| for storage tank vents.





. ; ‘35

In-Line Cleaning Practices
Process Description

In-line cleaning systems {also referred to ‘as
conveyorized cleaners) transport the work through
the machine on an automated continuous basis.
Most of the in-line cleaners that use: halogenated
solvents are vapor cleaners. In-line cleaners are

used in many different industrial applications. ©

However, they are most common in processes
where production volumes are large enough to
justify the higher capital costs of such equipment.

Excepi for the partsconveyor inlet and exit openi
ngs, in-line cleaners are usually enclosed. Althou
gh this helps to control solvent losses from the s
ystem, it does not eliminate them. Most in-line s
ystems have significant emission. In-line cleaning
systems are usually custom made for an applicati
on.

There are five main types of in-line cleaning syst
_ ems that use CFC-113 and MCF: cross-rod, mon
orail, belt, strip, and printed circuit board proces
sing equipment. These systems differ in their met

hods. of loading and unloading parts and in their

methods of transporting materials through the cl
eaning process. Systems are chosen based on the

needs of the manufacturing process, including th"

© type of part to be cleaned, type of cleaning req
uired, and speed and space requirements. Exhibit
13 shows one type of in-line cleaning system.

Convection

Excessive air currents around in-line solvent
cleaners disturb the vapor blanket’ within the
equipment which.causes solvent losses. When
excessive air movement is a problem, remove the

windward side to divert the draft away from the
cleaning unit.

In applications in the electronics industry, solvent
cleaning units are often placed immediately
following wave solder machines. This reduces the
cooling time before cleaning. If the boards are
entering the cleaner at a temperature greater than

the vapor temperature, the heat will be transferred.

40 the vapor and liquid solvent. This results in an
‘,additional heat toad which may exceed the

condenser's heat adsorption capabilities, resulting

in vapor discharge or machine shutdown by the
vapor safety thermostat.

Mounting small fans above and below the conveyor

to cool the boards before they enter the cleaning .
-Machine is one, solution to the problem. To

) prevent disturbing the vapor blanket within the
, Machine, which could result in increased solvent
{ loss, fans should “be directed away from the

. Openings of the equipment.

You may wish to consider a. number of
enhancements to the solvent cleaner. These are
hardware add-ons or modifications that require
capital expenditures and are not part of the

. Machine optimization aspects previously described.

System enhancements include: ;

‘Increased freeboard height

" “Increased cooling system compressor
capacity

Additional cooling coils on inlets and
outlets. ve

Cleaner
chilling/refrigeration should be consulted for their
expertise. Consider reviewing the. condensing
effectiveness of your: chiller/refrigeration system
with the assistance of a knowledgeable contractor.
Improved condensing efficiency through additional

-cooling coils at the entrance and exit of the wash

‘and perhaps through compressor resizing will
‘source or install baffles or partitions on the. —

Teduce evaporative and dragout solvent losses.
Keep in mind that refrigerant changes can result in

| losses of other.CFCs.

Use gas detectors to give accurate information on

the location of emitsions and to determine how .

effective your efforts are.

manufacturers and experts in



Exhibit 11
PISTON EFFECT

Vapor Blanket Collapse

‘The rapid introduction of a workpiece with a large
thermal mass will condense too much of the vapor
blanket. This will cause air to infiltrate the cleaner
and cause the vapor blanket to collapse. When the
vapor blanket is restored, the infiltrated air
Saturated with solvent vapors will be expelled from
the vapor degreaser (see Exhibit 12). If this occurs
on a. regular basis, contact the equipment
manufacturer to determine if additional heating

‘and.condensing facilities can be incorporated into _

- the vapor degreaser.

Avoid spraying work pieces by spray lance or spray
headers. If you must spray in this way, spray deep
. within the vapor zone, to avoid excess disturbance
of the vapor/air interface.

Avoid liquid solvent ricochet into the freeboard
zone or out of the machine when lance spraying.
Do not spray cold solvent because its vaporization

consumes heat from the vapor blanket, which”

increases the risk of collapsing the vapor blanket.

7 sg
EN

Use of soivent at a temperature near the solvent’s
, boiling point minimizes the potential for vapor
\ ‘blanket collapse and the loss of soivent-when the
' Vapor blanket is reestablished.” Typically this is
_ Part of the machine design. .

Exhibit 12
Vapor Blanket Collapse

Programmable Hoists

‘Arecommended maxiraum speed for work entering
‘and leaving the cleaner is less than 3 meters/min -
(10 ft/min). Higher throughput rates can cause

disturbances at the vapor/air interface that result in

high vapor losses. Automatic hoists and
programmed work transporters are recommended

because controlled speeds are difficult to. sustain |

manually.

i . 7
‘The inclusion of an integrated degreaser cover and :

hoist design is effective in reducing working

_ Solvent losses. The presence of a motorized,

horizontal sliding, two-piece lid can be integrated
with an automated programmable hoist. As the
hoist lowers the workiciad to the degreaser, the lid



A Three-Phase Plan

‘This study also resulted in a three phase plan to
recover and reuse solvents and eventually to
eliminate use <f CFC-113. ‘

PHASE 1
Education and training

Equipment enhancements

Process engineering changes
Operating disciplines

Accountability (make one person
responsible for managing the

Program)
Limiting new applications
This‘ phase reduced the solvent emission.

and usage by 20 to 30 percent, as shown in
Rxhibit 22.

PHASE 2

« Install new vapor recovery. system
(carbon bed adsorption), for point-of-
use only.

‘This phase is projected to reduce the total .

emission and usage by 55 to 70 percent, as
shown in the Exhibit 22.

PHASE 3

© Conversion to alternative methods of
Cleaning.

‘This phase will reduce the emission/ usage
10 zero. :

Phases 1 and 2 have been completed. Phase 3 is
being implemented and is expected to eliminate
CFC usage by mid-1992. .



4

3

Section 604 and Section 605:
Phaseout of Productionand —=—s_
Consumption of Class | and Class Il
Substances. :

‘These isions of the CAA present phaseout
schedules for Class I & Class II substances. The

it dates for ozone-depleting substances
‘listed in. the CAA are more stringent than the
Montreal Protocol. Exhibit 3 presents the
phaseout schedule for CFC-113 and MCF. Other
‘substances with ozone-deleting potential are also
Tegulated under the Montreal Protocol and the

- CAA. While they are not used in solvent cleaning

applications, these substances are used in other
applications. Section 605 of the CAA presents
provisions for the phaseout of HCFCs. The CAA
freezes the
phases them out by 2030. Since these restrictions
focus on production limitations, to the extent that
these chemicals can be recovered, recycled, and
reused, they may continue in commerce past the

*. applicable phase-out dates.

Section 608: National Emissions
Reduction Program :
This section calls for EPA to promulgate

regulations by July 1992 requiring emissions from
all refrigeration sectors~ (except ‘mobile air

conditioners that are covered in Section 609) tobe

reduced to their “lowest achievable levels.”
Regulations affecting emissions from all other uses

of Class I and Class II substances including solvent |
_ Cleaning are to take effect by November 1995.

This section also prohibits any person from
knowingly venting any of the controlled substances,
including HCFCs, during servicing of refrigeration
or ‘air conditioning equipment (except cars)
beginning July 1, 1992, and requires the safe
disposal of these compounds by that date.

Section 610: Nonessential Products”
Containing Chlorofluorocarbons

‘This provision directs EPA to promulgate

regulations that prohibit the sale or distribution of
certain “nonessential” products that release Class I
& Class II substances during manufacture, use,
storage, or disposal. In the CAA, Us- z~sss defined
several products as nonessential inci. :' ‘g CFC-

production of HCFCs in 2015 and“ Section 611: Labeling

containing cleaning fluids for noncommercial
electronic and photographic equipment, and CFC-
Propelled plastic party streamers and noise horns.
In addition, Congress established guidelines to
identify additional products that are nonessential.
Regulations banning ~snessential products that
release Class I substances must be promulgated by
November 15, 1991 and become effective
November 15,.1992. In addition, the CAA bans
the sale and distribution of ‘certain products
feleasing Class II substances, including aerosols
and pressurized dispensers and noninsulating foam,
by January. 1, 1994, Exemptions can be granted
from the ban on aerosols and pressurized

| dispensers due to, flammability and worker safety

This section of the CAA directs EPA to
promulgate regulations by May 15, 1992 requiring
labeling of products that contain or. were
manufactured with Class I or Class II substances
and containers containing these substances. The’
label will’ read ‘Warning: Contains or’.
manufactured with [insert name of substance), a.
substance which harms public health: and

* environment. by destroying ozone in. the w
. atmosphere". : .

The CAA defines three types of products that must

be labeled and specifies the time frame by which’
these products must be labeled. The three’

products and time frame are as follows:

a Effective May 15, 1993, containers in which a
Class 1 or Class II substance is stored or .
_transported, and products containing Class 1
Substances must be labeled; _

= Effective May 15, 1993, products manufactured
_with Class I substances must be labeled.
However, products manufactured with Class I
- substances can be temporarily exempted from
the labeling requirements of this section if EPA
determines that there are no substitute products.
or manufacturing processes that (a).do not rely .
on the use of the Class I substance, (b) reduce
the overall risk to human health and the



Other Control Technologies

' Carbon Adsorption
Because dragout losses are a major contributor to

ine overall solvent loss, causing high tevels of ©
" solvent vapor in the manufacturing area,-vapor -
These

capture: systems should be considered.

systems adsorb the solvent molecule on an
activated carbon bed which is subsequently
extracted by steam. After water separation, the
solvent is reblended with additives for reuse. :

‘The intake and exhaust ports of the cleaner are
vented to hoods where vapors are drawn under
Negative pressure through the activated: carbon
bed. Proper design of the collection hood at the
cleaner’ discharge is vital since this is where
dragout and drying losses are most significant.

Proceeds until the carbon bed

Adsorption
approaches saturation. At that time, steam is

injected onto the carbon surface to strip solvent
molecules for later condensation and water
separation. Exhibit 18 shows a point-of-use carbon
adsorption process schematic.

Three material streams are Produced: pure
solvent, clean air, and wastewater. :

/ Solvent is reblended/reconstituted-with additives
for reuse;

¢. Air is returned to the plant or exhausted;

¢ Wastewater'is treated and released to the sewer
system. With circuit board cleaners, there could
be some alcohol in the waste water streams and
local legislation should be reviéwed and
considered in equipment selection. Alcohol in
. the wastewater increases the biological oxygen
demand (BOD) load to the local semage
‘treatment plant. ,

Systems : can’ be sized to suit the scale of
application, and one adsorption system can service
more than one cleaner. However, carbon
"adsorption systems are expensive to purchase and
to operate unless their is a large quantity of
solvent to capture.

For maximum emission reductions, the bulk
Storage tank, the stills, and the adsorption system

45

es - - — —

\should all be located in an enclosed. room so that

.air can pass through the adsorption. system to
capture and recycle any fugitive soivent losses.

1 I 7
MCF and Carbon Adsorption

‘Steam desorption of MCF results in the loss of
Stabilizers and the formation of hydrochloric acid.
“This leads to corrosion problems and damage to

it. -In addition, the MCF has to be
iFestabilized after stripping for reuse.

"|New technologies to recover MCF vapors. by -
‘carbon adsorption have been developed. These
~ technologies eliminate the problem of MCF
chydrolysis and associated corrosion present in

. traditional carbon adsorption/steam

desorption
‘systems. These new adsorption methods include
replacing water with nitrogen as the stripping
“agent, employing a new condensation membrane
technology, hot gas desorption cycle, and polymeric
Particle adsorption.

JA carbon aitsorption system using a hot. sas
desorption cycle is shown in Exhibit 19. In this
‘process the solvent anc! the small quantity of water
are expelled from the activated carbon by hot air.
in a closed circuit. The solvent/water mixture then
passes through a condenser. The solvent is
separated from the water ina subsequent gravity
Separator. Solvent residues in the “processing
water” are then removed and the clean water is
discharged.

Safety Note:: ‘When operating carbon adsorption .
Systems, use proper chemical procedures, and
include fire provection on beds.

Air Stripping

‘Air stripping, which is a process similar to
distillation, can reclaim CFCs. In air stripping a
contaminated. stream is fed into a packed column.
from the top and air is injected at the bottom. As
the two streams pass one another through the .
golumn, they exchange volatile materials. The air
Phase and the volatiles are then carried from the
top for recovery usually by granular activated
carbon. The bottom products containing the
heavier phases are sent for recovery, perhaps. by
distillation. Emissions from air stripping are
probably subject to environmental regulation.



Exhibit 21 (Continued)

EMISSIONS REDUCTIONS:
PROBLEMS AND SOLUTIONS CHECKL'ST

- Possible Problems "Possible Solutions

Degreasing of absorbent materials Absorbent materials (such as cloth, wood, Porous
. : plastics, etc.) should not’ be cleaned in ‘vapor
: systems or used in the construction of baskets or
carriers.
Improper start-up and shut-down Activate condenser Prior to turning on heat.
Procedure .
. Do ot turn on spay ula ssble vapor level
has been established.

After cleaning operations are © complete, tum off
~ heaters and continue to operate the condensing

coils until the vapor zone has completely collapsed

and the boil sump cools well below the solvent .

boili i

Hot spots on heating coils should be repaired, as

they cause thermal breakdown of solvent.

Electric heater watt density. should not exceed 20
wauts/sq, inches.

Dascam sptem should be, cheat for
malfunction. .

Cooling coil design should be altered.

. Inadequate freeboard height Freeboard height to degreaser width ratio for
, . CFC-113 and MCF cleaning systems should be 1.0

Inadequate condensing capacity Turn on water-cooled systems and check. the
: : +. condenser discharge water temperature. Vapor
degreasers should be provided: with chilled water at
40°F (4.5°C), and discharge water temperatures,
‘should. be 50°F (10°C) for CC systems and 70°F

(21°C) for MCF systems. .

‘Possible repermitting and attendant Contact and work with your local air quaiity
changes. in regulatory requirements Tepresentative. .



environment, and (c) are currently or potentially
available. If EPA temporarily exempts products
manufactured with Class I ‘substances from the
labeling requirement. based on the lack of
substitutes, the products must be labeled by
January 1, 2015; and 7

- @ No. later than January 1, 2015, products
containing or manufactured with Class ptf
substance must be labeled. EPA may require
such products to be labeled as early as May 15,
1993 if it determines, after notice and

for public comment, that there are ©

substitute products or manufacturing process
available. .

The CAA allows for petitions to be submitted to
EPA to apply the requirements of Section 611 to
products containing Class II substances or 2
product manufactured with Class I or II substances
which are not. otherwise subject to the
_ Tequirements. ‘This petition process will operate
- between May 15, 1993 and January 1, 2015. For
products manufactured with Class I substances, a
Successful petition would result in, the labeling of
a product previously determined by EPA to be
exempt. For products containing or manufactured
with Class II substances, the petition process could
lead to labeling of a product that had been
unlabeled by default. .

Section 612: Safe Alternatives Policy

Section 612 establishes a framework for evaluating
the environmental impact.of current and future
potential alternatives. Such regulation ensures
that the substitutes for ozone-depleting substances
will not create environmental problems themselves.

‘The key provisions of Section 612 require EPA to: _

= Issue rules by November 15, 1992 which make
it unlawful to replace any Class I and Class I
Substances with a substitute that may present
adverse effects to human health and the
environment where EPA has. identified an

available or potentially available alternative that. -

reduces ‘the overall risk to human health and
the environment.

= Publish a list. of prohibited substitutes,
organized by use sector, anda list of the
corresponding alternatives;

| @ Accept petitions to -add or deiéte a ‘substance

.. previously listed as a prohibited substitute or an
acceptable alternative; :

: « Require any company which produces -a

chemical substitute for a Class I substance t

notify EPA 90 days before any new or existing

chemical is introduced. into commerce as ‘a
' significant new use of that chemical. In

addition, EPA must be provided with the

unpublished health and safety studies/data on
., the substitute. ©

| To implement Section 612 EPA will (1) conduct

i environmental risk characterizations for substitutes

' ‘in each end use and (2) establish the Significant

| New Alternatives Program (SNAP) to evaluate the

| future introduction of substitutes for Class I
|, substances. EPA has also initiated discussions with

| NIOSH, OSHA, ‘and other governmental and
-.:, mongovernmental associations to develop a
' eonsensus process for establishing occupational

exposure limits for the most significant substitute

: chemicals.

‘The environmental risk characterizations for the
Substitutes will involve-a comprehensive analysis

- based on the following criteria: ozone-depleting

potential, flammability, toxicity, exposure effects,
energy efficiency, degradation impacts, air, water
and solid waste/hazardous waste pollution effects,

' and global-warming potential. Economic factors

will also be considered. EPA will organize these
assessments by ‘use sector’ (i.e. solvents,
refrigeration, etc). ‘The risk characterizations will
result in risk-management strategies for each
sector and substitute. EPA will then categorize a
substance as unacceptable, acceptable with
limitations on use or quantity, acceptable without
comment, or delayed pending further study.
Petitions will be allowed to. change a substance’s
status with the burden of proof on the petitioner.

‘The SNAP program, effective November 15, 1992,

- will review future substitutes not covered in the

initial risk characterization process. SNAP will
evaluate a substitute based on the criteria
established for the risk characterization and will

classify it similarly.



CONSERVATION A AND RECYCLING PRACTICES
FOR CFC-113 AND METHYL CHLOROFORM

by
ICOLP Technical Committee* ; ee

John Thome (Chairman)
‘ . , Ray Allen :
, 7 Jonathon Andell . :
Kenneth Beach :
David Hey
Stewart Holm
dim Landers
Dara O'Rourke
Bill Richardson . \
Farzan Riza :
Richard Szymanowski: :

U.S. Environmental! Protection Agency

ad ICOLE i the Industry Cooperative for Onoae Layer Proncion ICDL» cerporte member compaies incude ATT, Boeing Company, ,

Government organization affiliates include the City of Irvine, California, the State Institute of Applied Chemistry (U.SS.R.), the Swedish
National Environmental Protection Agency, US. Air Force, and U.S. Environmental Protection Agency (EPA).

John Thome, Ray Allen, Jonathon Asdell, and Jim Landers are employed by Motorola; Kerineth Beach is employed by Honeywell; David
Hey is employed by ICI (UK); Stewart Holm is employed by the Halogenated Solvents Industry Alliance; Dara O'Rourke and Farzan Riza
are employed by ICF Incorporated; Bill Richardson is employed by Digital Equipment Corporation; Robert Ramsey is employed by
DuPont de Nemours & Co.; Richard Szymanowski is employed by Northern. Telecom; and Peter Thorstensen is employed by Manchester
a ee nae faded te te US Ook ed Tea rie ins and information teat helped prodace this
manual, ‘This manual was funded by the U.S. BPA and ICOLP. .



2

2 EEOOEOEOOe

Best Practices in Operation

Once current use of solvents is characterized, a
conservation strategy can be developed. At first,
choose conservation options that are easy to
implement in the short-term. These will offer
immediate results and will encourage employees to
continue and accelerate their efforts. The
following options for savings are typical for open-
top vapor degreasers that do not have some of the
more"advanced control techniques, and that may
differ for conveyorized equipment. .

Operator Training Curriculum

Opérator training is the second largest
conservation opportunity, second only to control of
air currents. Operating losses due to dragout
average 40 percent of the total losses. Other
practices such as basket overloading, vapor blanket
disturbances, spraying above condensing zone, poor
racking habits, and solvent removal for hand
cleaning can increase total losses from operating
habits to over 80 percent.

Operator induced losses obviously are reduced with
increased automation. Fully automated systems,
including part racking, are controlled by the

programmed operation of the equipment. -

‘Therefore, production programmers should also be
trained in good conservation practices.

It has been found that operators are generally
unaware of the financial and environmental costs
associated with the use of ozone-depleting
chemicals. Increased operator awareness can
translate into a reduction in consumption, since
operating practices and methods can usually be
improved. .

Operator awareness of the ozone-depletion issue
and taining in the handling of solvents is
recommended. Operators can change their

methods and practices, such as keeping lids and -
windows closed, turning off the cleaner when not ©

in use, conducting maintenance regularly, and
exercising care while working with machines and
equipment. :

‘Agcess to CFC-113 and MCF can be restricted to
strengthen management control. .

Part basket designers, production . scheduling

_Managers, and equipment maintenance .
should also be involved in training programs.
Parts must move slowly through the cleaning cycle.

- Racking and basket design are.critical factors in _
preventing or minimizing vapor blanket collapse ©
and solvent dragout. Maintenance practices can
contribute to losses from poor cleaning and
handling techniques. On a warm day up to five
gallons of solvent can be lost from an open

‘container due to evaporation.

.° A training. curriculum for most solvent vapor
degreasing processes is shown in Exhibit 8. The
training is most effective if given over a four- td
six-week period and in at least four separate
meetings. Any'single training period should not
exceed one hour. ' :

Handling Practices for CFC-113 and
MCF . : :

With more stringent production and emissions
controls on ozone-depleting ctiemicals, it is
imperative that solvents containing CFC-113 and
MCF be handled with the utmost care. These
solvents should be stored in secure drums to
prevent evaporation during storage and transfer
and should be clearly marked. ‘You should also
store drums with the bung end up to eliminate the
possibility of solvent spillage’ through a leaking
bung. :

If large quantities of solvents are used, consider a :
bulk storage systera and delivery of the solvent
through a piping system to the batch cleaners.

Solvent should be sampled periodically and tested
for acidity, moisture content, azeotropic imbalance,
and. other signs of degradation, Solvent
c tion is often symptomatic of a flawed unit
which in turn can generate excessive solvent waste.

Follow solvent - manufacturer’s instructions for
testing _ methods and. guidelines to
determine acceptable conditions for continued use
of the solvent. If solvent cannot be used, be sure
to follow appropriate procedures for off-site
_Teclamation and disposal. : .



68

Kohl, J.J., M. Person, Rose and P. Wright. 1986 (May). Managing and recycling solvents in the furniture , .

industry. Industrial Extension Service, School of Engineering, North Carolina State University. Raleigh, N.C.

Kohl, iP. Moses, and B. Triplett. 1984. Managing and recycling solvents: North Carolina practices, facilities,
and regulations. North Carolina State University. Raleigh, N.C.

Massouda, Bill. 1988. Assessment of chlorinated solvent usage and contro! costs in metal 1 cleaning and

electronics cleaning. U.S. Environmental Protection Agency, Office of Pesticides and“Toxic Substances. :

Washington, DC,

Ramsey, R.B. 1990 (September 1990). Vapor depreaser emission control. Presented at the International
Machine Tool Show. Chicago, IL.

‘Thorstensen, Peter. 1990 (September 13). Process equipment modifications to reduce CFC emissions.
Presented at the ICOLP Solvent Conservation Workshop. Chicago, IL.

US. Environmental Protection Agency. 1986. Analysis of treatment and recycling technologies for. solvents
and determination of best available demonstrated technologies. ;

US. Environmental Protection Agency. 1977 (November). Control of volatile organic emissions from solvent °

metal cleaning. EPA-450/2-77-022. Office of Air Quality Planning and Standards, Research Triangle, Park,
NG

USS. Environmental Protection Agency. 1989 (August). Waste minimization in metal paris cleaning. Office
of Solid Waste. ‘Washington, pc

U.S. Environmental Protection Agency. 1989 (August). Alternative contro! technology document -
halogenated solvent. cleaners. Office of Air Quality Planning and Standards. Research Triangle Park, NC.

U.S. Environmental Protection Agency. 1990 (March). Manual of practices to reduce and eliminate CFC-113

use in the electronics industry. EPA 400/3-90-003. Office of Air and Radiation. Washington, D.C.

+







38

optimize machine performance and reduce solvent
losses. ‘

Under normal operating conditions, original filters
reach the limit of their usefulness. relatively
quickly. Using more effective filters results in
fewer changes over time and less solvent loss.
Consider adding filters to extend machine solvent
life. "

&

For example, the use of a common motor vehicle

oil iter and a pump can filter out additional
impurities in the solvent distillation process. This
filter can increase the tiine between preventative
maintenance requirements which in turn decreases
solvent losses.
tsi

Do not use solvent appearance as the only tool for
cléaiti¢r drain and refill. Boil temperature should

also be analyzed. Solvent/oil specific gravity can
also be an easy method to determine the

contamination level of the solvent.

Superheated Vapor Drying

Supetheated vapor drying, as discussed under’ batch
cleaning operations, can also be used with in-line
cleaning operations.

Start-Up and Shut-Down Procedures

Solvent emissions during start-up can be
minimized through the following steps in the order
shown: : “

. ‘Start up the condenser cooling system and make
sure that it is operating properly; .

« Start up any auxiliary emission control
_ equipment;

© Check and adjust solvent levels in all
compartments; .

© Turn on heaters;

© Start up the spray pumps once a stable vapor
blanket is established;

Process work pieces only after the vapor blanket
has been established. Determine if the vapor
Dianket has been established by looking inside

the unit. Best practice is to do this only once.
Time how long the blanket takes to form, and
incorporate that into the procedure:

When shutting down the system, use the followin;
steps in the sequence shown: 5

© Stop work processing and clear the machine of
all work; | : *

© Close the cover on open-top units;
¢ Turn off the heaters;

. Activate sump cooling coils where provided;

ve Allow the vapor blanket to collapse completely;

« Turn off the condenser cooling system where
applicable. However, some units do not have
sump cooling coils. In this case, the condenser
cooling system should be kept on, on an
. intermittent basis. > :

Note: If cooling condenser is left running for

extended periods after shut-down, it could cause *

moisture condensation on the coils from room air.

The moisture would drip into the sump and

contaminate the solvent.

Idle Time Management

- Consider using one vapor degreaser to handle the

boards from two or- more machines.
Permitting requirements should be verified. Large

* losses are seen in degreasers that are under utilized
‘and have an extended idle: mode or that cycle as a

result of frequent start-ups and shut-downs.

Idle time management could require reworking
equipment placement, conveyor lines, controllers,
and other features. Benefits include not only

- reduction of losses of solvent but also removal of

extra equipment with a reduction in operating and
maintenance costs. Well designed in-line systems

- are provided with covers for controlling emissions

during idle times.



OOOO

‘Under these conditions, the solvent molecules tend Mechanical devices to insert and withdraw the eo
to migrate or diffuse from the region of high vapor ‘workload can result in significant savings. Such

concentration at-the condenser to the region of devices can range from inexpensive hoist motors to

low vapor concentration at the top of the sophisticated, programmable systems. :

degreaser. The rate of diffusion is a function of .

the freeboart depth (the deeper the depth, the Emissions during maintenance. of a solvent

slower the diffusion rate) and the condenser cleaning machine are also common and can be

temperature (the lower the temperature, the slower reduced through increased training and awareness.

the diffusion rate). | Auxiliary refrigerated onthe part of maintenance personnel. Emissions _—
condensers (-20°F/-29°C) located in the freeboard from spills will also be diminished through user

zone help to reduce the diffusion rate. awareness and care. ,

Diffusion, however, is an, insignificant process of

solvent loss com to other loss mechanisms. i
“ Saeaaree ie caniticant physical loss Measurement and Monitoring

process. Drafts or other air currents blowing - ‘

across the top of the degreaser, referred to as seer See eftectt oe aoring

convective losses, can be éliminated by locating the sources of I en vely determine

unit in a draft-free environment. Consider that - Leak devectors

moving a degreaser or installing a hood may Fefrigerant detectors will identify leaks of solvents.
Air currents which may cause diffusion should be

subject some operations to repermitting : . -
requirements, depending on the regulatory monitored with smoke generation tubes.
requirements. ‘Where excessive air movement is a o 7 t 14 a
problem, boner ider installing baffles or partitions on time wo verify he performance contuon wn
he win side 4 divert the air ts away calibration of solvent monitoring equipment. To
the degreaser. from drafts can also be . be effective, the monitoring equipment must be
reduced by using hooded enclosures in conjunction both accurate and responsive in the range in which
with automated work-handling facilities. it is expected to perform. Below is a partial list of
instruments that can be used for leak detection and
Insertion and withdrawal of the workload can lead
to losses due to disruption of the vapor blanket, as wee concentration monitonng. “ partial ist vor
well as dragout losses. Manual insertion and ig equipment appears .

withdrawal tend to increase these losses. __ end of this manual.

MEASUREMENT/MONITORING EQUIPMENT

Infrared 1-40,000 ppm Concentration Monitoring

Infrared * 100-9900 ppm Leak Detection/Concentration Monitoring

Flame Ionization 1-10,000 ppm Leak Detection/Concentration Monitoring

Detector Tube 50-1400 ppm Concentration Monitoring

Electronic Ounces/yr Leak Detection

Thermal Printer
Paper

‘Leak Detection



Exhibit 10. |
" BASIC VAPOR DEGREASER - BATCH CLEANING

can .

SPRAY
> TUBE

VAPOR THERMOSTAT . pa UP VENT

See meer NK C(Coonobiggn

: —— "TROUGH
SEA 2

WATER
‘SEPARATOR

> = OT SOLVE
contrat} |: HAMBER
BOX
PROTECTIVE S)
WATER OUTLET
souvent RETURN
:

7 . BOILING SUMP |

i}

CLEAN Gut NN ; :
EAN O _ tearm ene

La SUMP THERMOSTAT

Source: PPG Industries



Exhibit 5
- cro-t13 AND MET! HYL CHLOROFORM USAGE PROFILE

B. Quantification of Usage Patterns

_ Quantity Purchased: (specify units)
a 1991:
1990: 1992:

© CFC and MCF Disposal Practices

Anal quan ly ships wat
Annual disposal costs:

Annual quantity shi for
Teclamation: (specify units)

Annual cost of reclamation:

Annual quantity lost to the
environatent: epecity units)

‘Through leakage:
Through spillage:
‘Through testing:

Thi dra; and
evapo ott

| By other means (speci) —

Unaccounted:

Source: U.S. EPA 1990



_ FOREWORD

The 1987 Montreal Protocol on Substances that
Deplete the Ozone Layer, and subsequent 1990
amendments and adjustments, restricts the
‘production and ‘consumption of ozone-depleting
chemicals: ‘Two such chemicals, chlorofluoro-
carbon~ 1,1,2-trichloro-1,2,2-trifluoroethane
(commonly referred to as CFC-113) and 1,1,1-.
trichloroethane (commonly referred to as methyl.
chloroform or MCF), will be. completely phased
out in developed countries by years 2000 and 2005
respectively, ‘and ten: years later in developing
countries: :

~ Exhibit 1 lists the countries that are Parties to the
Montreal Protocol as of April 1991. In addition,
many companies worldwide have corporate policies
to expedite the phaseout of ozone depleting
chemicals. Exhibit 2 presents the corporate
policies on CFC-113 reduction for some of these
companies.

In addition to providing regulatory schedules for
the phaseout of ozone-depleting chemicals, the
Montreal Protocol established a-fund that will —
finance the incremental costs of phasing out
ozone-depleting substances by developing countries
that are Party to the Protocol. .

U.S. Clean Air Act
Amendments

“The U.S: Clean Air Act (CAA) was amended in _
- 1990, and contains several provisions pertaining to
“stratospheric ozone protection. Section 602 of the
CAA presents a list of ozone-depleting substances

that are restricted under the CAA. These ozone- -

depleting ‘substances are defined as Class I and
Class II substances.. Class I substances include all
fully halogenated ‘ chlorofluorocarbons (CFCs)
including CFC-113, three halons, MCF, and carbon
tetrachloride. Class II substances are defined to
include 33 hydrochlorofluorocarbons (HCFCs).
The sections of the CAA that are of importance to
users of this manual are discussed below.



53

—

CASE STUDIES OF INDUSTRIAL PRACTICES

_ The following section presents industrial case studies of conservation and Tecycling. ;

* The mention of.any company or product in this document is for informational purposes only
and does not constitute a recommendation, of any such company or product either expressed
or implied by EPA, ICOLP, ICOLP committee members, or the companies that employ the
ICOLP committee members. on woloe.

Case Study #1: CFC Reduction/ Elimination in Electronics Cleaning

* Case Study-#2: Using Industrial Hygiene Techniques to Monitor and Reduce
Solvent.Losses i : re

+) Case Study #3: Solvent Equipment Selection ~ A Case Study of Errors

* Case Study #4:. Emissions Monitoring arid Reduction
* Case Study #5: History of Equipment Upgrades.
° . Case Study #6:

Solvent Conservation and Recycling.



List of Solvent Recyclers and Equipment Manutacturers*
Ucensed Solvent Recyclers (provided by National Solvent Recycling Association)

Allworth, Inc.

500 Medco Road
Birmingham, AL 35217
(205) 841-1707

Arivec Chemicals, Inc.
7962 Huey Road

P.O. Box 549
Douglasville, GA'30122
(404) 942-1550 .

Baron-Blakesiee, Inc.
2001 North Janice Avenue
‘Melrose Park, IL. 60160
(312) 450-3900

Chem Pak Corporation
P.O. Box 7151
Warwick, RI 02887
(401) 738-2200.

Chemical Solvents, Inc.
3751 Jennings Road -
Cleveland, OH 44109
(216) 741-9313

Chemi tron Corporation

35850 Schneider Court
, Avon, OH 44011

(216) 871-8048

CWM Resource Recovery; Inc.
P.O. Box 453 .
‘West Carrollton, OH 45449
 (S13)-859.6101

Gibraltar Chemical Resources
P.O. Box 1640

Kilgore, TX 75662

(214) 894-0270

* This is not a comprehensive list of vendors. For

Or service offered by such entity.

more names check the

Anachemia Solvents, Ltd.

3549 Mavid Road os
Mississauga, Ontario, CN LSC 117
(416) 279-5122...

Avganic Industries, Inc.

114 North Main Street

P.O. Box 208 oF

Cottage Grove, WI 53527
- (608) 257-1440

“Berkley Products Company
P.O, Box E '
Akron, PA 17501

(717) 859-1104

Chemical Reclamation Services
P.O. Box 69 ° |
Avalon, TX 76623

(214) 299-5043

|

Chempro. | i

2203 Airport Way, South

Suite 400

Seattle, WA 98134
“(206) 223-0500

Clayton Chemical Company
1 Mobile Street .

. Sauget, IL 62201 |
(618) 271-0467 .

General Chemical :
P.O. Box 608 he
Framingham, MA 01701 |
(617) 872-5000

Hukill Chemical Corporation .
7013 Krick Road

Bedford, OH 44146
(216) 232-9400

Thomas Register. Licensed solvent
Tecyclers and equipment manufacturers can be. cited in subsequent editions of this manual by sending
information to ICOLP. ICOLP's address is Provided in Appendi

. n ix A. Listing is for informational purposes
only, and does not constitute any endorsement by EPA or ICO!

LP, either express or implied, of any product



. — LL
‘ | Immersion Cleaning. Consumption of a large
Cold Cleaning , .Nolume of solvent is common when immersion cold

. @leaning systems -- also known as dip-tanks -- are
Process Description - | weed as part of a manufacturing process. If _

* Cold cleaners use solvents at room temperature for

" parts cleaning. CFC-113 and MCF have been used
extensively in cold cleaning because of their
_ felatively low toxicity and resulting high workplace
exposure limits. Cold cleaners are usually small
maintenance cleaners or parts washers.

Cold cleaning operations can include brush or wipe :

cleaning, spraying, flushing, and immersion. The
most common machines which use CFC-113 and
MCF are of a type called carburetor cleaners.

Cleaning Methods and Emission

' Wiping. The major sources of emissions from
wiping operations are the disposal of used solvent
during the cleaning operation and the disposal of
Solvent-soaked rags. Solvent evaporation and
spillage from the solvent container can also result
in substantial solvent emissions.

‘The best way t0 redyce emissions from wiping

Operations is to use covers for solvent containers,’

{v dispose of used solvent-containing rags in closed
containers, and to store used solvent in well sealed
‘containers. Used solvents may be reclaimed or
-Tecycled. Several companies, listed on Pp. 63-65,
, Operate solvent reclamation and delivery services

that'may be suitable for your organization. Used '
‘solvents and spent rags can also be disposed of by ©

incineration as a way of reducing solvent emissions.
‘This should occur only in facilities that have been
designed for and authorized to perform
incineration.

Spraying or Flushing. When solvents are used ‘in
Spraying and flushing systems, they are usually
Tecycled because of their high cost. Distillation
equipment for these solvents is relatively

inexpensive and can be justified in terms of solvent -

savings alone. Containment systems and covers
“must also be employed during operation and

downtime. Spraying equipment should be operated-

at low pressure (less than 10 psi), and air-agitation
Must be avoided. In addition, spray droplets
should be as large as practical to minimize
evaporation ‘from the droplet surface.

- alternative solvents can replace CFC-113 and

MCF, emission reductinzs can be significant. (See
the other manuals in this series for alternatives 10
CFC-113 and MCF.) -

\. Although air-agitation systems ‘may be used to

| increase the cleaning efficacy
Systems, they also cause a higher . evaporative

of immersion

’ emission rate. The use of covers and increased

‘| freeboard ratio are both effective means of -

Teducing evaporative emissions. Covers can reduce

| ‘emissions by between 20 to 40 percent. Incrcasing
, the-freeboard-ratio to°1.0 may reduce evaporation
, by up to 70 percent. The area around and above

the cleaner should be kept free’ of drafts.

_ Removing and replacing covers horizontally (rather
. than lifting them off) will reduce air currents and
‘ ‘thus reduce evaporation losses.

* Dragout and carry-cut losses can be reduced by

requiring operators to allow the parts being

: cleaned to drain for 15 seconds and rotating parts
 toensure that solvent is released from recesses and

blind holes in the work pieces. Proper storage and

reclamation of used solvent can also reduce vapor

\ oe _
\ Parts that have been sprayed, dipped, or wiped may
be drained on an inclined rack that is attached to
| the degreaser. Autornatic hoists can also be used
| to drain parts over the degreaser.



| Exhibie 15.

_ FACTORS INFLUENCING THE DECISION
-TO RECYCLE SOLVENT WASTES ON-SITE

' Less waste leaving the facility. = | Capital outlay for recycling equipment.

Owner controls reclaimed solvent’s -——iability for worker health, fires,
purity. a __ explosions, leaks, spills, and other risks.

Reduced liability and cost of transporting Need for operator training. -
" waste off-site. \ eo, :

Reduced reporting (manifesting). ' Additional operating and maintenance

Possible lower unit cost of reclaimed
solvent. ; ;

Favorable economics for recovery (e.g., May be a need to restabilize the
reduced solvent requirements). ’* reclaimed solvent.

Reduction in disposal costs. Installation problems.

Lower liability. . : “Maintenance problems.



Exhibit 3

PHASEOUT DATES FOR CFC-113 AND METHYL CHLOROFORM
UNDER THE U.S. CLEAN AIR ACT
AND THE MONTREAL PROTOCOL

SEC PHASEOUT
Clean Air Act

Reduce from 1986
levels by:
1991 - 15%
1992 - 20%
1993 - 25%
1994 - 35%
1995 - 50%
1996 - 60%
1997 - 85%
1998 - 85%
1999 - 85%
2000 - 100%

ROF

lean Air Act

Freeze at 1989 levels
by 1991
Freeze at 1989 levels
continues in 1992
Reduce from 1989
levels by: .
1993 - 10%
1994 - 15%
1995 - 30%
1996 - S0%
1997 - SO%
1998 - 50%
1999 - 50%
2000 - 80%
2001 - 80%
2002 - 2004*
2005 - 100%

Montreal Protocol.

Freeze at 1986 production and consumption levels by July
1989

20% reduction from 1986 levels by January 1993

50% reduction from, 1986 levels by January 1995

85% reduction from 1986 levels. by January 1997

100% reduction from 1986 levels by January 2000

Also call for future assessment to determine if an earlier
complete phaseout by January 1997 is achievable .

Montreal. Protocol

‘Freeze at 1989 production and consumption levels by

January 1993

30% reduction from 1989 levels by January 1995
70% reduction from 1989 levels by January 2000
100% reduction from 1989 levels by January 2005

* New authority would be given to EPA to authorize, to the extent consistent with the Protocol, the
production of methyl chloroform in an amount not to.exceed 10% of baseline per year in 2002, 2003,
and 2004 for use in essential applications for which no safe substitutes are available. ae