PROCEEDINGS OF THE

u.s. ENVIRONMENTAL PROTECTION AGENCY

WORKSHOP ON

INTEGRATING CASE STUDIES CARRIED OUT

UNDER THE MONTREAL PROTOCOL

January 15-17, 1990

Washington, D.C.

Division of Global Change

Office of Air and Radiation

United States Environmental Protection Agency
TABLE OF CONTENTS

Meeting Summary

Meeting Agenda

List of Attendees - Attachments 1, 2, and 3

PRESENTATIONS

1. "Proposal For a Unified Approach", Dr. Stephen O. Andersen, Chief, Technology and

Economics Branch, Office of Air and Radiation, U.S. Environmental Protection Agency.

2. "Global Environmental Problems - Policy in Mexico", Mr. Sergio Reyes-Lujcin, Undersecretary

for Ecology, SEDUE (Secretarfa de Ecologfa y Desarrollo Urbano.)

3. "Status of Case Study: Egypt", Dr. Ahmed Amin Ibrahim, Consultant for Egyptian Environment

Affairs Agency.

i _

4. "Status of Case Study: Brazil", Mr. Alberto Carrizo, White-Westinghouse Climax, Brazil.

! ")

5. "Status of Case Study: China", Mr. Zhang Chongxian, Senior Engineer, National Environmental

Protection Agency - China. .

6. "Overview of UNEP Technical Assessment", Mr. G. Victor Buxton, Environment Canada.

7. "Technology Transfer Projects by the Industry Cooperative for· Ozone Layer Protection", Mr.

AD. FitzGerald, Director, Environmental Affairs, Northern Telecom, Canada.

8. "Switch from CFCs to Hydrocarbon Propellants", Mr. Montfort Johnsen, President, Montfort A

Johnsen and Assoc., United States.

9. "Adapting Aerosol Technologies to Developing Country Needs", Mr. Jorge Corona,

CANACINTRA (~mara Nacional de la Industria de la Transformaci6n), Mexico.

10. "Electronics Cleaning in Developing Countries", Mr. Brian Ellis, General Director, Protonique

S.A, Switzerland.

11. "Replacement of CFC-1l3 Solvent", Mr. Bryan Baxter, British Aerospace Precision Products

Group, United Kingdom.

12. "Assessment of Alternative Substitutes and Technologies in Refrigeration", Dr. Lambert

Kuijpers, Philips Research Laboratories, Netherlands.

13. "Important Considerations in Evaluating Substitutes to CFC Blowing Agents in Foam Plastic

Products", Ms. Jean M. Lupinacci, Office of Air and Radiation, U.S. Environmental Protection

Agency.

14. "CFCs and HCFCs as Feedstocks", Dr. Nobuo Ishikawa, Director F & F Research Center,

Japan.

15. "Halons: Advantages and Disadvantages", Halons Work Group.
AITACHMENT 4 - Terms of Reference for the Case Studies

AITACHMENT 5 - SUJVey Questionnaire for the Case Studies

APPENDICES

.SOURCE MATERIALS AND DOCUMENTS DISTRIBUTED AT THE WORKSHOP

1.

/" , 2.

3.

4.

5.

; .

"Replacement of CFC-113 in Industry", Swiss Federal Office of Environment, Forests and

Landscape.

"CFC Alliance Special Bulletin", Alliance for Responsible CFC Policy, United States.

"The Destruction of Halons in the Nordic Countries", Jan Bergstrom, Raine Harju, and Eva

Hyden, Nordic Council of Ministers' Steering Committee for the Halon Project.

"CFCs in India - Phase 1 Work Plan", Avani Vaish, Ministry of Environment and Forests, India.

"Protonique News", Protonique, S.A, Switzerland.
EPA WORKSHOP SUMMARY

The U.S. Environmental Protection Agency (EPA) sponsored a workshop on

"Integrating Case Studies Carried Out Under the Montreal Protocol" in

Washington, D.C., on January 15 to 17, 1990. The workshop was attended by

representatives of government and private organizations from Australia,

Brazil, Canada, China, European Economic Community (EEC) , Egypt, Federal

Republic of Germany, India, Japan, Malaysia, Mexico, Norway, Singapore,

Sweden, United Kingdom, United States, Venezuela, the United Nations

Development Programme (UNDP) , and the World Bank. In addition, a group of

experts on various use sectors of CFCs were also present. The purpose of the

. meeting ~as to:

• develop a methodology and framework to encourage uniformity

between case studies being conducted in various countries;

• obtain first hand information from representatives of various

countries on the status of case studies being conducted;

• assemble a group of representatives and experts from various

countries to share ideas, provide information, and discuss

arrangements for conducting case studies in each country; and to

• identify commercially availabl~, cost-effective, reliable

technology that could be used by developing countries to reduce

and/or eliminate their particular uses of CFCs, halons, and other

ozone depleting chemicals.

Exhibit 1 summarizes the status of the case studies being conducted in

various countries.

The Mexican, Egyptian, and Brazilian case studies jointly sponsored by

the U.S. and these host countries are well underway. Mr. Sergio Reyes Lujan,

Undersecretary for Ecology, SEDUE (Secretaria de Ecologia y Desarrollo Urbano)

discussed the progress of the Mexican case study. Mr. Reyes Lujan discussed

SEDUE's pioneering initiatives in efforts to protect the ozone layer by

reaching nine voluntary agreements with various industry groups to reduce

their consumption of CFCs and halons. It is expected that a first draft of

the Mexican Case Study will be available by February 15, 1990 and the cost

estimates for this study will be prepared by March 1990. The draft report on

the case study will be available for the April 4-6,1990 UNEP meeting.

Dr. Ahmed Ibrahim, consultant to the Egyptian Environmental Affairs

Agency, presented information on the status of the Egyptian case study. Dr.

Ibrahim noted that Egypt does not produce any CFCs and that the majority of

the CFCs use in Egypt results from the use in refrigeration and aerosol

applications. A number of Egyptian aerosol manufacturers have already

switched to alternatives such as liquified petroleum gas (LPG) which mainly

consists of propane and pentane. The use of LPG has been demonstrated as a

cost effective and technically viable alternative to CFC use in aerosols. Dr.

Ibrahim stated that the first draft of the Egyptian case study will be

completed by March 15, 1990 and the draft including some costs estimates will

be completed by the April, 4-6, 1990 UNEP meeting.
, \

Mr. Alberto Carrizo, representing the Brazilian case study project team

discussed the progress on the Brazilian case study. The Brazilian case study

project team includes representatives from IBAMA (Instituto Brazi1eiro do Meio

Ambiente e dos Recursos Naturais Renovaveis -- the Brazilian environmental

agency), Foreign Affairs, Health, and Industry &Trade Ministries, and members

of various industry groups. The project team expects to have a first draft of

the study by the April 4-6, 1990 UNEP meeting.

The case study on India is being conducted in collaboration with the

United Kingdom. Mr. Avani Vaish, Ministry of Environment &Forest, noted that

India currently has a production capacity of 7,500 metric tons that is

expected,to increase to about 20,0000 metric tons by 1995. He noted that the

majority of CFC use in India results from the use in refrigeration

applications. Mr. Vaish stated that preliminary estimates of costs are likely

to be available by the February 1990 meeting of the Protocol Parties. It is

expected that the cost estimates provided during the February meeting will be

refined and that improved estimates will be available for the April UNEP

meeting.

The case study on China is being sponsored by the United Nations

Development Program and Finland. Mr. Zhang Chongxian, National Environmental

Protection Agency, stated that China has an indigenous CFC production capacity

of approximately 30,000 metric tons and that the majority of CFC use in China

is in refrigeration and foam blowing applications. Mr. Chongxian stated that

preliminary results may be available by the June meeting of the Protocol

Nations and that the final estimates would be available by November 1990.

Venezuela is conducting its own case study and the government

representatives present at the workshop stated that they expect that

preliminary cost data will be available by the April 1990 meeting.

Sweden, possibly in cooperation with Norway is planning to sponsor a

case study on Kenya. An agreement formalizing the case study is likely to be

signed in the near future. It is expected that a preliminary report will be

available for the June 1990 meeting of the Protocol Nations.

Canada has decided to sponsor a case study on Malaysia. An agreement is

currently being worked out and Canada expects that preliminary information on

costs will be available for the June 1990 meeting of the Protocol Nations.

The Australian, EEC, Federal Republic of Germany, and Japanese

representatives expressed their willingness to sponsor case studies. The

following countries were suggested as possible candidates for additional case

studies: Algeria, Argentina, Chile, Czechoslovakia, Hungary, Indonesia,

Libya, Pakistan, Philippines, Poland, Saudi Arabia, Tanzania, Thailand, and

Yugoslavia. It was suggested that sponsoring and case-study countries should

contact each other.

The workshop participants formed six work groups to discuss and prepare

guidance material for the case studies. The working groups consisted of:

2
'.

• a group that developed the "terms of reference" for the case

studies (Attachment 4);

• a group for each of the end use sectors: aerosols, foam, halons,

refrigeration, solvents that developed the survey questionnaire

materials that could be used to gather relevant information on

each end use sector for the case studies (Attachment 5).

The materials developed by each of the work groups were distributed

among the workshop participants for final review. The workshop participants

by consensus agreed on the "Terms of Reference" and the survey questionnaire

materials prepared for the case studies. It was agreed that these materials

were guidelines and local conditions in each country might necessitate some

variation.

Technical Presentations

The technical presentations by the industry experts are included

elswhere in this volume. A brief summary of each presentation follows.

Mr. Montfort Johnsen, Technical Consultant, U.S., presented information

on the use of hydrocarbons as substitutes for CFCs in aerosol applications.

Mr. Johnsen stated that hydrocarbon propellants cost less than CFC based

propellants. He also stated that because the hydrocarbons are flammable,

special precautionary measures such as properly designed gas house have to be

used in the aerosol filling process.

Mr. Jorge Corona, representative of CANACINTRA (the Mexican Technical

and Economic Chamber of Industries) discussed the characteristics of

hydrocarbon propellants and explained how the Mexican aerosols industry has

adapted technology to local circumstances to successfully switch from CFCs to

hydrocarbons. He offered Mexican assistance to other developing countries in

adapting Mexican designs to their environment.

Mr. Bryan Baxter, British Aerospace Dynamics Ltd., U.K., discussed the

technical feasibility of using isopropanol as a possible replacement for CFC113 based cleaning for precision cleaning applications. He noted that the

flammability aspects of isopropanol are completely suppressed by blending the

isopropanol with perfluorohydrocarbons. In addition, he stated that British

Aerospace is designing special equipment that would eliminate the loss of

solvent vapor for this cleaning application.

Mr. Brian Ellis, Protonique, S.A., Switzerland, presented a comparative

assessment of various alternative technologies that could be used to replace

CFC-113 use in the electronics industry. These technologies include the use

of aqueous based processes with and without saponifiers, the use of low

solid/"no clean" flux, controlled atmosphere soldering, and the use of

hydrochlorofluorocarbon (HCFCs) and hydrocarbon (HC) based solvents.

Dr. Lambert Ruijpers, Philips Research Laboratories, The Netherlands,

presented information on alternative refrigerants being considered for various

refrigeration applications. Dr. Ruijpers stated that the currently available

3
substitute refrigerants include ammonia, HCFC-22, hydrocarbons, HCFC-142b and

HFC-152a. Medium term alternatives include HFC-134a, HCFC-123, and azeotropic

mixtures. Finally, long term alternatives include HCFC-124, HFCs 125, 134,

32, and 143a. Dr. Kuijpers summarized the current state of technology for

these refrigerants and presented information on the research efforts under way

to commercialize the use of these new refrigerants.

Ms. Jean Lupinacci, U.S. EPA presented information on alternatives to

CFC blow foams. Ms. Lupinacci stated that countries with large CFC

.consumption in flexible and packaging foams have the largest opportunity to

reduce their use of CFCs using alternatives such as water blown foams,

increase foam density, use of HCFC-22 as a blowing agent, and through product

substitu~es. In the case of polyurethane insulation foam applications the

foam industry faces greater challenges to reduce their use of CFCs. In these

end uses the use of HCFC-l23, HCFC-l4lb, and the use of water blow foams

represent promising alternatives.

Dr. Nobuo Ishikawa, F&F Research, Japan, presented a summary of chemical

processes that can transform CFCs, HCFCs, and methyl chloroform to other

useful chemicals. For example, methyl chloroform can be converted to HCFC141b and HCFC-142b. The HCFC-142b can then be converted to viny1idene

fluoride that is used to produce polymers and copolymers that are used in a

number of application (e.g., electrical applications such as wire insulation

and fiber optics, and as piezoe1ectronic materials). Similarly, HCFC-22 can

be converted to HCFC-225, HFC-134a, and a variety of polymers and copolymers.

4
- . EXHIBIT 1. STATUS OF NATIONAL CASE STUDIES

. 1

CASE STUDY COUNTRY

Mexico

.Egypt

Brazil

India

China

Venezuela

Kenya

Malaysia

SPONSORING COUNTRY

U.S.

U.S .

U.S.

U.K.

UNDP/Fin1and

None

Sweden &Norway

Canada

5

STATUS

First draft - February

12, 1990; Draft with

cost estimates March

1990; Report to UNEP

April, 1990.

First draft March 15,

1990; Draft with cost

estimates March 30,

1990; Report to UNEP

April, 1990.

Draft with cost

estimates April 1990;

Report to UNEP April,

1990.

Preliminary cost

estimates February 1990;

Better estimates April

1990.

Preliminary report April

1990; Final November,

1990.

Preliminary cost

estimates April 1990.

Not yet begun;

Preliminary report June

1990.

Not yet begun;

Preliminary report June

1990.
JANUARY 15

8:00-9:00am

9:00-9:30am

9:30-10:00am

10: 00am-12.: OOpm

12:00-2:00pm

EPA WORKSHOP:

Integrating Case Studies Carried

out Under the Montreal Protocol

January 15-17, 1989

J.W. Marriott at National Place

1331 Pennsylvania Ave.

Washington, D.C. 20004

(202) 393-2000

Final Agenda

Workshop Check-in and Coffee

Welcome and Introductions

Eileen Claussen, Director, Office of

Atmospheric and Indoor Air Programs, EPA

Proposal for a Unified Approach

-- Stephen Andersen, Chief, Economics

and Technology Branch, EPA

Status of Ongoing Case Studies

-- Alberto Carrizo, Gerente Divisao

Qualidade de Produto, Climax, WhiteWestinghouse, Brazil

-- Ahmed Amin Abrahim, Consultant to

Egyptian Environmental Affairs Agency

(EEAA), Egypt

-- Sergio Reyes-Lujan, SEDUE

Undersecretary for Ecology, Mexico

-- Zhang Chongxian, Division Chief,

Office for Foreign Affairs, China

Lunch
January 15

2:00-5:00pm

6:00pm

Open Discussion

Characterizing CFC and Halon Use

Applications (refrigeration, solvents,

foam, etc.)

Source (chemical imports, imported

products containing or made with

CFCs or halons)

Company/facility

Estimating Future Demand

Historic growth rates or specific

estimation for end-use sectors

Special Circumstances of Developing Countries

Access to new technology

Industrial and development policy

Infrastructure and training

Technical expertise and research

facilities

Presentation & Dinner

"Technology Transfer Projects by the

Industry Cooperative for Ozone Layer

Protection," Art FitzGerald

Dinner sponsored by the National

Institute for Emerging Technology (NIET)

Location: Hogates Restaurant

9th st. & Maine Ave. S.W.

Washington, D.C.

484-6300
\ I

January 16

9:00am-12:00pm

12: 00-2 : ,00pm

2:00-5:30pm

7:00pm

January 17

9:00am --

overview of UNEP Technical Assessment

-- G. Victor Buxton, Chief, Chemical

controls, Environment Canada

Best Existing Technology Presentations by

Technical Experts

-- See Attachment A

Open Discussion

-- Matching Best Technology to Existing

and Anticipated Uses

-- Utilizing Technical Experts for

National Case Studies

Lunch

Preparation of guidance for case studies

Dinner

Location: Eileen Claussen's Home

4733 Fulton st. N.W.

Washington, D.C. 20007

suggested Transportation - Taxi

Final drafting and editing of case study

outlines; end-use survey forms; demand

estimation methods; text and data files

Next steps (organization, operation &

cooperation)
Technical Experts

FOAMS:

Jean Lupinacci, EPA, USA

AEROSOLS:

Jorge Corona, Astral Internacional, Mexico

Montfort Johnsen, consultant, USA

SOLVENTS:

Bryan Baxter, British Aerospace, UK

Brian Ellis, Protonique S.A., switzerland

HALONS:

Hans Lagerhorn, Brandtekniska Ingenjosbyron, Sweden

Gary Taylor, Taylor/Wagner Associates, Canada

REFRIGERATION & AC:

Lambert Kuijpers, Phillips, Netherlands

CHEMICAL ALTERNATIVES TO CFC & FACTORY RETROFITS

Nobuo Ishikawa, F & F Research Center, Japan

, ,
COUNTRY NAME

ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES

TELEPHONE FAX NO.
COUNTRY NAME

ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES

TELEPHONE FAX NO.

Canada Robert Weir 819-997-6731 819-953-4676

Canadian Development Agency

200 Promenade du Portage

Hull, Quebec

Canada K1A OG4

EEC Heinz Hilbrecht 202-862-9578 202-429-1766

Energy/Environment/Transport

Commission of the European Community

2100 M St., NW 7th Floor

Washington, DC 20037

FRG Jurgen Lottmann 069-7431-3142 069-7431-2944

Kreditantstalt fur Wiederaufbau

Pa1mengartenstrabe 5-9

D-6000 Frankfurt am Main

Japan Yasu-hiro Shimizu 202-939-6725 202-939-6788

Environmental Attache, Embassy of Japan

2520 Massachusetts Ave, NW

Washington, DC 20008

Norway Eli Vike 47-2-659810 47-2-658890

State Pollution Control Authority

P.O. Box 8100 DEP N-0032

Oslo 1. Norway

Sweden Ingrid Kokeritz 468-799-1565 468-799-1253

Swedish Environmental Board

Smidasvajen #5

17125 Solna Sweden
COUNTRY NAME

ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES

TELEPHONE FAX NO.

Sweden Tom Hedlund 358-8799-1137 (Te1ex#)

Swedish "Environmental Board 11131 Environ S

Smidesvagen #5

Box 1302

S-l71 25 SOLNA, Sweden

USA Eileen Claussen 202-382-7407 202-382-6344

Environmental Protection Agency

Office and Air and Radiation

401 M St. SW

Washington, DC 20460

USA Stephen Seidel 202-382-2787 202-382-6344

Environmental Protection Agency

Office of Air and Radiation

401 M St., SW

Washington, DC 20460

USA Stephen O. Andersen 202-475-9403 202-382-6344

Environmental Protection Agency

Office of Air and Radiation

401 M St. SW

Washington, DC 20460

USA Jean Lupinacci 202-475-8468 202-382-6344

Environmental Protection Agency

Office of Air and Radiation

401 M St. SW

Washington, DC 20460
COUNTRY NAME

ATTACHMENT 1: DEVELOPED COUNTRY REPRESENTATIVES

TELEPHONE FAX NO.

USA

USA

Denise Mauzera11

Environmental Protection Agency

Office of Air and Radiation

401 M St, SW

Washington, DC 20460

William Rhodes

Environmental Protection Agency

AEERL

MD 62B

Research Triangle Park

North Carolina 27711

202-245-3554

919-541-2853

202-382-6344

919-541-7885

INTERNATIONAL ORGANIZATIONS:

UNDP

The World Bank

Erik Helland-Hausen

UNDP/BPPE/TAD

One UN Plaza

New York, NY 10017

Peter Bohm

1818 H St. NW

Room S-5125

Washington, DC 20433

212-906-5057

202-473-3426

212-906-5365

202-477-0565
COUNTRY NAME

ATTACHMENT 2: DEVELOPING COUNTRY REPRESENTA~IVES

TELEPHONE FAX NO.

Brazil Monica Moraes 061-274-6850 In Care of:

Brazilian Environmental Agency Karla Amorin

SAIN - QL 4 5561-224-5206

IBAMA

Brasilia - D.F. 70.000

Brazil

Brazil Regina Helena Costa 061-321-2324 In Care of:

Brazilian Environmental Agency Karla Amorin

SAIN - QL 4 5561-224-5206

IBAMA

Brasilia - D.F. 70.000

Brazil

Brazil Santiago Mourao 202-745-2766 202-745-2827

Brazilian Embassy

3006 Massachusetts Ave, NW

Washington, DC 20008

Brazil Alberto Carrizo 162-711235 162-725768

White Westinghouse, representing the

Brazilian Industry

Av. Jose Pereira Lopes, 250 - 13560

Sao Carlos - SP

Brazil
COUNTRY NAME

ATTACHMENT 2: DEVELOPING COUNTRY REPRESENTATIVES

TELEPHONE FAX NO.

Brazil

China

Egypt

India

Paulo Vieira

DuPont do Brazil, representing the

Brazilian Industry

AI. Itapecuru, 506 Alphaville

CEP 06400 - C.P.26

Baruerl - SP

Brazil

Zhang Chongxian

Senior Engineer, National Environmental

Protection Agency of China

No. 115, Xizhimennei

Nanxiaojie

Beijing, China

Ahmed Ibrahim

Consultant, Egyptian Environment

Affairs Agency

80 Ahmed El-Sayat St.

Dokki, Egypt

Avani Vaish

Director, Ministry of Environment

& Forest

Paryavaran Bhavan C.G.O. Complex

Lodi Road

New Delhi 110003

55-11-421-8005

861-6011193

202-701655

362840

55-11-4214051

861-653681

202-342-0768

(Telex #)

3166185 DOE IN
COUNTRY NAME

ATTACHMENT 2: DEVELOPING COUNTRY REPRESENTATIVES

TELEPHONE

J

FAX. NO.

Malaysia

Mexico

Singapore

Venezuela

Venezuela

Tan Meng Lang

Dept of Environment

12th Floor Wisma Some Darby

50662 Kuala Lumpur

Sergio Reyes-LujAn

Undersecretary for Ecology, SEDUE

Rio Elba No. 20 PISO 16

Col. Cuaahtemoc

06500 MEXICO, D.F.

Lim Choon Slew

Institute of Standards & Industrial

Research

1 Science Park Drive

Singapore 0511

Carme1ina de Lombard

Ministry of Environment

COVENIN

Avenida Andres Bello

Torre Fonde Comun, Piso 11

Caracas, Venezuela 51116-1050A

Milagros Diaz

Ministry of Environment

COVENIN

Avenida Andres Bello

Torre Fonde Comun, Piso 12

Caracas, Venezuela 51116-1050A

603-293-8955

905-553-9538

65-772-9568

58 2-408-1497

58 2-575-2298

603-293-6006

905-271-3205

65-778-3798

In Care of:

Jean Preston

582-285-0336

In Care of:

Jean Preston

582-285-0336
TECHNOLOGY

AEROSOLS

AEROSOLS

FOAMS

HALONS

HALONS

COUNTRY

Mexico

USA

USA

Canada

Sweden

ATTACHMENT 3. TECHNOLOGY EXPERT PARTICIPANTS

NAME

Jorge Corona

Director General

Astral Internaciona1 .

Mar Negro No. 99

Col. Popotla

11410 MEXICO, D.F.

Montfort Johnsen

President

Montfort A. Johnsen &Associates

26 Shera1 Drive

Danville, IL 61832-1354

Jean Lupinacci

Technology & Economics Branch

Global Change Division, U.S. EPA

401 M St, NW

Washington, DC 20460

Gary Taylor

Consultant

Taylor/Wagner Incorporated

177 Maxome Ave

Wi11owdale, Ontario-Canada

M2M 3L1

Hans Lagerhorn

Skandia Insurance Co.

S - 103 50 Stockholm

TELEPHONE

905-399-9130

217-442-1400

202-475-8468

416-222-9715

468-7881436
TECHNOLOGY

HALONS

COUNTRY

USA

ATTACHMENT 3. TECHNOLOGY EXPERT PARTICIPANTS

NAME

Tom Morehouse

Project Manager

Air Force Engineering &Service Center

HQ USAF/LEEL

Pentagon

Washington, DC 20330-5124

TELEPHONE

904-283-6194

REFRIGERATION &

AIR CONDITIONING

CFC ALTERNATIVES

SOLVENTS

Netherlands

Japan

Canada

Lambert Kuijpers

Project Leader

Phillips Research Laboratories

Building WAp.6.20

PO Box 80000

5600 JA Eindhoven

Nobuo Ishikawa

Director

F & F Research Center

2-9-3, Akasaka

Minato-ku, Tokyo 107

A.D. FitzGerald

Director, Environmental Affairs

Northern Telecom Limited

3 Robert Speck Parkway

Mississauga, Ontario

Canada L42 3C8

3140-742860

03-5828896

416-566-3048
TECHNOLOGY COUNTRY

ATTACHMENT 3. TECHNOLOGY EXPERT PARTICIPANTS

NAME TELEPHONE

SOLVENTS Japan Shigeo Matsui 044-549-2293

Environmental Protection Group

Toshiba Corporation

1, Komukai Toshiba-Cho

Saiwai-Ku, Kawasaki, 210

SOLVENTS Switzerland Brian Ellis 412-1382334

General Director

Protonique, S.A.

PO Box 78

CH-l032 Romanel

SOLVENTS USA Sudhakar Kesavan 703-934-3052

Vice President

ICF Incorporated

409 12th St. SW

Washington, DC 20024

SOLVENTS UK Bryan Baxter 438-753222

Chief Materials Scientist

British Aerospace

Six Hills Way

Stevenage

Herts, United Kingdom SGI 2DA
PRESENTATIONS
, .

PROPOSAL FOR A UNIFIED APPROACH

Stephen O. Andersen

Chief, Technology and Economics Branch

Office of Air and Radiation

U.S. Environmental Protection Agency
Brazil, Eg}1lt and Mexico Case Studies

• Managed by national environment agency

• Participation by other important agencies

• Strong cooperation with national industry

• Developing and developed country experts.
National Experts

• Excellent technical skills

• Experience in adapting technology to

. local conditions

• Better able to improvise and fabricate
Developing Countries as

Sources of Technology

• O~-site fabrication of hydrocarbon

aerosol factories

• Open-air aerosol filling stations

• Ammonia refrigeration

• CFC-12/HCFC-22 swing plants
Advantages of Cooperation

on Case Studies .

• Assure comparable methods and

presentation

• -Investigate all special needs

• Discover innovative technical solutions

• Identify model institutions

• Share best technical experts

• Organize for technology transfer
Comparable Existing and Future Use

• Same scope and outline

• Same chemical coverage: CFC, Halon,

MC, carbon tetrachloride

• Same basic tables and figures

• Same units of measure

• Same demand estimation
1 .

GLOBAL ENVIRONMENTAL PROBLEMS

POLICY IN MEXICO

Mr. Sergio Reyes-Lujan

Undersecretary for Ecology

Secretaria de Ecologia y Desarrollo Urbano
( /"1 I C/!., NO.1)

GLOBAL ENVIRONMENTAL PROBLEMS

POLICY IN MEXICO

PRESENTED BY:

MP. SERGIO REYES LUJAN

UNDERSECRETARY I _ FOR ECOLOGY

SECRETARIAT FOR URBAN DEVELOPMENT AND ECOLOGY (SEDUE)

Wetst", i ngtorl, D.C.
l '

1 ;

(j·1 I Cp·, Nl). :2 )

OUTLINE

I. INT.I?ODUCT ION

II. IMPLEMENTED MEASURES TO REDUCE THE USE OF OZONE DEPLETING

SUBSTP.NCES

A. VOLUNTARY AGREEMENTS WITH THE MEXICAN INDUSTRY

B. STATUS OF JOINT SEDUE/INDUSTRY/EPA CASE STUDY

III. ACHIEVED AND PROJECTED RESULTS

A. FOANS

B. AEF.~OSOLS

C. HALONS

IV. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS

, -

V. MEASURES TO BE IMPLEMENTED TO ADDRESS GLOBAL WARMING

VI. CONCLUSIONS

.-,

4
I. INTRODUCTION

Str~tospheric ozone depletion by chlorofluoroc~rbDns.

halons, and other ozone-depleting substances is one of the mo~t

important environmental problems of our time. For the first tlmE

ever a truly global agreement for the protection of the

environment was reached: the Montreal Protocol on Substances that

Deplete the Ozone Layer. The development of the Protocol

involved more than a decade of multidisciplinary research and a

number of international meetings.

Governments, industries, and non-governmental organizations,

took part in the negotiation~ under the auspices of the United

Nations Environmental Program (UNEP).

Mexico was invited to participate as an observer at the

working group to prepare a global framework convention for the

protection of the ozone layer, resulting in Mexico's accession to

the Vienna Convention. Since then, Mexico has actively

participated in deliberations under the auspices of the Unlted

Nations on I.gal and technical matters relative to CFC controls.

This is the case of the SEDUE's meetings with the twd CFe

manufacturers in Mexico before the Montreal Protocol. In these

meetings, the CFe producers agreed to collaborate with SEDUE in

controlling the production and emissions of ozone depletlng

substances. With these results, the Undersecretary of Ecology,

as representative of the Mexican Government attended Montr'eal

-.j
P~otOCOI'5 meetings.

the Protocol.

MexIco was the fi~st count~y in ratifYIng

II. IMPLEMENTED MEASURES TO REDUCE OZONE-DEPLETING SUBSTANCE USE

A. VOLUNTARY AGREEMENTS WITH THE MEXICAN INDUSTRY TO

REDUCE CFC AND HALON USE

(MICA NO.4)

As a ~esult of the commitment associated with the

ratification of the Montreal Protocol, the Mexican Government

proceeded to implement measures that will yield significant nearterm reductions in the consumption of ozone"depleting substances.

The Secreta~iat fo~ Urban Development and Ecology negotiated and

signed nine agreements with industry which control the

consumption of CFCs and halons. The CFC producers and halon

distributors, and representatives of industries that use CFCs in

Mexico voluntarily agreed to the same reduction measures and.

therefore, the SEDUE/Industry agreements control ozone-depleting

substances in upstream and downstream markets.

(MICA NO.5)

In the Area of polyurethane foams, the two CFC producers in

Mexico have committed to eliminate all of the distribution of

CFCs for flexible polyurethane foam manufacturing by 1990.

Flexible foam manufacturers that use the CFCs have agreed to

unde~take this reductIon. These industry groups have also

indicated their commItment to keep users updated with the latest

information on the development of CFe substitutes for rIgId
•

polyureth~ne foams so that these substitutes are adopted in the

future. The sIgnatories of these agreements also promIsed to

facilitate technology transfer.

Only 10% of all aerosol cans manufactured in 1988 In MeNico

contained CFCs. Based on 1988 CFC consumption in aerosols. the

suppliers of CFCs as well as aerosol m~nufacturers represented by

CANACINTRA (the National Chamber of Industries the major

Mexican association of manufacturing

Aerosol Institute, and the Chamber of

industries), the Mexican

the Perfume and Cosmetics

Industry, agreed to reduce CFC use by 50% in 1989 and to

eliminate the remaining Mexico considers that the

relatively small use

50%

of

by 1990.

CFCs in medicinal, electronic. ~nd

aircraft maintenance aerosols is essential and therefore has been

exempted from reductions due to the lack of adequate substitutes

for these uses. The signatories will also recommend the

labelling of ozone-safe aerosols.

Mexico imports halons through three major companies.

halon distributors have agreed to provide users with information

on conservation measures and recycling technologies and committed

efforts to mAintain users updated on important events regarding

the development of alternative fire extinguishing agents.

Finally, the National Board of In-Bond Industries, group

of export-oriented industries neighboring the U.S. border --~lso

known as Maquiladoras-- h~s also signed an ~greement with SEDUE

th~t covers a broad scope of environmental initiatives. Among

them, the Bo~rd has committed to promote

5

the control of
cont~minant emissions to m~et official standa~ds. Sp~cifically.

the National Board of In-Bond Industries will promote the

reduction of ozone-depleting substancp use to the maximum extent

feasible.

8. STATUS OF JOINT SEDUE/INDUSTRY/EPA ~ASE STUDY

(MICA NO.6)

1. Background

The United States and Mexico have a long history of

successful envi~onmental cooperation as p~oven by the various

consultations conducted since the initial international effo~ts

to protect the stratospheric ozone layer. Recent SEDUE

initiatives and the December visit to Mexico of the EPA expert

team headed by Dr. Stephen Andersen of the Glohal Change Division

con~olidated our coope~ative efforts and resulted in an agreement

to conduct a joint study in which SEDUE,

and the EPA are participating.

The case study will provide,

the Mexican industry,

first, an analysis of

current and projected future demand of CFCs and halons given

Mexican industry trends. The study will also provide a r~view of

the use of methyl chloroform and carbon tetrachloride in Mexico

in light of the current international concern regarding the ozone , -

depletion potential of these compounds not currently regulated by

the Mo~treal Protocol. Second, the case study will describe the

industries that use CFCs and halons and the technology used in

these industries, third, the analysis will evaluate the

costs of reducing CFe and halon use to comply with the Montreal
Hence, the study will p~esent the net costs an~

, ,

.ai11i;&'B3i.iii8i:a5!i5'Ii:.,.,. the finarlcino:;j needs cof C".I·..· count ...·y to cColTlj:.ly with

The case study cu~~ently unde~way will be an ext~emely

helpful source of information fo~ current and potential parties

to the Montreal Protocol not only because of the economic

assessment but also because it will list alternative technologies

appropriate to developing country circumstances.

(MICA NO.7)

2. Pr'oject Team

The project team integ~ates representatives of SEDUE,

the Mexican Chamber of Industries, and the U.S. EPA. The

responsibilities of each project team member is as shown in the

slide.

3. Project Team Operation and Information Sources

The project team has w~rked since December of last yea~

meeting to define the terms of reference of the study and

collecting data through interviews and communications with the

Mexican industry. Other sources consulted include existing

government data on CFC consumption in certain industries, market

r· e J:' (. r' t s , and technical notes ot specific companies. , -

4. Status ot the Study and Next Steps

The team is clll-'r'ently collectin'1 data on the vohlme of

CFCs, halons and other ozone depleting substances consumed in

Mexico and is drafting descriptions of the industries that employ

these substances. Next,

7

will i n v est i gat e t 1", e
manufacturing technology of the user industries to assess the

extent of the modifications required to adopt alternative

Finally, the project team will estimate and

evaluate the costs associated with the alternate technologies 1n

each end use and will generate aggregate cost estimates.

III. ACHIEVED AND PROJECTED RESULTS

As stated earlier, SEDUE successfully negotiated nine

industry a~reements to reduce the production and emissions of

ozone depleting substances in Mexico. Beginning discussions in

1987, these voluntary agreements were signed on November 9, 198Q

and include: two agreements with companies that produce CFCs and

distribute halons, and seven agreements with industries that

represent users of these substances.

These efforts lead to the following current and project~d

\·-esl.llts:

(MICA NO.8)

1. The consumption of CFC-l1 and CFC-12 as foam,blowing

agents and aerosol propellants dropped by 13.1% in 1989

with respect to 1987 levels. By 1991, we expect to

achieve a 31.7 percent reduction with respect to 1987

consumption.

(MICA 9)

2. This r-edl.letior, is j:.r-imelr·ily dl..le to the s~far'p dech?Cise

planned in the consumption of CFC-12 as blowing agent.

,.,

'='
This past year an annual decrease of 75% was achieved

in this area and further reduction are expected as

shown in the transparency.

(MICA 10}

3. Industry reports that the consumption of CFC-1i as

blowing agent is likely to grow by 10 percent given

current trends in the foam industry. However, growth

in this area will be more than offset by the impressive

decrease in the consumption of CFC-1i and CFC-12 as

aerosol propellants.

(MICA 11)

4. As shown in this transparency, the current consumption

of CFC-12 in aerosols will be dropped by apprOXimately

50 percent this year and by 1991, only essential uses

of CFCs will be allowed~

(MICA 12)

5. Similar reduction are planned for the use of CFC-11 in

aer-oso Is.

(MICA 13)

6. It is important to remember that today, only 12 percent

of all aerosols produced in Mexico contain CFes. Ttl i s

transparency shows the total number of cans produced in

Mexico, and of this total, those cans still containing

CFCs. The overall market is expected to grow at about

5 per-cent al....'ually; however', t.y 1991 only 3 j:.ei"CIH,t

of all aerosols produced will contain CFCs.
<.NICP-, 14)

7. In the h~lon ~~e~, ~pp~oximately 50 '1~ 0 f h~ 101",

emissions a~~ avoidable.

.. ~.".

ThiS ~misslons will be

(MICA 15)

c:ontr·cliled thr·ol.!,;/t. nUlTtbei-· clf conser·vation measures

which include limiting ~eleases du~ing testing and

demonst~ation p~ocedures. By the yea~ 2000, we expect

that halon ~missions will represent only 56% of 198q

emissic·ns.

8. This tr~nsp~rency shows the specific effect of each

emission reduction measure. By the year 2000, most of

the avoidable halon emissions will be controlled

(MICA 16)

leaving only those emissions associat~d with the actual

extinguishing of fires.

'71 • Finally, in addition to conservation measures,

al~ernatives to the use of halons as fire extinguishing

agents are projected to be introduced in 1992, and by

1996 these alte~natives are projected to replace almost

entirely the consumption of halons.

10
IV. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS

(MICP, 17)

Although Mexico is a developing country it can be a source

of some new and adapted technologies to protect the ozone layer.

Mexi~o has highly skilled and inventive enginee~s who have

adapted and develo~ed technology to local conditions, such as

climate, and to be flexible as market changes occur.

· l

For example, as Mr. Jorge Corona will explain, 01.1 r- a e r- 0 5 0 I

industry has simplified the technology to fill aerosols and,

overall the Mexican design approach is cost-effective and safe.

The know-how for adapting or designing new technology is

available in Mexico. These technologies may be applicable to

other- developir,g cOlmtr-ie's irlter-ested irl pr-otecting the ozone

layer-.

, -

11
v. MEASURES TO BE IMPLEMENTED TO ADDRESS GLOBAL WARMING

(MICA NO. 18)

The combustion of fossil fuels is one of the largest source~

of pollutant emissions that contribute to the probl~ms of global

warming and ozone depletion •. Mexico is awa~e of this problem and

will promote through institutions and organizations involved in

th15 area th~ implementation of a program to preserve and improve

the efficiency of fossil fuel utilization.

The program will also control the emissions of methane from

landfills and will promote research in the use and development of

alternative fuels.

The rational use of water through the legal reevaluation of

the technical and economic components of water supply management

are ve~y important for Mexico, as well as

efficient techniques for water use.

the implementation of

The use and consumption of energy in Mexico requires the

guidance of a program to increase the efficiency of ene~gy

production and use, foster the development of alternative energy

systems to those based on fossil fuels, or addresses a

~estructurin9 of oil prices. There is also a need to accelerate

the replacement of old machinery with new energy efficient , -

technology.

Other measures to address air pollution that should be

encouraged include t~ee planting, ~eforestation, and new

a~ricultural technologies

milk.

for the production of ~lce, meat, and

12
<: r1 I CA NO. 1.~) VI. CONCLUSIONS

1; THE PROTECTION OF THE OZONE LAYER RULES OUT THE

POSSl-BILITY OF "HHP" SHP,F:ES OF OZONE DEPLETHK,

COMPOUND USE. ALTHOUGH MOST OF THE CHLORINE IN THE

ATMOSPHEPE IS DUE TO EMISSIONS FPOM DEVELOPED

COUNTRIES. DEVELOPING COUNTRIES MUST ALSO STOP THEIR

PRODUCTION AND CONSUMPTION OF THESE SUBSTANCES.

2. IT IS NECESSAPY TO TIGHTEN THE IMPLEMENTED MEASURES TO

PEDUCE OZONE DEPLETING COMPOUND EMISSIONS AND TO TAKE

ALL NECESSARY ACTIONS TO ACHIEVE THE REDUCTIONS NEEDED.

~. THE CASE STUDY UNDERWAY IN MEXICO WILL EVALUATE THE

PRESENT AND FUTURE DEMAND OF OZONE DEPLETING SUBSTANCES

AND THE ECONOMIC NEEDS ASSOCIATED WITH THE

IMPLEMENTATION OF THE MONTREAL PROTOCOL. THE STUDY WILL

ALSO PROVIDE USEFUL INFORMATION ON NEW TECHNOLOGIES AND

APPROACHES USED IN MEXICO.

4. MEXICO'S TECHNICAL KNOW-HOW MAY BE USEFUL TO OTHER

DEVELOPING COUNTRIES.

5. MEXICO IS CONSIDERING TO ALLOW MANUFACTURING OF CFCs

FOR MEDICAL AND OTHER USES FOR WHICH NO SUBSTITUTES ARE

CURRENTLY AVAILABLE.

6. THE MEXICAN GOVERNMENT PLACES HIGH PRIORITY IN AN

ENERGY CONSERVATION PROGRAM FOR MEXICO.

7. TO ATTAIN SUSTAINABLE DEVELOPMENT THERE IS A NEED TO

REDUCE POLLUTANT EMISSIONS FROM MAJOR CITIES AND

PROMOTE COST EFFECTIVE AND EFFICIENT ENERGY SOURCES AND

TECHNOLOC; I ES.

13
i .

r .

8. THE VIENNA CONVENTION AND THE MONTREAL PROTOCOL

REPRESENT A PATTERN THAT CAN BE USED FOR A WORLDWIDE

CONVENTION ON GLOBAL CLIMATE CHANGE.

14
SEOfJ~

.- .•

GLOBAL ENUIRONMENTAL PROBLEMS

POLICY IN MEXICO

-I

\

I

l

I

J

I

I

I

•.(
POLICV

I. INTRODUCTION

IN Ml:::XICO

II I"PLE"E~TED nEA,URES TO REDUCE THE USE OF OZONE DEPLETING

SUBSTANiCES

&.- .......

A. UOLUHTAftV AGREEMENTS W.TH THE "E~.CAN .NDUSTRV

B. STATUS OF ~O.NT aEDUE/.NDU8TRV/EPA CASE aTUDV

III. ACHIEVED AND PROJECTED RESULTS

_. AJl:ftOaOLa

c. HALOHa

•

IV.

v.

VI.

ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS

CONCLUSIONS
INTRODUCTION

.- •.

•

THE rtoNTREAL PROTOCOL IS THE FIRST GLOBAL AGREmENT TO ADDRESS A CR I TICAL

ENUIROMtENTAL PROBLEtt OF OUR TI"E

"EXICO HAS ACTIVELY PARTICIPATED IN THE INTERNATIONAL EFFORTS TO PROTECT

THE OZONE LAYER

"EXICO WAS THE FIRST COUNTRY TO MTIFY THE ItOtITREAL PROTOCOL DUE TO CLOSE

COLLABORAT ION DETUEEfli THE GOUEIMtDlT AND INDUSTRY
SEDUE/I NDUSTRY/EPA' _S CASE STUDY

• ANALVZES THE PRESENT AND POTENTIAL CONSUtlPTION IN nEXICO

OF CFCs, HALONS AND OTHER OZONE DEPLETING SUBSTANCES

• ANALYZES THE SPECIFIC APPLICATIONS AND USES OF THESE

SUBSTANCES IN THE nEXICAN INDUSTRV

• ASSESSES THE OPTlotIS TO REDUCE THE CONSUt1PTION OF THESE

SUBSTANCES AND THEIR It1PLDtENTATION COST
SEDUE/INnUSTRY/EPA STUDY GROUP

.l

. DIRECT10N •_.

GENERAL COORD INAT ION

INDUSTR IAL COORD INAT ION

DATA t'lANAGEnENT

TECHNICAL ADVISER

SEDUE

nlNISTRY OF FOREIGN AFFAIRS

NATIONAL OHA"BER OF INDUSTRIES

SEDUE

EPA

,I
EPAJls STUDY GROUP

..... OAH1P-ft~RA....

(1) COLLECT ION OF EX 1ST ING DATA ON CONSUttPT ION AND DMFT

DESCRIPTION OF mE INDUSTRIES THAT USE OZONE DEPLETING

SUBSTANCES

(2) MTA COLLECT ION ON THE PRODUCT ION TECHNOLOGY EnPLOYED

IN SPECIFIC INDUSTRIES USING SUCH SUBSTANCES

(3) ASSESSftENT AND COSTING OF ALTERNATIVE TECHNOLOGIES

ADEQUATE mE DOnESTIC CHARACTERISTICS OF EACH INDUSTRY
THE SEDUE/INDUS1RY AG,.EEMENTS

UPSTREAM AND pOWNSTREAM

...•

CONTROL OZONE DEPLETING SUBSTANC~

Nine Sedue/lndustry

CFC Produces and

Halon Dlstrlsbutors

Voluntary Agreements

End Use Industries

,.
VOLUNTARY AGREEMENTS WITH THE MEXICAN INDUSTRY TO REDUCE CFC AND HALON USE

End-Use

Polyurethane

Foams

Agreement Signatories

DuPont

Quimqbasics

Mexican Polyurethane Institute

Nature of Organization

CFC Producer

CFC Producer

Industry Association

Measures

• Reduce CFC distribution and use by 100%

by 1990 in flexible foams

• Update information on dev"opment of CfC

substitutes for adoption in dgid foam systems

• Facilitate technology transfer

Quimobasicos

Aerosol

Products

Dupont .- . CFC Producer

CFC Producer

In 10% of all aerosols units stiR containing I

CFCS in 1988:

• Cut CFC use by 50% in 1969

Halons

Miscellaneous

National Chamber of Industries

Mexican Aerosol Institute

Chamber of Perfume and

Cosmetics Industry

DuPont

CAISA

ICI

National Board of In-Bond

(Maquiladora) Industries

Main Association of all

Manufacturing Industries

Industry Association

Industry Association

Halon Importer/Distributor

Halon Importer/Distributor

Halon Importer/Distributor

Association of Export

Industries Neighboring

the U.S. Border

• Cut remaining 50% by 1990

• Medicinals, electronic cleaners, and aircraft

insecticides and deororants are exempt

• Recommend labelling of ozone-safe aerosols

• Provide users with information on halon

conservation measures

• Update users on development of alternatives

• rromote the reduction of ozone-depleting

substance use and emissions
SEOUE

6 MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

REDUCTION IN THE USE OF GFC'S AS BLOWING AGENTS AND PROPELLANTS

CFC- II AND CFC 12

CONSUMPTION

% DECREASE

8.6

13.1

26.3

31.7

4000

3500

1500

1000

500

o

3093 .- ....

% DECREI\SE IN USE DURING

PERIOD

PERIOD

1987·1988

1987·1989

1987·1990

1987·1991

YEAR 1987 1888 1888 1990 1991

HISTORICAL AND PROJECTED CONSUMPTION

__________-------------------,o-1iO-UR'T': eFC PRODUClRS

,J
SEOUE

6 MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

REDUCTION IN USE OF CFC -12 AS BLOWING AGENT

eFe -12 ·AS BL(j)WING AGENT

700 ANNUAL 0/0 DECREASE

::::::;::: CONSUMPTION

600 YEAR % DECREASE

500

400

U)

z

300

0

ti 200

100

o

YEAR

606

HISTORICAL AND PROJECTED

CONSUMPTION

1988

1989

1990

1991

15.3

75.6

12,0

9,0
MEXICAN PROGRAM TO COMPLY WITH MONTREAL PROTOCOL

USE OF eFC-1I AS BLOWING 4GENT

CFC -II AS BLOWING AGENT

2000

1800

1600

1400

(/)

Z 1200

0

t1000

U

-

a: 800

tW

:E eoo

400

200

0

'(l.:.R 1981 1988 1989 1990 1991

4NNUI\L % CIlI\NGL

YEAR % CIiI\NGE

1988 - 0.8

1989 20.9

1990 10.0

1991 +10.0

:;:;::::::. DOME ST IC CONSUMPTK1'J

;::;:;:;:;:; AND EXPORTS

HISTORICAL AND PROJECTED CONSUMPTION SOURCE ctC PHODUCfHS
Exhibit 2

1986 PRODUCTION OF HALONS AND ·CFCs

Weighted By ODP

Halons
HALONS: ADVANTAGES AND DISADVANTAGES

Halons Work Group

I. Advantages of Halons

• Low Toxicity for Humans

• Non-Damaging to Electronics

• Low Space and Weight Requirements

• Highly Effective Fire Suppressant

• Low Installed Cost

• System Efficiency

II. Disadvantages of Halons

• High Ozone Depletion Potential (ODP)

Upper Bound is 30 ODP

Average Estimate is 10.6 ODP

• Greenhouse Warming Potential

• High (and increasing) Relative Costs

$150 - $200 per square meter for Halon Systems

$10 - $15 per square meter for Water Sprinkler Systems
III. Halon Production Levels and Relative ODPs

• In 1986, Halons accounted for only 2.5% of total CFC production by

weight. CFC-ll, -12, -113, -114, and -115 accounted for 97.5% of

production by weight.

• In the same year, however, Ha10ns accounted for 12.9% of total

production when compound contributions are weighted by ODP. CFCs

accounted for 87.1%.

• The breakdown of Halon production for that year was as follows:

Halon 1211 56%

Halon 1301 - 40%

Halon 2402 - 4%

• Quantities of Halon banked around the world are estimated as:

11,200,000 tonnes of Halon 1211

7,000,000 tonnes of Halon 1301

650,000 tonnes of Halon 2402

• Stockpiling is now in progress because:

DuPont will cease production in 1999.

Companies plan to inventory enough Halon for systems

operation until 2050.

_ I

- ,
HALONS:

ADVANTAGES AND DISADVANTAGES

Halons Work Group

- 1.

_ l

- j

- ,

- j

, I
.... "'" "", ""

t O.

" _.." ..,...,.....- "~.•..- .' w·_·,'··_ .........'.,"" . -, J-V· · 1i1~~ i$lc ,

t;J~i ODP eLf' (..{WP - _ ..

l ,.

22 CHce,f 2 't7 -·4·{ o.o!) f). Ilf-. O.3S

123 c~aL- tf3 153 2~ o. (j 2 (). f') Z o. 02

f2'f cHCtF - CFJ 13'7 -(2 0.02 0. 0 '( 0./

(4fb CH3 -CC(2f II 7 32 o. 1 o. ( o. I

14-2b CH3- CctFl 10/ -7 O.os o· I 0.37

2:l~c~ CF3-C,fl -C~Clz 2.03 ~I ? ?

• 7

• • •

-.- -, --

225 cb CF1 c( .. Cfl. -CHtt F 203 s, 7 I

• 7 I

,

• .

i

CT celLI- '~lj. '77 I. I ,. 0 O,3lr McF Cl-l 3 CCl3 , 33 '71 0.11-{- I 0.02

, -
- ,

CFC- 1/3 - VC r; ,,0.+ \',V ei.

.IVldlA~+t~a.(l~ est~bl;~d,

o ~Q.S'( prf)te~s.

, .

;l1( Tr=~ r ../ .. ..

..

i ..it

::!ffifC -134~ i

: CHl.f-Cf3

: \li3~1! 1: )lCTF~7 •

r ' - 1 r'. I

-, -: • or,~J~d ( (J L L

- Vf' "fJ f- :.. '-' r F , '

t "-- 0 7

1

(<< HL(f\J;O

, fl\

t H~

~! rIfFE )

, C.HF =Gf1. ..i

:: ,-, HF
1/ I ~Jt, 11, UJ, &T)- Hrl., f ' . '"'

----....-- _. - -'" ----~------

.J - V -Ip }- .. t,;'3----I#::...~'-+-:-b-:-. p__0c---+-_1---L.:----!'~--

32 CH1.f2.1 - 52 -' !,7 ~CFC-220)1-\o ~t~ 0

r. 12.5" .1 CHF2- CF3 12.0 _. '+9 ~t 0 f=.';'" GWP *- Co, 6)0

(f> 13lf I CHF1 -CHf2 102 -').0 1-~ %?

"- ' I

u, '.) 134ct Ii CH2F-CF3 f02 - 27 CfC-(2.0)1\l;t"l.~7ii1Jo ~-~ :

i ~\

\~t' ~i14-30, I CH3-CF3 ~lI- -lfg .,'~--,. qwp* (0,'7)0

'~ 0 r52a. I, CH3-C.~Fl l,l -25" Pl'~ffo GUJP1f' (0.03),

I. I ~1.7 'Cf3-CHF-CF3 1'70 -'('7 q(J~·t?~ C'-.. ' 0
HALOGENOCJ1,RBONS 'N IDE L¥- USED IN INDUS lfW

! J . I

Code r-Formula b. p. °C Life/y OOP I) GWP' . Main uS

I

.- "'" «

CFC-11 - CC1 3F 24 60 1. 0- 1.0 Foaming

! CFC-12- CC1 2 F2 -30 120 1. 0- 3. 1 Coolin; I

,

rCC1 2 F-CCIF 2 J

CFC-113- 48 90 0.8- 1.4 Cleanin

I - . ""t

I CFC-114- CCIF 2 -CClF 2 4 200 L 0- 3. 9 Blene:,.,'.... I . - ; .-' '~

L I i

CFC-11S·J CClF 2 -CF 3 -39 400 O. 6- 7. 5 . Blend :'r::::

HCFC-22 CHClF 2 -41 1S O. OS O. 35 Coolin;;

I

.- -=--- .__-.-...

halon 1301 - CFJBr -58 10. 0- ,.... . r:re el'"

halon 121 1• CF 2CIBr -4 1 O· I - .

.,j.

I -~r-e '2,l( :

L halon 2402· CF 2BrCF 2Br 47 6. O· I ~::e e, ~--_.

_1II I

CT 2 )

,

CC14 .77 50 , , I I. ; oI • 1'" ..,:J :..,;- (''''''c S

MCF J' CHJ-CCl J 74 6. 3 O. 13 O. 024 Cleaning

* Proauction is regur~ed by the Montreal Protocol.

.)Ref: Synthesis Report UNEP/O·zl. Pro. WG. I I (1) /4, Nov. 4, 1989.

2) Carbon tetrachloride) 3) Methylchloroform or 1, 1, 1-i richloroet harE
-

, "

• ') 6l~~orneY'

- "

Dl&

• 7 Cbplrlrr>1€

~to..)to~Y\ c _ SQ.»ac - .•

(CI.. st.'c.

• b

•

HOf-£' -~2- per;vo-1 ;ves l ~ol~d)

~. ,

rJE}/ $ $ [TFEJ

C,HCtf2 Cf~: CP2

I ,

! •

, .

I.

'~ (: SIt('foo.

f. o.t.,+~ ve

;' ~o."tet\ ~ls

i (olt I,JOrer

: J'e~ e~L er.~)

• \ • • t I , • I ,,- .
A(e-t;~ {e '" (; 1

CH~CH

.~ HF

[H FO·-~~\)·!i, t I

C(13 - Cl-(F

plCJ..~t~(, elo:)to~c

" .t\rj +- &A n JiY\ Q f

.~VdF _ ...~_. __ tCHi.:: CF2

...--. ~----- PDI,ptler [Cotvt~",e;-

,

)

t

..

o

I,

I'

r '

t, • • (-.If.

u

p

j

,

I .

r'

I:

:: [HeFe -Iq.~fl] ":f.fce>

•

CH3-C~f~

:: [T' (jFL- GH3'C~3

; .At HF

,. rHCfC:J~I~)

CH3 -CU,r-

[
Characteristics of Pentafluoropropanol (5FP) =====~~_"_ i=-c=-"~, "_"= ===== ===========-,------~-====

L.o - !

(51~P_) (/" eFe-llL) I

, ..

- ~[o lee u I a r Weight l~O 187.5

--- noiling Point eC] 7a";";> 47

Specific gravity 1.509 1.561

Surface ten s ion [dyne/em] (19~ 18 I -

I1eat o f vapouri zation [cal/g] 6~ 4 3 ~1 . '1

Sol ubi lit y o f H2O [%] CI3.tlJ 0.01 •

r-Iash Poi n t eC] none non e

Ozone Depletion Pot e n t i a I 0 0.8

Green House Effect Pot e n t i a I <0.1 0.3'-'-0.8

-. .... -'.~.

Mutagenicity none ". non e

F ish bioaccumulation none none L

rJ a pan e s e TSCA 2-3364 2-95

TSCA 422-05-9 76-13-1

EINECS 2070127 2009361

Acute o r._<!.J t Q X i --

cit

...-----.y... LDSO [mg/kg] 2,250 43,000

I n hal a t ion toxicity LCSO [p pm] 7,000 (2 H) 87,OOO(6II} --.-
r •

f -

l..

, >

CFCs AND HCFCs AS FEEDSTOCKS

Dr. Nubuo Ishikawa

Director, F & F Research Center

Japan
CFC's & HCFC's

as Feedstocks

Nobuo ISHIKAWA

(Japan)

1/.16/90, Washington, DC
a

TABLE 1 (Continued)

SUMMARY Of TECHNICAL OPTIONS AVAILABLE fOR CfC REDUCTIONS

The actual amount of water substitution possible will vary geographically by 15-50 percent according to the choice of raw materials, initial

energy efficiency value of the insulation and energy efficiency standards. The following table illustrates the average reductions expected worldwide:

Region

N. America

u. Europe

Japan

Other

Total

•

eFC Cons~t ion

(Tomes)

9,400

9.900

~. 700

13.200

37,200

X Reduction

15-30

50

15

15-30

Total

(Tonnes)

'.4'0-2,820

4,950

705

1,980-3,960

9,045-12,435

b The actual amount of water substitution will vary geographically by 15-50 percent according to the type of facers, polyurethane or

polyisocyanurate foam chemistry, energy efficiency, and combustibility requirements.

Region

H. America

W. Europel

Other

Total

eFC Cons~t ion

(Tonnes)

21,700

29,300

51,000

X Reduction

15

25-50

Total

(Tonnes)

3,255

7,325-14,650

10,580'17,905

c In polyurethane rigid packaging, rigid integral skin. and other miscellaneous polyurethane applications, it is technically possible to reduce

CFes by 80 to 100 percent by 1993. for flexible integral skin foams, the level of CFC reductions worldwide is expected to be around 50 percent.

6
'ABLE 1

SUMMARY Of 'ECHNICAL OP'IONS AVAILABLE fOR efe REDUCTIONS

TOI'Vles of

efC Used Possible Global Possible Global

Type of foam (1986) Near Term Options Reductions by 1993 Longer-Term Options Reductions After 1993

•

Polyurethanes:

flexible Slabstock 45,600 New polyol technology 8O-100X HCfe-141b 0-20~

Increased foam

density/Increase water

"AB" technology

Cft recovery

Methylene chloride

Product Substitutes

(fibrefill, latex foam)

flexible Moulded 13,700 New polyol technology 80-100X HCfC-141b O-lOX

Increased waterl HCfC- '23

increased densities

Rigid Insulation: 30Xt!1 Appl iance 37,200 Increased water HCfC-141b Jlemaining CFe use

slbst i tut ion (IS-SOX) HCFe-ll3

Product

substitutes

Vacu~ panel

insulation

laminate 51,000 Increased water 28Xt!1 Hefe-141b Remaining eFe use

slbstitution (IS-SOX) HCFe-123

Product substitutes Product

(EPS, perlite, subst Hutes

fiberboard)

Spray, Slabstock, 44,200 Increased water 15-50X HCFe-141b Remaining efe use

lind Poured- in- substitution HCFe-123

place Product substitutes Product

subst i tutes
TABLE 1 (Continued)

SUMMARY OF TECHNICAL OPTIONS AVAILABLE FOR CFe REDUCTIONS
Longer term options for reducing CFC use in Foam Plastic Products

Longer term options Foam products for which option is appropriate

Insulation Cushioning Packaging Other

HCFC-141b

HCFC-123

HCFC-124

HCFC-125

HCFC-134a

Product substitutes

Vacuum panels

Modified resins and

atmos. gases

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o
GLOBAL PHASE OUT SCHEDULE FOR CFCS IN FOAM PLASTIC

Near Term (by 1993):

The foam plastics industry can reduce approximately 60

percent of 1986 CFC consumption with available substitutes:

increased and total water blowing (carbon dioxide blowing

agent), new polyol technologies, hydrocarbons, HCFC-22,

HCFC-142b, and others.

Polyurethane flexible foams, polyurethane packaging and

miscellaneous foams, extruded polystyrene packaging foams,

extruded polystyrene insulation, and polyolefin foams have

announced CFC phase out by 1993.

Long Term (after 1993):

The foam plastics industry, principally polyurethane and

phenolic insulation foams, will depend upon the development

and acceptable use of HCFCs to achieve a complete phase out

of CFCs.
, .

, .

j •

r ..

f ' i

..

'c Reductions in Foam Plastics Can Vary Significantly from

)untry to Country Depending Upon:

;e patterns' in Each country

countries with large CFC consumption in flexible and

packaging foams have opportunity for largest and

quickest reductions:

Water blown foams

Increased foam density

New polyol technology

HCFC-22

Product substitutes

Countries with large CFC consumption in polyurethane

insulation foams for appliances, buildirigs and pipes

face greatest challenge for substitutes:

Increased water blowing for immediate reductions

in CFC consumption.

HCFC-141b and HCFC-123 most promising longer ter~

substitute.

Energy efficiency is important criteria ~n

substitute selection .
------------_._----._-----_. _ ..

Near term options for reducing CFC use hl Foam Plastic Products

Near term options Foam products for which option is appropriate

Insulation Cushioning Packaging Other

New polyol technology

Increased foam density

Increased water blowing

Total water blowing

"AS" technology

CFC recovery

Methylene chloride

Product substitutes

Air loading

HCFC-22

Hydrocarbons

Hydrocarbon/HCFC-22 blends

HCFC-142b

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o

o
Global· CFC Use in Foam Plastics

(by type of product)

Cushioning

22%

Packaging

12%

Other

8%

22%

12%

58%

Insulation

58%

Source UNEP Foam Technical Options
Figure 1

Types and Major Uses of CFC-.Blown Foam

Furnltur. CUlhlonl

I ..- Siabstock Bedding

C.rpet Und.rlle.

..- Flexible Polyurethane Foam

L.- Moulded S.at CUlhlonl

Moulded Furniture

Open Cell

Foam

Rigid '-- Packaging Polyurethane I--- Poured Packaging

Foam

..- Bunstock Building InaulaUon

... Polyurethane 10-

Rigid - Laminated Roofing Sh.ath. ..- Insulating IFoam

- Poured Rntg.aUon and

Building Inaulatlon

- Sprayed Wall and Root

InaulaUon

- Closed Cell I- Foam I- Polystyrene i-- Boardstock Building InlulaUon

Phenolic BuIldIng InaulaUon

Stock Food Traya ,. Polystyrene I--- Sheet carry-out ContaInera

encartDna

. Rigid CUshIoning ""- Packaging l-I- POlypropylene Packaging Foam

ProtKUve

Polyethylene Peckagtnt

FIoetatlon Devlcea

Source: leF Incorporated, f989 2
1986 Global CFC Use - by Application

(in metric tons)

Aerosols

299,700

CFCUse86

Solvents

177,600

Other

77,700

16%

28%

-2~. CY '-) tl)

25%

Refrigeration

267,000

Foam Plastics

267,000
Global' CFC Use in Foam Plastics

(in metric tons)

Polystyrene

37,600

(14%)

Polyolefin - 13,000 (5%)

Phenolic - 6,900

(3%)'

Source: UNEP Foam Technical Options

Polyurethane

209,400

(78%)
! .

r .

r .

r . ,

i

t '

, .

I .

f '

,

,

j

I .

IMPORTANT CONSIDERATIONS IN

EVALUATING SUBSTITUTES TO CFC

BLOWING AGENTS IN

FOAM PLASTIC PRODUCTS

Ms. Jean Lupinacci

Office of Air and Radiation

U.S. Environmental Protection Agency
Important Considerations in Evaluating substitutes

to CFC Blowing Agents in Foam Plastic Products

Prepared by:

Jean M. Lupinacci

Chairperson,

UNEP Foams Technical options Committee

EPA WORKSHOP

Integrating Case studies Carried

Out Under the Montreal Protocol

January 16, 1990
REFRIGERATION APPUCATION AREAS

Refrigeration/Retailrrransport/Storage/AC-Chilling/Automotive

Refrigerators Retailrrrans. Storage AC-Chill. Automotive

Containment + +(?)

Recycling -/+ ++ ++ ++ ++

Reduced Charge + + 0 0 +

HCFC-22 ++ + +

Drop-ins (R-sao) -/+ 0 0 -/+ -/+

i " Substitutes Existing + ++ +/-

f" •

(ammonia, HC)

New Substitutes ++ -/+ + ++

j -

++ very interesting from reliability/environment point of view

+ Interesting

0 not applicable/marginal

not interesting
Examples:

• Recycling will be interesting from a point of view of cost-effectiveness, environmental

acceptability, etc.

However, recycling of refrigerant from disposed refrigerators may not be cost-effective,

but may be of high public interest (environmental consciousness). '

• Application of HCFC-22 in equipment can reduce the dependence on CFC-12 in a lot of

equipment (in case it uses CFC-12) at short notice.

• ' Most of the developing countries have high CFC consumption shares in the retail/storage

sector. Mostly due to recharging of leaking systems and component failures/repair. High

reductions of consumption can be achieved by education of engineers and the creation

of good practice methods.

• Reduction of charge may be applicable in smaller systems where piping is also used as

construction material. 10/20% reduction may be possible.

• Ammonia technology should receive considerable attention and can provide substantial

saving in CFe-consumption.

• New substitutes have to be applied in refrigerators, e.g., there is no reliable solution so

far (near Mure).
I '

I "

!

i "

ASSESSMENT OF

ALTERNATIVE SUBSTITUTES AND TECHNOLOGIES

IN REFRIGERATION

Dr. Lambert Kuijpers

Philips Research Laboratories

Netherlands
25% Refrigeration

25% Foams

25% Aerosols

Solvents

Miscellaneous

UNEP - TECHNOLOGY ASSESSMENT

Global Values

Refrigeration varies over countries: 5-50 percent

Low percentage of refrigeration in developed countries which have:

• Low amount of CFC-solvents

• No automotive air conditioning

• Aerosols

1986/87 Values

- I

FRG

Refrigeration <10%

10% Refrigerators

70% Retail/Storage, Transport

Automotive

USA

Refrigeration =35%

4% Refrigerators

30% Storage, 20% large

units

40% Automotive

PRC

Refrigeration 45%

10% Refrigerators

90% retail, storage, chilling
The first application of this technique will be a batch pcb defluxing

machine which is currently being assembled this year. A diagram of the

principle of the system is shown in the figure. Simplified versions of the

technique can be used for dewatering as well as precision small parts

cleaning.

Because of the high cost of the p.f.h. and also because it has a high

global warming potential, the prototype cleaner is designed to be hermetically

sealed with zero solvent loss and its commercial viability will depend in

large measure on the success of this aspect of the design. The alcohol is the

"working solvent" for the system and can be made up automatically as flux or

other soil rich solvent is discarded to waste or recovery.
SEALED LJO

ATER

ERATED

NSER

R BLANKET

GCOILS

H'ADI

Ot

,. ,r ..

REFRIG

- CONDE

~VAPOU

.~ ~--------------- ~COOLIN

-.~~ -. III ,.~. SPRAY

, ,

", ~, ""II ~" ;.1/ ~, ;"

,,'. .,;~ 'I

\ , , I

\ . I

\ I

•

II. ALCOH .. -

__ P.F.H. ..........

e::;;,. J HOTW

\ c.. J

C -.,

PUMP

eFe FREE DEFlUXING SYSTEM
j •

REPLACEMENT OF CFC-113 SOLVENT

Mr. Bryan Baxter

British Aerospace Precision Products Group

United Kingdom
REPLACEMENT OF CFC-113 SOLVENT

Presented at the EPA Workshop: Integrating Case Studies

Carried Out Under the Montreal Protocol

January 15-17, 1990

B.H. Baxter, British Aerospace Dynamics Ltd.

It is an easy oversimplification to assume that the only industrial use

of CFC-113 is as the major solvent in the defluxing of soldered electronic

circuits and components. The risk of such an oversimplification is that it

can lead to the conclusion that the introduction of aqueous cleaning, no-clean

flux options and controlled atmosphere soldering techniques can virtually

eliminate the need for CFC-113. Unfortunately, whilst these factors apply to

certain uses of the solvent, particularly in the large volume commercial

electronics manufacturing industry, they fail to cover adequately many other

uses of 113.

In particular dewatering and drying accounts for a large part of CFC-113

production. ·In some industries, especially optics and small component

manufacture, up to 60 percent of 113 consumption is for this purpose. In

comparison with alternate techniques such as oven or air-knife drying, it

offers energy efficient "one shot" drying and produces spot free cool

components of particular value in the optics and medical prosthesis

industries.

The precision engineering industry also uses large amounts of 113,

especially in clean areas where its low odor, zero flammability and low

toxicity are essential and its chemical compatibility with reactive metals

such as beryllium is difficult to match using alternate solvents.

The defense electronics industry is also radically different from large

scale commercial manufacturing; a wide range of technologies often needs to be

processed in the same area, sometimes in relatively small batches. Unlike the

commercial sectors where circuits can be designed to meet cleaning techniques,

the defense equipment manufacturer is often called upon to produce components

for long-running contracts using long "frozen" drawings and plannings.

One alternative to CFC-113 which is effective as a defluxing agent, a

cleaner and a dewaterer, is 2-propanol or isopropanol. However, this solvent

suffers the considerable disadvantage of high flammability. At British

Aerospace we are developing a process jointly with two other companies in

which this flammability is completely suppressed by the use of a perfluoro

hydrocarbon. This solvent, although immiscible with the alcohol, vaporizes

with it form a vapor mixture which is completely non-flammable.
i.

HC+

derivs.

HCC, CC &HCFC solvents ,.._---:,.

I \

, , J"RA Flux\ , \

\ \

\ \

\ \

\ \

\ \ \ .-----

\,

,

RAFlux

Hydrocarbon/surfactant+water Saponifier +water

Water

cleaning

I .

Practical substitute methods for CFC solvent cleaning in electronics

@ Protonique SA, 1989
I .

]

r -

I

f -

i "

ELECTRONICS CLEANING IN DEVELOPING

COUNTRIES

Mr. Brian Ellis

General Director, Protonique, S.A.

Switzerland
Some ideas concerning electronics cleaning in developing countries:

Assumptions: at present prices, a wave soldering machine +In-line CFC-113 machine for medium-large production of

medium professional quality (e.g. computer, telecomms etc.) costs $120,000 In capital and an Index of 1 to run.

Following figures are very approximate average estimations, based on average European' figures for capital costs of

mlddle-of-the-range equipment, solvent costs, salaries, social charges, rent, energy and other overheads.

Indices: lowest figure best, highest figure worst.

Process Capital Running Overall Ease Space Reliability Comments

type costs k$ costs costs of use Index Index

Index Index Index

No-clean conventional rosin flux 20-50 .2-.3 .1-.25 .6 3-5 Not OK for truly professional use

No-clean low-solids flux 30-80 .5-.8 .4-.8 .6 2-4 OK for some professional usage2

No-clean Inert-gas soldering >300 1-2 1.5-3 1.5-2 2-51 OK for some professional usage3,4

Water-sol. flux +water cleaning 150 .5-.7 .7-1.1 1-1.2 1 .8-2 OK for most professional usage1,8

Rosin flux + saponifier cleaning 150 .6-.8 .75-1.2 1-1.3 1 .9-2.5 OK for most professional usage1,7,8

Rosin flux + HC/surf. +water 350 2-3 >2 2 2 <11 OK for most professional usage3,4,5,6,

7

Rosin flux + HC derlv. (alcohol) 400 .5-1 >2 1.8 1.8 1-1.21 OK for most professional usage3,4,5,7

Rosin flux + HCFC, HCC, CC 120 .9-1 .95-1 1.1 1 1.1 OK for most professional usage1,6,7

1 Established method: technology & equipment easily available

2 Recent method: technology and equipment available

3 New method: technology still partially under development

4 Massive nitrogen installations required

5 Important fire and explosion precautions required

6 Major potential or real environmental problems

7 Potential operator health &safety problems

8 Overall quality is very process-dependent

© Protonlque SA, 1990 -------------------------------------------_/
_.,,'.,.'.'.. c_..... ~- .,._,.... .,_ _ _,. -_..... _.

CONVENTIONAL TECHNOLOGY

* * * *

* PROPELLANT *

FILLING

* STATION *

REST OF AEROSOL PRODUCTION LINE

* * * *

*=Leak detectors, alarms, & devices for shutting down gas supply

lines.
COMPARATIVE CHARACTERISTICS OF ALTERNATIVE PROPELLANTS

(BASED ON CFCs AS STANDARD)

Cost Environmental Simplicity/

(Raw Material) ODP GWP Flammability Toxicity Reliability

Hydrocarbon 0 +++ - -

CO2 0 + - - (-)

N2 0 0 - (-)

DME/HCFC-22 + ? +/- - (-)/=

HCFCs + + ? -
TECHNOLOGY ADAPTED TO MILD CLIMATE AREAS

PROPELLANT

FILLING LINE

(OPEN) .

/ EXPLOSION-PROOF WALL

REST OF AEROSOL PRODUCTION LINE
HYDROCARBON PROPELLANT CHARACTERISTICS

Propane/lsobutane (Different Blends)

DRY

Deordorized (Usually by Removing Sulphur Compounds, Aromatic and Non-Saturated

Hydrocarbons) .
EXAMPLE OF INFORMATION REQUIRED

FOR ADAPTING TECHNOLOGY TO LOCAL CIRCUMSTANCES

Present Plant Design

Pneumatic or Electric Instruments

Location (Distance to Inhabited and/or Industrial Areas)

Climate (Maximum and MinimiuM Temps; Humidity)

Prevalent Wind Direction

Present Layout

Propellant Storage Tanks (Design, Location)

Availability of Hydrocarbons
ALTERNATE TECHNOLOGIES FOR CFCs USES IN AEROSOLS

1. Substitute Propellants

Hydrocarbons

CO2 ; N2 ; Other Compressed Gases

2. Alternative Delivery Systems

Pumps

Pistons

• DME; DME/FCFC-22

HCFCs (142a; 152a)

Mechanical Pressure Dispensers

Non-aerosol Alternatives (e.g., roll-on,

sticks, brushes...)

Airless Sprayers (paints)
DIFFERENCES IN PLANT DESIGN REQUIREMENTS

For Non-Flammable Propellants

. No special explosion-proof equipment needed

For Flammable Propellants

Special explosion-proof equipment

installations and instrumentation needed

Sophisticated leak detection required

Plant shut-up equipment

Alarms

Escape routes

Location (far from existing industries

and urban areas)
•

•

•

•

Advantages

Stability

Inertness

Compatibility

Non-reactive

Non-toxic

Non-flammable

Odorless

Proper Pressure Ranges

CFCs AS PROPELLANTS

Disadvantages

Deplete Stratospheric Ozone Layer

High Global Warming Potential

Price
I. INTRODUCTION

II. BEST COST-EFFECTIVE ALTERNATIVE TECHNOLOGIES FOR CFC USE IN AEROSOLS

A. Available Alternatives

B. Selection Criteria for Alternative Propellants

III. ADAPTING TECHNOLOGY TO DEVELOPING COUNTRY NEEDS

A. Switch From CFCs to Hydrocarbons in Mexico

B. Cost Effective Open-Air Hydrocarbon Filling Platforms

IV. EXAMPLE OF INFORMATION REQUIRED BY TECHNICAL EXPERTS FOR ADAPTING

TECHNOLOGY TO LOCAL CIRCUMSTANCES
, -

! .

J •

, .

! -

(i.e., additional space and ventilation are' available) the total

investment required to adapt plants to safely handle these

flammable propellants may be recovered in one or two years due to

raw material savings.

Selection criteria for Alternate Propellants

The selection criteria for alternative propellants include raw

material costs, ozone depletion potential (OOP), global warming

potential (GWP), flammability, toxicity, and simplicity/reliability

of use. using CFCs as the basis for comparison, hydrocarbon

propellants, carbon dioxide, nitrogen, mixtures of OME/HCFC-22, and

HCFCs are ranked based on these criteria, as shown in slide 5.

Hydrocarbon propellants and the compressed gases are less expensive

than CFCSi however, hydrocarbons are flammable, and the technology

needed to effectively use compressed gases is more complex. The

newer options, OME/HCFC-22 mixtures and HCFCs, are more expensive

than CFCs have low OOPs and GWPs, may be flammable, and the current

filling technology may be adequate to use them effectively. Except

for HCFC-22, which has been used in the refrigeration industry for

a number of years, the toxicity of the HCFCs is under review.

Most of the modifications needed to switch from CFCs to

hydrocarbons are related to safety, that is, dealing with the

flammable products. This requires considerable additional

investment, depending on the plant circumstances.

III. Adapting Technology to Developing country Needs

Switch from CFCs to Hydrocarbons in Mexico

currently, only 12 percent of all aerosols produced in Mexico

contain CFCs. The Mexican aerosol industry has committed to

phaseout the use of CFCs by 1991 by signing a voluntary agreement

with the Mexican environmental agency, SEOUE. The agreement does

not apply to medicinal aerosols, electronic cleaners, and aircraft

aerosols, for which no substitutes are currently available. The

Mexican aerosol industry has reduced its CFC consumption and

switched to hydrocarbons by adapting conventional technology to

local circumstances.

When switching from non-flammable propellants to flammable

propellants (i.e., hydrocarbons), various plants design

requirements must be met. The plant needs special explosion-proof

equipment and instrumentation, sophisticated leak detection

systems, plant shut-up equipment, alarms, escape routes, and

finally, the plant must be located far from popUlated areas.

Cost Effective Open Air Filling Platforms

An example of how all of these new plant design requirements

can be adapted to local circumstances is the use of open air

filling platforms. In developed countries where winter conditions

are harsh leading to potential gas line freezing and clogging, it
is common practice to construct filling areas (gas houses) in a

closed room with concrete walls. For safety reasons the room is

isolated from the rest of the aerosol filling line (see slide No.

7). The room is equipped with leak detectors, alarms, and devices

for shutting down gas supply lines in case excessive concentrations

of hydrocarbons accumulate. The cost associated with such gas

house construction design is high. Mexico, as many other

developing countries has relatively mild and uniform weather yearround. Filling lines are positioned outside the plant building

with an explosion proof wall separating the filling line from the

rest of the aerosol production line (see slide No.8). The design

approach is inherently cheaper and with adequate ventilation (ei~her natural or from explosion-proof fans) the open air filling

platform is also safe. This design approach has been used in

Mexico for many years with no reported incidents to date.

This is only one example where developing country engineers

have used ingenuity and common sense to adapt conventional

technology to local circumstances.

IV. Example of Information Required by Technical Experts for

Adaptinq Technoloqy to Local circumstances

Mexican technical experts welcome the opportunity to assist

other developing countries in eliminating the use of CFCs and

adapting aerosol plants to safely use hydrocarbon propellants. An

example of the information that these experts would require to

evaluate the specific circumstances of an aerosol plant include:

• present plant design,

• use of pneumatic or electric instruments,

• plant location (distance to populated and/or industrial

areas),

• climate (minimum and maximum temperatures, humidity)

• wind ,direction,

• present layout,

• design and location of propellant storage tanks, and

• availability of hydrocarbons.

• r

> •
, ADAPTING AEROSOL TECHNOLOGIES TO

DEVELOPING COUNTRY NEEDS

Mr. Jorge Corona , .

Camara Nacional de la Industria de la Transformacion

r . ,

l.

! .

l _

• 'f ,.

I ,

I -

J .

Mexico
ADAPTING AEROS·OL TECHNOLOGY TO DEVELOPING COUNTRY NEEDS

Mr. Jorge Corona de la Vega, CANACINTRA, Mexico

I. Introduction

In the past Mexico followed the worldwide trend of developing

an aerosol industry based on CFCs as propellants. CFCs are still

the most suitable chemicals for propellant applications, due to a

number of technical advantages and no technical disadvantages.

However, CFCs have great environmental disadvantages, namely their

Ozone Depletion Potential.

When news came that CFCs had the potential of affecting world

ecosystems by depleting the stratospheric ozone layer, it became

clear that the efforts made to develop an aerosol industry in

Mexico were in serious jeopardy, and that something had to be done

immediately. Looking for a suitable substitute proved to be a

difficult task.

II. Best Cost-Effective Alternative Technologies for CFCs in

Aerosols . I

The alternative technologies that may be used to substitute

CFCs in aerosols can be classified into two groups: substitute

propellants and alternative delivery systems. A number of .1

materials may be used to replace CFC propellants including

hydrocarbons, compressed gases (e. g ., carbon dioxide and nitrogen) , dimethylether (DME) and mixtures of DME with HCFC-22, and HCFCs

(e.g., HCFC-142b, HCFC-152a). The alternative delivery systems

replace the traditional metal container with pumps, pistons,

mechanical pressure dispensers, non-aerosol alternatives (e. g. , roll-on, sticks, brushes, etc. for deodorants and personal

products) and airless sprayers (for paints.)

Not all these alternatives match the numerous advantages that

made CFCs the preferred propellants for aerosol applications

worldwide. CFCs are stable, inert, compatible, non-reactive, nontoxic, non-flammable, odorless, and possess the pressure ranges

ideal for aerosol applications. Nevertheless, the globally

recognized disadvantages of CFCs are their high ozone depletion,

global warming potential, and high price.

Although some of the above technologies are adequate as

substitutes for CFCs in certain applications, the aerosol industry

in Mexico has opted to use of the most cost-effective technology:

hydrocarbon propellants. Hydrocarbon propellants include different

blends of propane and isobutane. For the effective use of

hydrocarbons as replacement for CFCs, the supply of these gases

must be free of moisture, sulphur compounds, aromatic, and

unsaturated hydrocarbons. In Mexico, hydrocarbons are five times

less expensive than CFCs, and in cases where plants are flexible
l.

I .

l.

r .

l •

l .

r '

i

.

There are continued pressures to completely phaseout CFCs from

the U.s. aerosol industry; however, some products such as the

Metered Dose Inhalant (MDI) products do not lend themselves to

sUbstitution. If toxicological studies are positive, HFCs may be

feasible alternatives.

In addition to a total phaseout of CFCs, the U.s. aerosol

industry faces a number of environmental pressures associated with

other materials used in the industry. These include potential

restrictions on Volatile Organic Compounds in states such as

. California and New Jersey, and the potential addition of methyl

chloroform to the list of regulated compounds under the Montreal

Protocol.
GLOBAL WARMING POTENTIAL (GWP) AND OZONE DEPLETION POTENTIAL (ODP) OF' GASES

JANUARY-1990

NUMBERING

SYSTEM

(CC-10)

CFC-11

CFC-12

CFC-13

CFC-113

CFC-114

CFC-115

HCFC-21

HCFC-22

HfFC-31

HCFC-123

HCFC-124

HFC-125

HCFC-132b

HCFC-133a

HCFC-14lb

HCFC-142b

HFC-134a

HFC-143a

HFC-152a

HFC-16l

CHEMICAL IDENTIFICATION

CCl~ Carbon Tetrachloride

CC13 F

CC12F2

CClF3

CC12F.CClF2

CClF2·CClF2

CClF2·CF3

CHC1 2F

CHClF2

CH2ClF

CHClF.CClF2

CHF2·CClF2

CHF2·CF3

CH2Cl.CClF2

CH2Cl.CF3

CH3 ·CC12F

CH3 ·CClF2

CH2F.CF3

CH3 ·CF3

CH3 ·CHF2

CH3 ·CH2 F

GWP,

COMPARED

TO CFC-1l

0.36

1.00

2.99

9.6

1.42

4.19

8.24

0.30

0.29

0.30

0.019

0.093

0.42

0.06

0.07

0.085

0.06

0.22

1.00

0.019

0.01

GWP,

COMPARED

TO CFC-12

0.12

0.34

1.00

3.20

0.48

1.42

2.80

0.10

0.10

0.10

0.0065

0.032

0.14

0.02

0.024

0.029

0.02

0.075

0.34

0.0065

0.03

GWP,

COMPARED

TO CO2

3,600

10,200

30,000

96,000

14,500

43,000

84,000

3,100

3,000

3,100

190

950

4,300

600

700

870

600

2,250

10,200

190

100

ODP,

COMPARED

TO CFC-1l

1.11

1.00

1.00

0.45

0.80

1.00

0.60

0.04

0.05

0.05

0.02

0.02

0.05

0.05

0.10

0.06

0.00

0.00

0.00

0.00

(HCC-l10)

(HCC-20)

CH3 .CC13 1,1, I-Trichloroethane

CHC1 3 Chloroform·

CO 2

CH~ Methane

CH3 .CH3 Ethane

CH3 .O.CH3 Dimethyl Ether·

N2 0 Nitrous Oxide

0.022

0.00

0.000097

0.0024

0.0065

0.00

0.0017

0.0074

0.00

0.000033

0.00083

0.0022

0.00

0.00058

200

1

25

67

18

0.11

0.00

0.00

0.00

0.00
I -

!

I '

[ .

!

,

l

I .

, . ,

SWITCH FROM CFCs TO

HYDROCARBON PROPELLANTS

Mr. Montfort Johnsen

Montfort Johnsen and Assoc., Ltd.

United States
SWITCH FROM CFCs TO HYDROCARBON PROPELLANTS

AN INDUS~RY PERSPECTIVE

Mr. Montfort Johnsen, Technical Consultant.

The aerosol industry worldwide produced approximately 8.3

billion units in 1989 of which 3 billion where produced in the u.s.

The use of CFCs in the u.s. was banned in 1978 and today only few

products exempt form this regulation, continue to use CFCs. The

U. S. aerosol industry has adapted to the use of hydrocarbon

propellants as the predominant replacement for CFCs. When

countries evaluate this substitution option, a number of technical

and economic factors must be considered:

• Hydrocarbons propellants are much less expensive than

CFCs. In the U. S., hydrocarbons cost approximately $O.ll/lb or $O.24/kg, whereas CFCs cost more than $l/lb

or $2.2/kg.

• Hydrocarbon propellants (primarily propane, isobutane,

and butane) are flammable; therefore, gas houses must

be adapted to safely handle these materials, and

employees must be trained to ensure that potential

hazards are mitigated.

• In some cases the risks to a neighboring urban community

may be too high, and thus, total relocation of the . j

manufacturing plant should be considered. . I

• CFCs are compatible with many active ingredients and

substances due to their good solvency power. Compared

to CFCs, hydrocarbons have inferior solvency power and

are incompatible with certain materials. In the U.S.,

the switch to hydrocarbons required extensive. I

reformulation and product re-development which included

the use of co-solvents to aid hydrocarbon solubility.

• The availability of hydrocarbons for aerosol use must be

carefully evaluated. Aerosol propellants must meet high

purity standards. In addition, different gas mixtures

yield different pressures needed for product formulation

flexibility. Some countries have supplies of natural

gas, but lack the infrastructure to purify and separate

the various hydrocarbons.

• For safety reasons, some countries require that

hydrocarbons be stenched with sUlphur derivatives so that

leaks are detected during transportation. The technology

to purify these gases may be costly.
, "

Other Solvents

A proposed CFC-113 substitute, methyl chloroform (1,1,1-trichloroethane),

will likely become a controlled substance under the Montreal Protocol. HCFCs

and chlorinated solvents are under review for environmental safety as well. If they

do contribute significantly to ozone layer depletion or to global warming, restricted

use will result. Northern will, therefore, not knowingly recommend substances that

could become restricted materials. .

Purchasing Practices

Northern Telecom will cease buying, by the end of 1991, products

containing CFCs or Halons. Vendors will be encouraged, through

correspondence from Northern Telecom Purchasing, purchase orders and such, to

stop using CFCs to manufacture products. This will help vendors develop their

own programs to end the use of CFCs and Halons.

, -
I -

i .

f \

r •

!

( .

! .

, ,

, .

L

i ,

-OICITAL.. CORP PR

CONTACT LIST

Stephen Anderson. Chief

Technology & Economics Branch

Environmental Protection Agency M/C ANR445 Room 745

401 M Street. S.W.• West Tower

Washington. DC 20460

(202) 47'-9403

FAX (202) 382-6344

David R. Chittick

Vice- President. Environment &t Safety Engineering

AT&T

One Oak Way

Room 2WA15t

Berkeley Heig~ts. NJ 07922

(201) 771-3600

FAX (201) 771·3782

Margaret Kerr

Vice-President. Environmental/Health/Safety

Northern Telecom. Ltd.

3 Robert Speck Parkway Miasis88Ugl. Ontario

Canada LAZ 3C8

(416) j66·3021

fAX (416) j66-3348
NORTHERN TELECOM'S POSITION

on

CFC AND HALON ELIMINATION

Northern Telecom's goal is to cease buying CFCs and Halons by or befol_

the end of 1991.

CFC·113

CFC-113 will not be purchased after 1991. For circuit board cleaning, t~ _

focus will be on selecting low solids, no-clean fluxes and on choosing new

technologies that do not require cleaning. Alternative solvents and other cleanir

processes would be considered only if no clean options prove impractical.

With the industry wide drive to eliminate CFCs, our circuit board cleaners w'"

have low resale values. The cleaners will be scrapped after removal from service

Miscellaneous uses of CFC-113 will be replaced with environmentally sa"-

alternatives. '

(~ -L~ ~.~~ jl~ :.-

Halons - [4..~ t.v.·' ,~.. ....\ olo -...u.J.. 't\~

Corporate Standards 9001.14 and 9001.15 detail Halon needs and usWe believe that the need for Halon hand held extinguishers and Halon 1301, tOl

flood systems is minimal.

Halon hand held fire extinguishers will be replaced with recommend!

'alternate extinguishers. Halon 1301 total flood systems will be decommissionec

where appropriate before the end of 1991.

Refrigerants

Conservation programs are emphasized for cooling, refrigeration and ai'

conditioning installations. Corporate Standard 14017.00 details equipment, le~~

testing, service, system operation and preventive maintenance procedurE

Cooling and air conditioning equipment will be converted when new alternaH

chemicals are available.

Miscellaneous uses of CFCs

We believe that all purchased products containing CFCs can be replac~(

with environmentally safe substitutes before the end of 1991.
_...........--............_--------~ -DICiITAl. CORP PR

- 4 -

, .

r'

l _

r -

I

l _

I •

t !.'

The cooperat1ve expects other companies that ule ere lolvent. to

join in their effort. The firlt me.ting of the new orqanization will

be held in November.
-DIGITAL.. CORP PR

BASIC Q & A

o

Q.

A.

Q.

A.

Q.

A.

Q.

A.

When was ICOLP founded?

In October 1989. Its fonnadon was announced at the

International Conference on CFC and Halon Alternatives held

in Washington, DC.

What makes ICOLP a "unique" association?

ICOLP is a repository and "clearinghouse" for technical and

research information. It is not an advocacy group and docs

not lobby Jovemment. Among its chief aims is to

distribute Information on CFC alternatives to smaller firms

and to engage in technology transfer internationally.

What is the biggest challenge facing ICOLP?

Adapting manufaeturin, processes to CFC alternatives is an

extremely complex and costJf undertalUnJ. To meet this

challenge. companies belonging to the lCOLP cooperative are

willing to pool their resources and share research.

What are members' responsibilities?

ICOLP members are expected to:

o Commit to a CPC elimination plan as soon as

safe, affordable alternatives are available

Cooperate in identif)1.ng. testing and

publishing non-proprietary infonnation on

Iltematives

o ' Demonstrate new alternatives to companies internationally whenever and wherever possible.

Q. What kind of'projects wiJl ICOLP engage in?

A. 0 The cooperative testing of alternatives

o Demonstrations of new technolqgies and

processes that reduce uSAle of CFC solvents

o Technology and trade missions, including sponsorina and ~aniclpating in international

conferences on CPCs
f -

r -

, - ,

, .

.-

1_

- .. -- ....... -

- 2 -

work with existing industry, technical and govern.ent

organizations to develop the moat efficient meana of gathering

and distributing information on alternative. worldwid.,

particularly to developing countri... Th. new Cooperative

plans to work closely with exl.tlng informatlon-ahating

program. such a. the one being conducted by the American

Electronics Association.

The announcement was made here at the International Conference on

crc and Halon Alternative. by repreaentative. of the new group: David

Chi ttiek, env! ronment and .afety vice preaident tor AT'T, and Margat-et

~err, vice pre.ident of environment, health and .atety for Northern

Telecom. The International Conference 1. eO-Iponlored by the U.S.

Environmental Protection Agency, the Alliance for Relponsible cre

Policy, Environment Canada and the National Inltitute for Imerging

Technology.

ere. solvent. are man-made chemicala commonly used in

manutacturing a. a component desrealer or a. a cleaner for electronic

circuit boards and preci.ion mechanical partl. Theae _an-made

compounds are luapeeted of depleting the protective olone.layer that

shield. the earth from the sun'. harmful ultraviolet radiation al well

&s contributing to global climate change.

(mo'e)
-DICITAL CORP PR

, ,

- 3 - .

crc use 1s now regulat.d under an international treaty call.d th!

Montreal Protocol, which has been ratified by 4S countries. Und.r thp,!

Protocol, crc use is scheduled for a SO percent reduction by 1998. Ir.)

response to new scientific data about olone layer depletion, Presid.nt'

Bush, major Unit.d states companie. and many other countri.s have

called for the complete phaseout of the use of crc. by the year 2000

or sooner providing safe substitutes are available. But .v.n a

complete phaseout will not return the olon. layer to natural ltve18.

The work of the cooperative will b. valuable b.eau•• it will not"

be easy or inexpensive to eliminate the u.e of erc solv.nt. around th. '

world before the year 2000. No single technology or .ubatanc. can

replace erc.. The.e solvents are used in a wid. variety of cleaning

processes that art dependent upon the type of manufacturini, the

materials to be clean.d and the contaminant. to be remov.d.

eooperation among these companies will alia help to en.ure that new

alternative. to crc solvent. are .ate to use in the work place.

Furthermore, customer requir.m.nts, such a. military .pecifications,

sometime. encourai' or require us. of cre .olv.nts. The Coop.rative

will work to overcome the.e types of problem••

Developing countries have .pec1al needs for information on new

technologie. to replace exi.ting ere .olvent u.... The Coop.rative i~,

committed to working with .olvent-uling manufacturers worldwide to

speed the protection of the olone lay.r.

- more -
i "

-D!CITA:" CORP PR

ICOLP FOUNDING MEMBERS

AT&T

NORTHERN TELECOM

GENERAL ELECTRIC

DIGITAL EQUIPMENT CORPORATION

FORO MOTOR COMPANY

HONEYWELL

MOTOROLA

TEXAS INSTRUMENTS

THE BOEINO COMPANY
N.w.R.,••••

For f\.rther information:

Lydia Whitefield, AT&T

(201) 771-3260

Art ritzgerald, Northern Telecom, Ltd.

(416) 566-3048

Industry Cooperative'::

Ozone Layer Protectif.

For rtleale Tuelday, October 10, 1989 -- 1:00 p.m. (lOT)

washington, D.C. -- AT&T, The 80eing Company, Digital Equipment

Corporation, Ford Motor Company, General Electric, Hontywell,

Motorola, Northern Telecom and Texas Inltrumentl today announced the c 1

fo~mation of a new orqanization to work with the Environmental

Protection Agency in a world-wide effort to reduce and eliminatt

chlorofluorocarbons (CrCI) us.d al lolventl.

Kembers of the new organilation, known a. the Indu.try

Cooperative for Ozone Layer Protection, will join force. to:

encourage the prompt adoption of .afe, environ.entally

acceptable alternative .ub.~anc8' and technologies to replac

current ere solvent use.,

act as a clear1n9hou'8 for information on new alternatives tvi

ere .olv.nt.,

(more)
....... ~.~""'- ---'- ..,

'TABLE OF CONTENTS

I '

[ -

ICOl? Mission Statement p. 1

ICOLP Founding Members p. 2

r'

Basic Q&A p. 3

Contact list p. 4
-D:CITAI... CORP ?R

MISSION STATEMENT

The Industry Cooperative for Ozone Layer Protection's (ICOLP)

primlU'}' roJe Is to coordinate the exchange of.non-proprietary

infonnation on alternative technologies, substances and processes

for existing industrial CFC solvents. By working closely with

CFC solvent users. supplien and other interested oraanizations

in all countries. ICOLP seeks the widest and most effective

dissemination of infonnatlon harnessed through its member

companies and other sources. To achieve these Objectives, ICOLP

has been founded on the following principles:

o To encourage the prompt adoption of

safe. environmentally acceptable,

non-proprietary alternative substances,

processes and technoloaiea to replace

current industrial CPC solvents.

o To aet as an International clearinghouse for

information on alternatives,

o To work with existing private, national and

international trade groups, orpnlzations

and government bodies to develop the most

efficient means of creating. gathering and

distributing information on alternatives.

. ,

. !
r .

i .

r -

i

1_

, -

, - j

l _

TECHNOLOGY TRANSFER PROJECTS

BY THE INDUSTRY COOPERATIVE

. FOR OZONE LAYER PROTECTION

Mr. A.D. FitzGerald

Director, Environmental Affairs

Northern Telecom, Canada
- 0 I CIT ," L.. COR P P R

Industry Cooperativet

Ozone Layer ~otect :

< ,

BACKGROUND INFORMATION

- ,

, .
:-----------

/

I

- --1

I

,

10 J--.----------- ""--"-'--- ---

(Jdlotonn..) 10..---------------------..,

-4 .~------------------------l

• fttaduotton • I",portl

OL..-- r ......-f-......._+- '-'--+-......-+-'--+-_........-t._.a-.

, '-t'f---'--+---'---1 T

.70

i _

, '

J

. - ,

.,

CkIle"'...M) 100r-------------------------,

eoo~---'----------·--

~--- ,--~,...-------_._-.. _- ..

IOO~-,ol~-----------------

i

--- -----1

- ---;

100~----------·----- __ _ ---4

ot--......-+--.l_+--'- --JI.--+--&..-+- ------t-""---f--...-

1170 .,. .,4 7 til-
Relative Contributions to Greenhouse Effect

. ' .1

2000 2030

Source: Presentation by AFEAS based

on WMO Report of 1985

1940 1970

Year

1110 1910

GrMnhou.. U·..•

• Other

• C.rbon dioxide

• Nlleoue ox"

.........

• HCFC. Met HFC.

o CFC.

o

1850

20

40

10 '.-------

80 '

100

120.

PerCMlI

contribution

to"'"

lobi.

global

warming
I • • "", ,,' ,I • j 'to'. ,~,: • • I ' ' .'. ,( . ." ". . - .,J . . ".. . .'. ,I.' • '. 1. 4

.. :' • •• J. • • • 'J.:li 4 ' 110;, •

~, '. '.. e. • r : .', .'. ! .' ." t'~'~••' • • ••• • : ,1' \ ',\

e IT IS TECHNICALLY FEASIBLE TO REDUCE CONSUMPTION OF THE 5

CONTROLLED CFCs BY APPROXIMATELY 75% BY 1995 AND

VIRTUALLY PHASE OUT CFCs, BY THE YEAR 2000

elT IS POSSIBLE TO REDUCE HALON (1211,1301, 2402) BY

50 - 600/0 ALMOST IMMEDIATELY THROUGH CONSERVATION

MEASURES. A TOTAL PHASEOUT COULD BE ACHIEVED WITH

INCREASED FIRE DAMAGE RISK. HALON IS CURRENTLY USED IN

AREAS WHERE OTHER FIRE PROTECTION TECHNIQUES OR

CHEMICALS WILL SUFFICE.

elTISTECHNICALLY FEASIBLETO PHASEOUT METHYLCHLOROFORMI

AND EMISSIONS OF CARBON TETRACHLORIDE ALMOST

IMMEDIATELY SINCE SUBSTITUTES ALREADY EXIST FOR THE

MAJORITY OF THEIR USES

e WE WILL NEEDTO CONTINUETO USE CARBON TETRACHLORIDE AS

A FEEDSTOCK FOR PRODUCTION OF HCFC. AND HFC. (IT IS

TECHNICALLY FEASIBLE TO REDUCE OR ELIMINATE EMISSIONS)
." '. '~'::II. \' 4.. . • . • .' . \ol ('\( : .', "I ,

: • ..'..' • • I .'... I ...

. . • a ' • ~I .' :,

• • J ••• . . . .• . .. '

• USE OF HCFC. IN ACCORDANCE WITH EXPECTED MARKET

DISPLACEMENT (BY DU PONT) AT THE YEAR 2000 WILL ALLOW

FOR AN ACCELERATED PHASEDOWN SCHEDULE AND WILL NOTADD

SIGNIFICANTLY TO GLOBAL WARMING OUT TO 2030

• THE SUBSTITUTION OF CFC. BY HCFC. WILL HAVE THE NET

RESULT OF SIGNIFICANTLY REDUCING THE CLx CONC. IN THE

ATMOSPHE"E UNTIL SUCH TIME AS CFC EMISSIONS HAVE BEEN

ELIMINATED

• THE PERMISSIBLE USE OF HCFCs IN THE NEAR AND MEDIUM TERM

IS CRITICAL TO THE·ACHIEVEMENT OF THE EARLY PHASEOUT OF

CFC. SET OUT IN THIS REPORT

\

I

I
!

I

i

I

. I

I

I

(2) CFC Phase-out

(3) Methyl Chloroform Freeze

(4) Carbon Tetrachloride &

Methyl Chloroform Phaae-out

(5) 20% HCFC Substitution

Average ODP of 0.02

(1) Montreal Pr()tocol &

Defacto Carbon Tetrachloride

Freeze 1

2045 2065 2015

Year

2005 2025

Total Clx Concentrations

1985 Through 2100

11.0 -.----"T"'"-......,.~---..:..._------_ '~ .•. 'I •

,

. 10 0 ~,; ;::"'f., " . ~~ ..

9.0

1.0

7.0

1:

•

...

Q.

c

o

-

--

iiI 6.0

5.0

4.0·

3.0-----

2.0

1.0

0.0 -+-__...--...--..........-__ro--......-.~~........--r-.....--..-

1985

Aaaumptlona:

2000 Pha..-out of Fully Halogenated CFCa (Except Curve 1)

HCfCaCapture 50%ofWh.tCFC Market Would H.v.Been Without Regulation (Except Curve 1); Aaaumed Annual

Aver....Growth R....forFullyH.'ogen.tedCFCa, ....lIne HCFC-22(non-sub8tltute).nd....hyl Chloroform

.r. Approximately 3% for the Period 1986 to 2050. After 2050 U..II AlSumed to be Conat.nt.

Av.rage GOP of Subatltute. I. 0.05 (Except Curve 5)

100% Global P.rtlclpatlon

Not.s:

Whll. posslbllltl•••xl.t for.nIncr••••1n c.rbon t.trachlorlde U ••, such growth Is unllk.ly glv.n the awarene.s

of carbon tetrachloride'. pot.ntl.1 contribution to .tralospherlc ozone depl.tlon.
l'n

l _

! '

i _

.~ ,

I.

i ,

! >

/~---------------------------

_<PROGRAMME FOR ALTERNATIVE FLUOROCARBON TOXICITY

TESTING)

-14 COMPANIES PARTICIPATING

-CHEMICALS ARE HFC-134a AND HCFC-123

-COMPLETION EXPECTED LATE 1.2· EARLY 1993

-

-8 COMPANIES

- HCFC-141b

-RESULTS 1992 -1113

-

e7 COMPANIES

- HCF·124 AND 125

- COMPLETION DATE NOT KNOWN

_<ALTERNATIVE FLUOROCARBON ENVIRONMENTAL ACCEPT·

ABILITY STUDIES)

e14 COMPANIES

elNVESTIGATING OOPs, OWPs, AND OTHER PROPERTIES

eRESULTS EXPECTED BY LATE 1989
- ----- --------- ----

, ,

i .. j

e CATALYTIC INCINERATION

ePYROLYSIS

e ACTIVE METALS SCRUBBING

eWET AIR OXIDATION

eSUPER CRITICAL WATER OXIDATION

e CORONA DISCHARGE

• ZEOLITE CATALYTIC REDUCTION

(JAPAN - CFC-113)

eWE NEED A WORKING GROUP OF RELEVANT EXPERTS TO

RECOMMEND CRITERIA ON A "PER TECHNIQUE" BASIS

e WE NEED TO HAVE PREPARED A UNEP DOCUMENT "GUIDELINES FOR

THE CRADLE-To-GRAVE MANAGEMENT OF SUBSTANCES WHICH

DESTROY THE OZONE LAYER"

_ i

. ,
ESTIMATED USAGE OF HALONS'

BY APPLICATION

Cultural heritage 5~

FI."u"able liquids 10%

Tranaportatlon 12~

HALON 1301

Tranapor,tion 25"

i ,

I"duatr'" a~ . inatitution, 301'

Electronic. 35~

R.aidential 10~

HALON 1211

louree. "'ten. "c"ni~AI a....... C..MUte.

- --_._--- -_. ------_._----------- - - -- _.-._- -- ----- ------ .- - ----

ny D. Leah, Environment Canada

a, Canada (819) 953-1670
\

!

-VERY LITTLE RECOVERY OF CFCs CURRENTLY

-DRAMATIC INCREASE EXPECTED SHORTLY DUE TO:

•• PUBLIC DEMAND

•• REDUCED CFC SUPPLY

•• INCREASING CFC COST .

•• TECHNOLOGY NOW AVAILABLE

-PROBLEMS ARE INFRASTRUCTURE RELATED

-IMPORTANT TO CREATE RECYCLE INFRASTRUCTURE NOW

BECAUSE WE WILL NEED IT FOR HCFCs AND PERHAPS

OTHER CHEMICALS
----------------- ._--

., j

I'

I

eNO EQUIVALENT PERFORMING SUBSTITUTE FOR HALONS IN

CERTAIN APPLICATIONS

I'

( .

e HALONS CURRENTLY USED WHERE DAY CHEMICALS OR OTHER

, . TECHNIQUES WILL SUFFICE

j

1 I

i i

..

e50·600/0 REDUCTIONS ARE ACHIEVABLE BY CONSERVATION AND

BANK MANAGEMENT ALONE

eMAJORITY OF HALON COMMITTEE IN FAVOUR OF A PHASEOUT

1992 • • • • • • • • • CAP AT 1986 LEVELS

1995 • • • • •• • • • 75% OF 1986

1997 • • • • • • • • • 50°4 OF 1811

2000 • • • • • • • • • 25°k OF 1118

2005··· • ••••• 0%

• _ J

eQUESTION OF PHASEOUT OR NOT RELATES TO ACCEPTABLE RISK

I. eSOME COMMITTEE MEMBERS PREFER TO AWAIT SUBSTITUTES

BEFORE DECIDING ON A PHASEOUT

j.

1_
Projected Halon Consumption

250

,

I ,

, 200 '

Halon

Consumption 150

(Adfustec:t

kiloton...·) I

100

50

" ----------------------~~ I ,

Control Regime

_ Protocol

_ 500/0 Reduction

D Phaae-out

1980 1985 1990

Year

1995 2000 2005

• Sum of kllotonnea of each Halon multiplied by Ita

re.~t,ve ozone dep,etlQn ~ote~tlal (O,DP).
_ ..•..-'0 _. -,... -'-.

_._ ..... _._ .......

~.

\

~.'_: ..

I

.250/0 OF WORLD CONSUMPTION (POLYURETHANES, POLYSTYRENE,

POLYOLEFINS, AND PHENOLIC PLASTICS USED FOR BUILDING AND

APPLIANCE INSULATION, CUSHIONING FOAMS, PACKAGING,

FLOTATION, SHOE SOLES ETC.)

- CFCs ARE USEDTO: COOL EXOTHERMIC REACTION, GIVE "R" VALUE

TO INSULATING PRODUCTS, CONTROL DENSITYIN FLEXIBLE FOAMS

-TECHNICAL OPTIONS VARY WITH EACH FOAM TYPE

-TECHNICALLY FEASIBLE TO REDUCE GLOBAL CONSUMPTION OF

CFCs 11, 12, 113 AND 114 BY 60-70% BEFORE 1993

_ 300/0 OF THESE REDUCTIONS RELY ON HCFCs

• TOTAL PHASEOUT IS FEASIBLE BY 1995

j . I

!
-------------- ----------------------- - -

- ,

-MAJOR USE OF CFC-113

- NO UNIVERSAL SINGLE SUBSTITUTE

- A SERIES OF ALTERNATIVES AND COMBINATIONS EXIST FC'

SUBSTITUTION

-SO·/. REDUCTIONS ARE ACHIEVABLE THROUGH

CONSERVATION ALONE

-CONSERVATION AND RECOVERY CAN REDUCE CFC-113 \

CONSUMPTION SUBSTANTIALLY IN NEAR TERM "

- AQUEOUS, CHLORINATED AND TERPENE-BASED CLEANE I::

ARE ALSO ALTERNATIVES

• 1

- VERY SMALL USE

_ WHITE SPIRITS, HCFCs 225ca AND 225cb ARE PROMISIN( ;

ALTERNATIVES

ITIS TECHNICALLY FEASIBLETO PHASEOUT ALL CFC-113 SOlVEN'"

USE BY THE YEAR 2000
Technically Feasible Phasedown

for the Various Refrigeration Uses

* USA/EPA scenario

1990 1992 1994 1996, 1998 2000 2002 2004

Year

0-1----...--...- .....

1986 1988

50 -.-

150

250....--------------------:----:-----, Assumptions: (1) Gradually increasing use of recycle

material to 60% by 1999

(2) Complete substitution (new equipment) -------- -- ----. by acceptable alternatives by 1999 ---- ----- --

100

200 ---

Kilotonnes

Refrigeration Categories

_ Industrial 0 Transport

.. Chilling 0 Cold Storage

o Heat Pumps .. Domestic

_ Retail c::J Automotive

• USA/EPA scenario for reductions resulting from recycling, retrofitting

blends (stili under carcogenlclty tests) and use of HFC-134a.

Source: Technical Options Report
REFRIGERATION, AIR

HEAT PUMPS

NGAND

_25% OF WORLD CONSUMPTION, 5-8% BEING FOOD PRESERVATION,

1% DOMESTIC REFRIGERATORS

• MUST DISTINGUISH BETWEEN NEW AND EXISTING DESIGNS

-CURRENTLY AVAILABLE SUBSTITUTES INCLUDE: NHf' HCFC-22,

HYDROCARBONS, HCFC-142b AND HFC-152a

• MEDIUM TERM (WITHIN 3-4 YEARS): HFC-134a, HCFC-123, AND

AZEOTROPIC MIXTURES

• LONG TERM (BEYOND 4-5 YEARS: HCFC-124, HFCs 125,134,

32 AND 143a

-15-20 YEARS NEEDED FOR FULL PHASEOUT UNLESS CURRENT

BLENDS PROVE FEASIBLE AS A.DROP-IN (EG. HCFC-22/124/tiFC-152a) .
1 ' 1

I .

i

l .

, .

! .

1 .

/----------------------.,..--

eAPPROX. 270/0 OF GLOBAL CONSUMPTION (300Kt)

eSUBSTITUTES INCLUDE HYDROCARBONS, COMPRESSED

GASES, HCFC-22 AND VARIOUS BLENDS

e NEW HCFCs ARE ALSO POSSIBLE SUBSTITUTES

e "VIRTUAL" PHASEOUT IS POSSIBLE NOW

e MEDICAL USES (10-12 Kt - 3-4 Kt BEING INHALANT DRUGS)

MAY REQUIRE ANOTHER 5 YEARS

e12/88 (120/0 EO/88e,4 CFC-12) IS MAJOR USER OF CFC-12 FOR

STERILISATION IN HOSPITALS

e10/9O (10% EO/9O% C02lIS A POSSIBLE SUBSTITUTE BUT

REQUIRES RETROFITTING (HIGHER OPERATING

PRESSURES)

• OTHER TECHNIQUES EXIST: STEAM, FORMALDEHYDE, GAMMA

IRRADIATION, BUT ALL HAVE LIMITATIONS .

• MAIN PROBLEIlIS HEAT SENSITIVE DeVICES (12/88 IS

UNIVERSAL, STEAM USEFUL ABOVE 121°C,

FORMADEHYDE - 85°C)

• PHASEOUT IS TECHNICALLY FEASIBLE BY 1995 (MAY TAKE

LONGER IN THE DEVELOPING COUNTRIES)

• FAST FOOD FREEZING (SUBSTITUTE WITH CRYOGENICS)

• OTHER MINOR USES INCLUDE: TOBACCO PUFFING,

FUMIGATION, LEAK DETECnON, CANCER TREATMENT

AND STANDARD LABORATORY PROCEDURES
Technically Feasible Phasedown Projections

for Major CFC Use Categories

2000 2005

CFC Use Categories

_ Aerosol

• Solvent

o Foam

o Refrigeration

1995

Year

1990

O+-.....-~--r--"T---.~.,....--r---r--,-~--....---r---.~...--...,.......,....-.-...............

1986

80

20

60

40

120

100

Projected

Consumption

asa

Percentage

011986

Consumption

- - ,. ... .~ ... " ,..-- , -' "
Qrganization

Technlca' Option Committees

\ '

Refrigeration

Air Conditioning

Heat Pump

Electronic

Dry CINning

Solvents

Aeralol

St......

Misc. u...

110 Direct Participants

1 _

Even greater number involved in Peer Review
-IT IS TECHNICALLY FEASIBLE TO PHASE DOWN THE CONTROLLED

CFCs 70 - 75% BY 1995

-IT IS TECHNICALLY FEASIBLE TO PHASE DOWN THE CONTROLLED

CFCs BY 95 - 98% BY THE YEAR 2000 (A 98% REDUCTION WOULD

DEPEND ON THE USE OF BLENDS AS "DROP-INS" FOR

EXISTING EQUIPMENT)

- REMAINING CFCs WILL BE NEEDED FOR SERVICING OF EXISTING

EQUIPMENT(LARGE INDUSTRIAL REFRIGERATION UNITS, CHILLERS,

AUTOMOTIVE AIR CONDITIONING) AND A SMALL AMOUNT FOR

MEDICAL USES (INHALANT DRUGS)
~, RESPOND TO MONTREA'L PROTOCOL ARTICLE (6)

DEFINE TECHNICALLY FEASIBLE REDUCTION SCHEDULES

REVIEW RELEVANT TECHNICAL CONSIDERATIONS

SUBSTITUTES, FORMULAE, OOPs, GWPs

STATUS OF TOXICITY TESTING

STATUS OF COMMERCIALISATION

RECOVERY AND RECYCLE

DESTRUCTION TECHNIQUES

,

/1:l REPORT ON METHYL CHLOROFORM, CARBON TETRACHLORIDE

.. PROVIDE TECHNOLOGY TRANSFER AND DEFINE COMPLIANCE

TECHNIQUES VIA THE 5 SECTOR-SPECIFIC TECHNICAL

OPTIONS REPORTS
1986 World Usage of Controlled CFCs

(a) by Region

f'

Africa 1%

Western

Europe 32%

Eastern Europe 11%

(b) by Use

Foams 25%

Aerosols 27%

North America 35%

Latin America

& Caribbean 3%

Asia and PacifLc 18%

Source: UNEP

Refrigeration 25%

Others 7%

Source: Sector data or

best estimates
! '

OVERVIEW OF

UNITED NATIONS ENVIRONMENT

PROGRAMME

TECHNICAL ASSESSMENT

Mr. G. Victor Buxton

Environment Canada
REPORT OF THE TECHNOLOGY

REVIEW PANEL
STATUS OF CASE STUDY: CHINA

Mr. Zhang Chongxian

Senior Engineer

National Environmental Protection Agenq

China
STATUS OF CASE STUDY: CHINA

Zhang Chongxian

National Environmental Protection Agency - China

Ladies and Gentlemen:

First of all I would like to take this chance to express my sincere

thanks to our host -- USEPA for their hospitality and all the arrangements

providing us with the chance to exchange experiences and discuss the

background information relating to the progress of the country specific

studies on ozone depleting substances.

China has indicated its willingness to cooperate with the international

community to protect the ozone layer. To this effect China regularly

participates in international meetings on the problems of the ozone layer and

ozone depleting substances and signed the Vienna Convention .in September of

1989.

Before the London Conference, about a year ago, almost no one who was

involved in the production and use of ozone depleting substances in China knew

of the destructive effect of ozone depleting substances on the ozone layer and

the harmful consequences of the increased exposure to UV-B radiation.

However, after the London Conference, NEPA used the opportunity of the World

Environmental Day to launch a great number of educational activities on this

concern. As a result of the work the Chinese government appointed NEPA as the

coordinating agency for all monitoring and regulating activities relating to

the issue of ozone depleting substances.
-2-

NEPA also represents China in international efforts on the ozone

depleting problems based on discussions in such meetings. NEPA advises

various Ministries of government of China on the scope of the problem,

. measures adopted by the international community to address the problem, the

relevance to China's practice and so on with the aim of internal consensus on

the work of protecting the ozone layer and agreeable necessary steps to be

taken in China.

With limited resources available, NEPA has done some work and achieved

certain progress. In this aspect I have to address our gratitude to USEPA

missions headed by Dr. Eileen Claussen and Dr. Hoffman. They visited China

respectively within the year and half. Their activities in China tremendously

helped to raise the awareness of Chinese CFC producers and users on the

importance of protecting the ozone layer and on the possible approaches to

solve the problem.

Currently, China like other countries, is extensively producing and using

ozone depleting substances for refrigeration, foam blowing, air conditioning,

cleaning, disinfecting, fire fighting and protecting, propelling and other

miscellaneous uses. Following the decentralization of ministerial power in

1984, all the industries mentioned above are managed separately and scattered

in terms of investment decisions, production planning and so on. Local and

provincial administrations usually put local interests and development plans

ahead of central planning directions. Therefore, the government needs to know

the details of the production and use of ozone depleting substances in China,
-3-

the costs for converting to non-ODS and very importantly the international

assistance and aids that would be required.

NEPA does not currently have the capacity in financial resources,

expertise and management capability to independently undertake the study.

Moreover, because of the political and commercial sensitivities of the issues

involved, NEPA and other Ministries want an unbiased body like UNDP which is

also the representative of UNEP in China along with donor countries to provide

assistance.

From November to December 1989, an international expert team invited by

UNDP visited China for the establishment of the project. The aim of the

project is to provide the decision makers of China as well as the UNEP Working

Group with a feasibility study and policy options concerning the control and

final elimination of the ozone depleting substances including production and

use, the costs involved in conversion to other non-ODS and products, as well

as the international aids required and to propose a plan of action including

projects to be launched and assisted by multi- or bi-lateral aids.

After 20 days of hard work, the basic findings are as follows:

1. China currently produces three of the controlled CFCS: they are

CFC-ll, CFC-12 and CFC-113. Production is under the administration

of the Ministry of Chemical Industry. At present China has 30,000

tonns CFCS production capacity and the practical production was

about 20,000 tonnes in 1988 and 1989 respectively. However, China

also imports CFCs, especially CFC~ll and CFC-12. The total amount
, .

-4-

of import CFCs reached approximately 20.000 tonnes in 1989. That.

means China's average consumption of CFCs is about 0.04 kilogram per

capita per year in 1989.

2. Currently about 44% of total CFC consumption is in refrigeration.

air conditioning manufacturing and servicing. More than 40% of the

total consumption of CFCs are used as blowing agents in

manufacturing rigid and flexible foams. Almost 90% of the total

CFCs are used for manufacturing refrigerators, air conditioners, and

other refrigeration equipments suggesting that the future trend of

the growth of CFC use will remain high following the modernization

of the nation's industry and people's living conditions.

3. Until 1988 the possession of household refrigerators was about 20

million units. And the 1988's refrigerator production stood above

8.8 million units, plus 2 million imported refrigerators. there was

a big leap of overall possession of refrigerators between 1988 and

1989 alone.

The future trend of refrigerator production rate will fluctuate

between 3-7 units a year. However, the production capacity will

remain 12 million units a year. Compared with the total number of.

Chinese households this figure is still lower than the future

demand. We could expect that the focal point of future CFC

consumption in China will still be at the section of refrigerators.

air conditioning and foam blowing.
-sFinding substitutes for CFC-11, CFC-12 will be essential for China

to reduce the consumption of CFCs.

4. In addition to refrigeration and air conditioning, attention must be

paid to foam blowing. For example, rigid polyurethane foaming for

the purpose of insulation has big potential market in China

following the reform of industries and energy efficiency, the

flexible foaming will develop rapidly following the improvement of

the household furniture, the development of packaging industries and

so on.

In general, CFCs use is expected to increase 7-10% annually during

the 1990s.

Referring to solvents, aerosols, cleaning agents, and ha10ns, the

application of CFCs will continue increasing at a rate of about 7%

annually based on the present low level of consumption as a starting

point.

5. CFC substitute production: China produces about 10,000 tonns of

HCFC-22 annually. At the present time most of the chemicals are

used as a feedstock for "Teflon" production. The application of

HCFC-22 for refrigeration needs to be further developed. China also

produces about 100 tonns of HFC-1S2a as refrigerant to apply for

experiments. The preliminary results showed very promising
-6-

possibility to create a pilot project to apply the HFC-l52a to

household refrigeration.

Referring to the country specific study, what we are going to do next.

After the preliminary study of UNDP export. Mission, the project design has

been worked out in order to drive overall and more precise information on this

regards:

The project is composed of three phases: in the first phase NEPA will

collect statistical and substantive information on ODS production and use in

compliance with the "national studies: proposed outline." I do think every

country has its own specific condition, this outline will only provide the

basic requirement needed for the consideration by the international community

in order to gain assistance and aid. For the completion of the information

collection NEPA has to cooperate with various Ministries and do a lot of

organizational and standardizational work, for this purpose financial

assistance is necessary for NEPA success.

The second phase is designed for the international expert team to arrive

in China for additional information and evaluation of the technical

feasibility and the step-wise strategy for phasing out the controlled CFCs and

costs involved. This is really a very complicated process to complete in

China.
-7-

In the third and last phase, the integration of respective reports will

be completed and submitted to UNEP for financial and technical aid and

assistance.

Finally, regarding the country specific study in China, I do think the

Chinese situation is staying at a preliminary stage. Through our meeting I am

able to learn a lot from your practice and experience. It is very valuable

for implementing the study in China.

Thank you.
c l

I

· ,

• l

, I

· ,

• J

"--1!

". j

.- 1

'- }

• 1

_ J

-}

· 1

-,

· j

, l

,J

· )

,

! · j

J

1

J

II

CASE STUDY COORDINATION WORKSHOP

BRASIL

SOURCES OF INFORMATION

BUSINESS SURVEYS

- SUB COMMITEES

- CFC PRODUCERS

- TRADE ASSOCIATIONS

- GO.VERNMENTAL STATISTICS

GOVERNMENTAL DATABASE / PROJ.ECTIONS
INDUSTRY INVOLVEMENT

JOINT PARTICIPATION WITH THE BRAZILIAN DELEGATIONS

CONFERENCES,/ WORKSHOPS

SUPPLY TECHNICAL EXPERTISE, GENERAl.. DATA AND

OTHER RESOURCES TO DEVELOP TECHNICAL REPORTS

TO THE PROTOCOL MEErINGS

SEMINAR "CFC's, ALTERNATIVES AND STRATEGIES"

MARCH 08/09 - SAO PAULO

MONTHLY TECHNICAL MEETINGS AT ASINEE

SINCE MID-19B7

o

o

o

o

III l

CASE STUDY COORDINATION WORKSHOP I

BRASIL :

(

I' " -1

J~

f\

l

.1

r

J'

I

I')

! .

r

o LIASON ACTIVITIES WITH GOVERNMENT AGENCIES
, ,

- j

. ,

, 1

, .

IV

CASE STUDY COORDINATION 1VORKSHOP

BRASIL

PROGRESS

- CFC GROUP WITHIN ABINEE

- CFC's ELIMINATED FROM COSMETICS AEROSOLS

(BUTHANE/HCFC'a)

- INTRODUCTION Of' ALTERNATIVE BLOWING AGENTS FOR

FOOD PACKAGING FOAMS

- EARLY STAGES OF DEVELOPMENT OF CFC

RECOVERY SYSTEMS

- ELECTRONICS / REFRIGERATION INDUSTRY

"QUEST FOR TECHNICAL DATA"

- RESOURCES AVAILABLE

• COMPRESSOR DESIGN AND MANUFACTURING CAPABILITY

• FLEXIBLE PRODUCTION FACILITIES

• WELL ESTABILISHED COMPONENTS SUPPLIERS

• ACCESS TO TECHNOLOGY FROM PARENT COMPANIES
{ !

r····

l ,

STATUS OF CASE STUDY: BRAZIL

Mr. Alberto Carrizo

White-Westinghouse Climax'

Brazil
.... ... - 1

I

CASE STUDY COORDINATION WORKSIIOP <,

BRASIL

ORGANIZATION

PROJECT TEAM

- LEADERSHIP

IBAMA (BRAZILIAN ENVIRONMENTAL AGENCY)

- GOVERNMENTAL AGENCIES;

- FOREIGN AFFAIRS

- HEALTH MINISTERY

- INDUSTRY & TRADE MINISTERY

- ASSOCIATIONS;

- ABINEE; ELECTRICAL AND ELECTRONIC INDUSTRY

- ASRAVA; REFRIGERATION, AIR CONDITIONNING AND HEATING

- ABIPLAS; PLASTICS

- ANFAVEA; AUTOMOTIVE MANUFACTURERS

- ISF; INSTITUTE OF COLD TECHNOLOGY

- TECHNICAL -ADVISORS:

Dr. SUELY CARVALHO; SAO PAULO UNIVERSI1Y, CNEN
- 2 -

Feron 11

Feron 12

Feron 22

Others (F 502 + F 114 + •• )

4436 Tons

3453 Tons

446 Tons

453 Tons

Total 8788 Tons

4. The Eg. venture in limiting the emission of CFC which

I already related in various international forums, is

worth to be repeated for consideration towards application

in other developing countries.

5. On February 23rd 1981, the Eg. MInistry Of Industry.

(MOI) received an alert from the USEPA. through 'the Eg.

Embassy in Washington as to CFC's and their harmful

effects on human health and the restrictions to be imposed

on their outlet uses particularly in aerosols.

6. MOI. appointed an adhoc committee, (Decree, MOI; 638/81)

joining in its membership the chairmen and technical

directors of the CFC consumer units in the fields of

refrigeration, Air-conditioning, aerosols, foam Plastics,

•••• etc). The committee was reformed (Decree MOI; 446/86)

joining to its membership representatives of other

conserned bodies; Federation of Industry, Ministry of 1

Health, General Organization for Standerzation. I should

remember that I had the privilege to act as technical

rapporteur of that committee.

7. The committee performed a number of technical and

economical studies taking into consideration the probability

of the difficulty of future importation of such substances.

Also the probability that its procurement will be confronted

with a rapid price escalation. (It its worth to declare

that committee was totally right in its prediction, the

price of importation of one kg of CFC increased from LE 0,9

in year 1985 up to L& 3.7 in 1989).
- 3 -

8. The committee performed a number of technical and economical

studies, put forward a number of recommendations to MOl.

inter-allia the following:

a) No new permits or licences should not re given to projects

that depend in their production on the use of CFC as

well as non agreement to exten~ions of such existing

projects.

b) Introducing other substitutes for CFC that are locally

available or abundant and easy to procure, as well as

studying the possibility of introducing legistlation

banning the use of CFC's in such activities where

substitutes are available and cost effective as well as

the possibility of imposing taxes on CFC importations

& incentives for substitutes.

c) proposing the implementation of a procedural system

that could enforce the disposal of salvaged equipment

holding CFC and residuals thereof.

9. The committee found that LPG = liqufied Petroleum gases

(mainly propane & pentance) could be used as a cost

effective substitute to CFC's in Aerosol industry. It is

locally available and far cheaper than CFC's.

10. "Kafr El Zayat" Company for pestisides was the first company

that changed over to use LPG in 1984. Other public sector

companies have followed its example. Today (1990) all

pUblic sector companies use LPG as propellant in Aerosols.

Also 3 of the private sector companies have changed over to

LPG.

11. Here it is clear that LPG has succeeded as subsitute in

Egypt because it was more cost-effective than its CFC's

counterpart otherwise they would have not so quickly

widespread.
l ,

, .

- 4 -

12. This fact is in conformity with the report of the techno

committee chaired by Ms Ingrid Kokeritz (Sweden) (1)

concerning the uses of substitutes for CFC's in aerosols

such as hydrocarbons, propane and butane (page iii):-

The Hydrocarbon cost per kilogram is however, substanitally

lower than that of CFC's(20-30% of the current cost of

CFC's). In most cases, a conversion to hydrocarbons will

therefore result in a net gain for the producer and a

cheaper product for the consumer.The lower cost of hydrocarbons where suitable supplies of these 'propellants

exists, may be especially important to developing countries.

13. It is also in conformity with the EPA report R&D N° 60012-

89-062 (2) Page "5":

In the U.S., hydrocarbon propellants cost less than 20% of

the rapidly escalating costs of CFC's. Approximately 30% of

U.S. aerosols are pressurized with propane, butane, isobutane

or their blends•. "

14. I think that a regulatory fee and auction system on the

production of CFC halons are very well justified. This is

contrary to the position of the U.S. council for International

Business that cited in their publication of Sept. 89(3) that

their argument is that the outcome is likely to slow progress

for U.s. companies towards development of alternative products

and place them at a competitive disadvantage vis avis

production in other countries.

15. My own information is that Norway has already passed a bill

to impose fees on CFC's & CFC products. Such Action should be

well spreaded and introudced by all countries on equal bases

so as to leave no space to competitive disadvantage. I

strongly push for a global tax or fee or any auction system

on all controlled substances so as to modify economic

appraisals of the substitute (and weight their balance) •
- 5 -

16. To phase out CFCS we should find and examine substitutes

for its uses in all activities, not only aerosols but also,

foam plastics, refrigerators, air conditioner~ .etc.

It is estimated that ·our production capacity of refrigera~~

will reach about 750'000 units/yr of houshold units, 15'000

deepfreezers and 9'000 Exposition or commercial unit. The

installed capacity of Air conditioning of various types will

be equivalent to about 130.000 units window type 2~ HP.

There is the argument that such units run in closed circuits

but how about leakage and dissipation in repair & maintenanc o

Another problem is foam plastics and styropore. It is a

rapidly growing sector, not only in Egypt, but also in all

developing countries: Egypt's national output of foam plasti

and styropore totals to about 10.000 tons/yr.

17. The world community is looking for a total phasing out of

CFC's. All nations are consolidated to face this global

challange. In this respect I would quote EPA Administrator

William Reilly in his memorandum (4) about the unbridled

enthusiasm of the EPA international front for all the World

solidarily towards CFC and climate change problem and in ful~

support of the U.S. policy in that a field. He clearly stated

that the President Bush 5 points on the international

front, the first was committing the nation to the full phase

out of CFC's towards the end of the century.

1. Report by the technical options committee on Aerosols,

sterilants and miscellaneous uses.

2. E.P.A. Research & ~evelopment;

Aerosols Industry success in reducing CFC propellants usage

EPA-600l2-89-062. November 1989.

Prepared by Air & Energy Engneering Research Laboratory.

3. Summary of International Environmental Issues and Positions

of the US Council for International Business:-

"Environmental Challenges for Industry" September 1989

1212 Avenue of Americas New York 10636-1689.

4. Memorandum of USEPA Washington DC. dated September 7, 1989

Subject six Month Update by Administrator J.W.Reilly •

.-,

.
I "

f >

t

i

( .

STATUS OF CASE STUDY: EGYPT

Dr. Ahmed Amin Ibrahim

Consultant, Egyptian Environment AfTairs Agency

Egypt
Facsimile (202) 382 6344

To: Eileen Clausen Director Office Of Air & Radiation EPA.

Some Remarks on Strategies of

Limiting the uses of CFC's

Presented by Ahmed Arnin Ibrahim

To EPA Workshop January 15-17, 1990 Washington.

1. E9ypt was one of the first countries that signed the

Vienna convention;' March 22nd 1985 and the Montreal

Protocol September 16th 1987; Egypt ratified both on

August 8th 1988. In its consolidation with the

International Community Egypt has taken intiatives in

limiting the emissions of the controlled substances

(which are the CFC's).

2. The Montreal Protocol carne into force on January 1st

1989; and requires the following:

a) Freeze at 1986 consumption and production levels of

the controlled substances (CFC 11, 12, 113, 114, 115)

on the basis of their relative ozone depletion . ,

weights (O.D.P.)

b) By 1993 reduce the emission of controlled substance

to 80 %.

c) By 1998, a further reduction by 20% to limit the

controlled substance to 50%.

3. Egypt does not manufacture any of the controlled substances (CFC's) but totally depends on importation to

fullfi11 its needs. The import figures ware 8788 tons

in 1982 and dropped sharply to 2163 tons in 1985.

This was due to the efforts undertaken to use CFC's

substitutes in producing Aerosols with the following

breakdown as to form grade classification as regards

the 1982 figure:-
U I. CONCLUS I OMS

1. THE fROTECTION OF THE OZONE LAYER RULES OUT THE POSSIBILITY OF

....AI~·· SHARES 0 .. OZONE DEPLETING COMPOUND USE. ALTHOUGH HOST OF

THE ~"LORINE IN THE ATMOSPHERE IS DUE TO EMISSIONS ..ROM DEVELOPED"

COUNtRIES ~~T ALSO STOP THEIR PRODUCTION AND CONSUMPTION OF TH~S£

SU.S~~. . .

2. IT IS NECESSARY TO TI~TII:H THE IMPLEMENTED MEASURES TO REDUCE

OZONE DEPLETING COMPOUND EMISSIONS AND TO TAKE ALL NECESSARY

ACTIONS TO ACHIEVE THE REDUCTIONS NEEDED.

3. THE CASE STUDY UNDERWAY IN MEXICO WILL EVALUATE THE PRESENT AND

FUTURE D~HD or OZONE DEPLETING SUBSTANCES AND THE ECONOMIC

NEEDS ASSOCIATED WITH THE IMPLEMENTATION OF THE MONTREAL PROTOCOL.

THE STUDY WILL ALSO PROVIDE USEruL INFORMATION ON NEW TECHNOLOGIES

AHD APPROACHES USED IN MEXICO.
ADAPTING TECHNOLOGY TO DEUELOPING

COUNTRY NEEDS

•

• nEXICO CAN DE A SOURCE OF'MW AND ADAPTED TEOfiOLOGY TO PROTECT nu:

OZONE LAYER

• THE nEXICAN DESIGit APPROACH HAS PROVED TO BE COST-EFFECTIVE AND SAFE

• mE nEXICAN KNOU-HOU nAY BE USEroL TO OTHER DEVELOPING COUNTRIES
L&.

ea

SeOUE

MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

SOURCE AND REDUCTION OF AVOIDABLE HALON EMISSIONS

1989 EMISSIONS = 100 ok

• LEAKING EQUIMENT

111I1111I11 TESTS AND DElAOIlSTP.ATIONS

rrtf TRt.INING

~:~~~:~ FIRE EXTINGUISHING

010 YEAR HYDROSTATIC

TESTING

3 YEAR MAINTENANCE

RECHARGE SERVICE

1992 1993

.- .•

YEAR 1989 1990 1991

20

30

50

90

0/0 100

100

10

INDEX
SeOfJE

6 MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

SOURCE AND REDUCTION OF AVOIDABLE HALON EMISSIONS

,

BASE EMISSIONS 19189=100 0/0

SOURCE:

FIRE EXTINGUISHING

TOTAL 1989 0/0

ELIMINATING TRAINING Wlnl1201

AND 1301 EXCEPT FOR THOSE

APPLICATONS CRITICAL TO LIFE

SAfETY.

COMPLETING ELIMINATION or

SALES TESTS AND DEMONSTRA- noos ALTERNATIVES MEANS,

SUCH AS V1OCO TAPES,flLMS,

TRANSmRENCIES. AND PHOTO - GRAPHS CAN BE USED.

STRICTLY COMPLYING WITH EXTlN'

GUISHER QUALITY NORMS TO

AVOID EMISSIOOS FROM FAULTY

EQUIPMENT,

IMPLEMENTING GAS RECOVERY

5lSTEMS DURING RECHARGE OF

EXTINGUISIIING EQUIPMENT.

USING GAS RECOVERY DURING

MAINTENANCE AND liYDROSTATIC

TESTING Of EXTINGUISHING

EQUIPMENT,

"

'r'
La.

e'a

SEOUE

MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

SOURCE AND REDUCTION OF AVOIDABLE HALON EMISSIONS

INDEX 1989 EMISSIONS = 100 %

_LEAKING EQUIMENT

RECHARGE SERVICE

111I11I1111 TESTS AND DE/IIONSTP.ATlONS

1~1t~H) TRt.INING

~:~~~:~ FIRE EXTINGUISHING

010 YEAR HYDROSTATIC

TESTING

.. .. 3 yEAR MAINTENANCE

1992

.- .•

YEAR 1989 1990 1991

20

90

30

50

10

0/0 100

100
MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

REDUCTION IN CFC USE FOR AEROSOL PRODUCTS MANUFACTURING

AEROSOL PRODUCTION

60

ANNUAL %CHANGE

54

}}} TOTAL PRODUCTION

CANS WITH CFC S

TOTAL CANS

YEAR MARKET WITH CFC'S

--'--

1988 8.7 - 20. 7

1989 3.8 + 1.6

1990 5.1 -50.0

1991 4.8 -48.3

INCLUDES MEDICINALS AND OTHER

EXEMPT PRODUCTS.

1987 1988 1989 1990

50

HISTORICA~ AND PROJECTED PRODUCTION

--- fA",IP(C

INSTITUTO MEXICANO DEL AEROSOL, A.C. CAMARA NACIONALDE LA INDUSTRIA DE PERfUMERIA YCOSMETICA CAMARA NACIONAL OE LA INDUSTRIA DE TRANSfORMACION

~N:;E~X';'IC;';;A;';;N;A';E:;R;O;S;OL;;';IN;';'S;;'T;';IT;';U;';;T;;';E;"';;N~A;;;T;';;'IO;;';'N';';';A';';'L~C';H;';;'AM;"'SE-R";"O-f-TH';E-P-E-"F-U-M-E-A-"-D---N-AT-I-ON-A-L-C-H-A-M-S-ER-tF I NDUSTRIES

COSMETIC INDUSTRY
LA MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

ea REDUCTION IN CFC USE FOR AEROSOL PRODUCTS MANUFACTURING SEDfJE

400

350

300

250

en

z

0 200

U

-

a: 150

W

100

50

0

YEAR 1981 1988

CFC -11 AS PROPELLANT

I\NNlJt,t Of.:, DECRE 1\5l

YEI\R <Yo OECREI\SE

1988 16.2

1989 6.6

1990 48.9

1991 40.0

{<:~ CONSUMPTION

1989

HISTORICAL AND PROJECTED CONSUMPTION

SOURCE:CfC PROOUCfHS

,
L~ MEXICAN PROGRAM TO COMPLY WITH THE MONTREAL PROTOCOL

..A'-'" ,&~

SeOfJE REDUCTION IN CFC USE FOR AEROSOL PRODUCTS MANUFACTURING

CFC -'2 AS PROPELLANT

1000

900

800

700

600

500

UJ

Z 400 0

tO 300

a:

tW 200

100

0

Y£AR

ANUAL % OECR(I\SE

YEAR % OlCH[ I\SF

1988 12.1

1989 +2,4

1990 49.7

1991 65.0

::::::::: CONSUMPTION

1987 1988

HISTORICAL AND PROJECTED CONSUMPTION

__________________________·-..,;'iiiFIIIIi·IIIioi' SOURCE cre prWDuCll6
MEASURES TO BE IMPLEMENTED TO ADD~ESS

GLOBAL WARMING

•••

• nEXICO WILL InPLEnENT A PROGRAtt TO PRESERVE AND - InpROVE THE EFFICIDICY

OF FOSSIL FUEL UTILIZATION

• nEXICO IS WRKING TO InPROUE ITS WATER SUPPLY"I1ANAGErtDlT

• ENERGY EFFICIENCY AND nEASURES TO ADDRESS AIR POLLUTION WILL DE

ENCOURAGED
ADAPTING TECHNOLOGY TO DEUELOPING

COUNTRY NEEDS

· nEXICO CAN BE A SOURCE OF·HEY AND ADAPTED TECHNOLOGY TO PROTECT ~E

OZONE LAYER

· ~E nEXICAN DESIGN APPROACH HAS PROVED TO BE COST-EFFECTIVE AND SAFE

· ~E "EXICAH KNOU-HOU ~y BE USEFUL TO OTHER DEVELOPING COUNTRIES
ATTACHMENT 4
TERMS OF REFERENCE FOR THE CASE STUDIES

I. EXECUTIVE SUMMARY

STUDY METHODOLOGY

The feasibility study should be conducted in phases:

1) Generic Use Pattern Analysis (determine where and how, how much of

these chemicals are used and their source of supply and distribution,

i:e., produced locally/imported/exported, etc.) using published

statistical summaries and estimates by chemical producers, distributors

, and user association if possible or estimates based on estimates of

production of products containing CFCs or products made with but not

containing CFCs. Also, prepare an estimate of current and future needs

(for the next ten years) taking into account national policies, economic

plans or projected growth in demand.

2) Sector Specific Use Pattern Analysis (analyze how these chemicals

are used within the sector and evaluate the options for: retrofitting

plants to use alternative "environmentally friendly" technology; using

alternative chemicals; manufacturing alternative products; maximizing

conservation measures (recycle, recapture, re-use); or other mitigative

measures (example no clean fluxes, etc.). Determine both the short and

long-term alternatives and potential technological modifications for

manufacturing processes, etc.

3) Assess the Cost Implications for country-wide compliance with the

Montreal Protocol. (Determine costs on a sector basis for a 10 year

period, including anticipated increases in costs for chemicals,

servicing, maintenance, new products, etc.)

4) Develop a Feasible Compliance Schedule (taking into account the

equipment acquisition times, etc.). Identify options to implement the

report conclusions and recommendations including sources of new

technology and financing. Develop a realistic timetable for achieving

compliance with the Montreal protocol.

Capital Investment (including application engineering)

New,Facilities

Retrofit

Decommission

Research, Pilot Plants, and Demonstration

Operating Costs

Chemical Inputs and Labor

Energy (including consideration of global climate change)

Maintenance
II. INTRODUCTION

A. Purpose and Scope

B. The Role of CFCs and Ha10ns in Stratospheric Ozone Depletion

C. The Montreal Protocol and Subsequent Developments

1. The Montreal Protocol

2. Ozone Depletion Potential (ODP) and Global Warming Potential

(GWP)

3. CFC and Halon Use in (Country Name)

4. Global and CFC and Halon Use

5. Other Chemicals of Concern

D. Nati~na1 Policy on Ozone Layer Protection

E. National Advantage of Ozone Layer Protection

F. National Circumstances Likely to Influence Technology Transfer

1. Fire Codes

2. Solvent Specifications

3. Free Trade Zones/Off-shore Facilities and Ships

4. Logistics

5. Occupational Health and Safety

6. Domestic Content Rules

7. Import Restrictions

G. National Case Studies as a Means to Facilitate Technology Transfer

III. PRODUCTION AND CONSUMPTION OF CHLOROFLUOROCARBONS AND OTHER

OZONE-DEPLETING COMPOUNDS

A. Production Levels and Status of Current Production Capacity

1. Historic, Current and Planned Production Levels

2. Capacity and Location of Existing Facilities and Capacity under

Construction

3. Age and Flexibility of Existing Production Facilities

B. Trade of Ozone Depleting Chemicals and Products

1. Imports and Exports (with reference to Protocol Membership)

2. Prices and Import Tariffs and other Regulations (such as CFC

taxes)

C. Consumption by End Use

IV. TECHNOLOGY AND EQUIPMENT CHARACTERISTICS IN CURRENT END USES

(Includes discussion of existing manufacturing facilities)

A. Refrigeration, Air Conditioning, and Heat Pumps (including estimates

of CFC contained in existing equipment)
B. Aerosols and Sterilants

c. Solvent Cleaning

D. Foams

1. Flexible Polyurethane Foams

2. Rigid Polyurethane Foams

3. Phenolic Foams

4. Extruded Polystyrene

5. Polyolefin Foams

E. Halon Fire Extinguishing Agents

1. Halon 1301 (including estimates of "banked" halon)

2. Halon 1211 (including estimates of banked halon)

3. Halon 2402

V. ESTIMATED FUTURE CHLOROFLUOROCARBON NEEDS

A. Methodology for 10-Year Projections

B. Projected Compound Demand by End Use

VI. OPTIONS TO REDUCE CHLOROFLUOROCARBON USE; RECYCLING, ALTERNATIVE

COMPOUNDS AND TECHNOLOGIES

A. Recycling and Other Conservation Practices

B. Chemical Substitutes

C. Product Substitutes

VII . TRAINING AND INFRASTRUCTURAL REQUIREMENTS

VIII. STRATEGY FOR COMPLYING WITH THE MONTREAL PROTOCOL: THE CASE OF

A. CFC Reduction Measures for the Short Term (1990-1995)

(Best Available Technology from January conference)

B. CFC Reduction Measures for the Intermediate Term (1996-2000)

C. CFC Reduction Measures for the Long Term (2000-2010)

IX. COSTS OF TECHNOLOGY TRANSFER

APPENDIX A: SOURCES OF NEW TECHNOLOGY AND TECHNICAL ASSISTANCE
r .

r -

I -

Aerosols Yorkgroup - Terms of Reference

SUGGESTION TO INTEGRATE DISCUSSION OF TECHNOLOGY AND EQUIPMENT CHARACTERISTICS

(SECTION IV) WITH OPTIONS (VI) AND RESPECTIVE COSTS (IX) WITHIN EACH SECTOR.

For example, the Outline for Aerosols would be:

III. AEROSOLS

A. Technology and Equipment Characteristics in the Aerosol Industry

B. Substitutes and Costs

i. Hydrocarbon Propellants

ii. Non-flammable Propellants

iii. Alternative Delivery Systems

For a projected mix of substitutes adopted estimate costs for Model

Plant Scenarios including:

• Capital Investment and Other Fixed Costs, and

• Operating Costs

C. Summary (sector specific)

Other Comments

CFC consumption estimates for aerosols obtained from CFC producers may

be cross-checked if the volume and type of aerosols manufactured with CFCs is

known. Even if this check cannot be performed, it is believed that

uncertainties of ± 20 percent in this sector-specific consumption estimate are

acceptable for the purpose of the case studies because conversion costs are

insensitive to total CFC volumes consumed, but rather depend on the number and

characteristics of aerosol filling plants.
r'

, .

!

r'

I.

i

I"

1 .

ATTACHMENT 5
To be completed on Industry, application, company or site basis (If possible)

NATIONAL CFC STUDIES

PROPOSED FORMAT FOR SURVEY QUESTIONNAIRE

GENERAL INFORMATION

, ,

" I

, 1

Company Name:

Address:

Survey Respondent: _

Position:

Voice Phone:

Fax phone:

Number of Employees (1989): _

Sales (FY 1989):

Date Founded:

Estimated Annual Consumption of the following compounds (in Metric Tons):

CFC-12

CFC-502 _

Halon 1301 _

; CFC-11 ; CFC-113 _

; CFC-500 _

; Halon 1211 ; Halon 2402 _

Methyl Chloroform _ ; Carbon Tetrachloride

Describe how the above compounds are related to your business (e.g., they form part of the final·

products produced in your company, they are purchased by your customers to operate existing

equipment, etc.):
, ,

- 2 -

Please indicate which of the following applications describes your current use of

chlorofluorocarbons, and/or halons. Respond to this questionnaire at the indicated section:

[ ] A. Refrigeration

[ ] B. Aerosols

r'

[ ] C. Solvent Cleaning (includes use of CFC-113, Methyl Chloroform, and Carbon

Tetrachloride)

, .

[ ] D. Sterilants

I •

1 - [ ] E. Foams

! .

[ ] F. HaJons

1 .

i .

j.

i .
- 3 -

REFRIGERATION

I. DOMESTIC/HOUSEHOLD REFRIGERATION

( ,

A. General Description of the Sector

1. A short description of the history of manufacturing refrigerators

2. Which are the critical parameters for the country in this sector?

- ,

3. The size and the structure of the industry:

• Numbers of factories (licensed/joint ventures)

• Installed production capacity per shift

• Age of production lines and lifetime

• Types of products manufactured (static, frost-free cooling)

• Size (inner/brutto volume) of typical products

• Direct labor and total number of employees involved

, ,

4. How many refrigerators/freezers have been produced during the last ten

years (specific data per year; imports and local data as well)?

5. How many refrigerators can be considered as "installed" capacity?

What is an estimate for an "installed" amount of refrigerant?

6. What is the production target for the year 2000 (as well as estimates for

import data)?

7. How much refrigerant (type of refrigerant, probably CFC-12) is used in

charging of the refrigerators, specifically the circuit of the appliances; typical

values of products; and furthermore

Is the refrigerant produced domestically?

If not, why is it imported?

What is the average refrigerant charge used (per unit of size)?

8. Which types of insulation are applied (type and quantity)

e.g., volume of insulation per product?

B. Components (compressors) Manufacturing

1. Are components (heat exchangers and valves, not the compressors) made

in-site/locally or bought from external suppliers

information on the type of heat exchangers?

information on manufacturing techniques

2. Are compressors made in-site/locally or bought from external suppliers?

In case of domestic compressor production

3. The size and the structure of the compressor industry:

• Number of factories (licensed/joint ventures)
- 4 -

Direct labor and total number of employees involved

• Installed production capacity per shift

• Age of production lines and lifetime

• Capacities of compressors produced (cooling capacity)

4. Are compressor electric motors made in-site or bought externally?

5. How many compressors have been produced during the last ten years

(import and export data)?

6. What is the production target for the year 2000?

C. Other Topics

1. What is the future trend expected in manufacturing refrigerators:

Manufacturing technology change

• Types of appliances

• Typical volume of a refrigerator

2. (OptionaQ Which standards are applied in tests (ISO. NF, DIN, own)

• Inner and ambient temperatures

Which responsibility belongs to National Manufacturing Organizations?

Ie 3. How efficient is the service organization?

, .

•

•

•

•

How many servicing operations

Amount of refrigerant (typical) used in servicing

Is servicing performed via factory/brand organization

Education level of servicing engineers

4. (Optional) How many refrigerators are being disposed of and what is the

future expectation? Will it be possible to collect disposed refrigerators? Now,

or in the future?

5. What is the average lifetime of a refrigerator (reasons for disposal)?

II. RETAIUCOMMERCIAL REFRIGERATION

A. General Description of the Sector

1. A short description of the history of manufacturing cabinets, stores, etc.

2. Which are critical parameters for the country in this sector?

3. The. size and the structure of the industry:

• How many production sites.

Average size of a production site
- 5 -

• Status of manufacturing technology.

• Direct labor and total number of employees involved

4. How many:

•

•

•

display cabinets

Cold stores

Ice makers

Other equipment

have been produced during last ten years (specific data per year; also

import and local data)

5. What is the production expected for the year 2000 (as well as estimates for

import data)?

6. How much refrigerant (types, HCFC-22, CFC-12, 500, 502) is used in

equipment manufacturing (first charge whether it concerns domestically

produced refrigerant or import)? What is the charge used in the typical

products?

7. Which types of insulation are applied (type and quantity) (e.g., volume of

insulation per product)?

8. How many units have been installed (domestically produced or import)?

• Distribution with respect to age (10-20 years, 5-10, 0-5 years old)

• Typical charges of these units

9. Engineers involved and their education level:

•

•

•

Education level of engineers

National engineer societies (education level)

Training courses

10. What is the future trend expected in manufacturing this equipment?

Manufacturing technology changes

Types and typical volumes

11. (Optional) Which standards are applied in tests (ISO, NF, DIN, own)?

• Inner, ambient temperature levels

Which responsibility belongs to National Manufacturing Organizations

B. Components (compressors) Manufacturing

1. Are components (like heat exchangers and valves, not compressors) made

in-site/locally or bought· from external suppliers?
- 6 -

Information on the type of heat exchangers

Information on manufacturing techniques

2. Are compressors made in-site/locally or bought from external suppliers?

In case of domestic compressor production

3. The size and the structure of the compressor industry:

• Number of factories (licensed/joint ventures)

Direct labor and total number of employees involved

• Installed production capacity per shift

• Age of production lines and lifetime

• Capacities of compressors produced (coding capacity)

4. Are compressor electric motors made in-site?

5. How many compressors have been produced during the last ten years (also

import and export data)?

• Separate data for each of the refrigerant types

6. What is the future production target (e.g., 2000)?

•

•

•

C. Servicing

Quantity concerned

Shift from/towards other types

Shift from/towards other refrigerants

, '

1. How efficient is the servicing operation?

• Amount of refrigerant (typicaQ used in servicing

• How many servicing operations per unit

• Amount of refrigerant used for servicing per year compared to the

charge of the unit

Is servicing performed via factory/brand organization

• General practice in servicing

2. What has been the amount of refrigerant used for servicing per year vs.

charge of equipment (split up to types of equipment)

3. Which kind of engineers perform servicing?

• Education levels (permanent education)

• Training on the job/service manuals

• Service engineers organizations

• Number of engineers involved

• Is there a shortage/surplus of engineers

4. Which are typical aspects of servicing and critical parameters (which

components fail, leak detection available)?
- 7 -

5. Disposal:

• What is the average lifetime of a unit (reasons for disposaQ

• How many units are being disposed of

• Future expectations

/ ,

, I
·8·

III. TRANSP'ORT REFRIGERATION

A. General Description of the Sector

1. A short description of the history of manufacturing transport refrigeration

equipment.

2. Which are the critical parameters for the country in this sector?

3. The size and the structure of the industry

• How many production sites

• Average size of a production site

• Direct labor and total number of employees involved

• Status of manufacturing technology

4. How many

•

•

•

•

Units in trains

Units in vans and lorries

Units in ships

Other equipment

..

Have been manufactured during the last ten years (specific data per year;

also import and local data)

5. What is the production target for the year 2000 (as well as estimates for

import data)?

6. How much refrigerant (types, HCFC-22, CFC-12, 500 or 502) is used in

equipment manufacturing (first charge; whether it concerns domestically

produced refrigerant or import)? What is the charge used in typical products

(indications as to size)?

7. How many units have been installed (domestically produced or import)?

• Distribution with respect to the age of the product (10-20, 5-10 and

0-5 years old)

• Typical charges of these units

8. Engineers involved and their education level, some information on

• Education level of engineers

(equal questions as in retail refrigeration)

9. What is the future trend expected in manufacturing this equipment

• Manufacturing technology change

• Types and typical volumes

10. (optional) Which standards are applied in tests (ISO, NF, DIN, own...)
- 9 -

• Inner and ambient temperatures applied

Which responsibility belongs to the National Manufacturer Organization(s)?

B. Components (compressor) Manufacturing

1. Are components (like heat exchangers and valves, not the compressors)

made in-site/locally or bought from external suppliers

• Information on the type of heat exchangers

• Information on manufacturing techniques

2. Who provides the compressors

, 1

•

•

•

C. Servicing

Same structure as the retail refrigeration industry

Differences

What is the target for the near future

1. How efficient is the service organization

• How many servicing operations per unit

• Amount of refrigerant (typicaQ used in servicing (separated to the

refrigerant type of equipment)

• The amount of refrigerant used for servicing per year compared to

the charge of the unit

• Is servicing performed via factory/brand organization

• General practice in servicing

2. What has been the amount of refrigerant used for servicing per year versus

new charging of equipment (split up to types of equipment) . !

3. Which kind of engineers perform servicing

• Education levels

• Training on the job/service manuals

• Service engineers organizations

• Number of engineers involved

• Is there a shortage/surplus of service engineers

4. Which are typical aspects of servicing and the critical parameters (which

components fail, leak detection available, etc.)

5. Disposal

• What is the average lifetime of a unit (reasons for disposal)

• How many units are being disposed of/future expectations
\ .

- 10 -

IV. AIR CONDITIONING

a. AC by the use of small and middle-sized units

b. AC by the use of large (reciprocal and centrifugal chillers)

(questions have to be answered separately for the two categories of equipment, small AC

requirement and large chilling equipment)

A. General Description of the Sector

1. A short description of the history of manufacturing air conditioning units

2. Which are the critical parameters for the· country in this sector?

3. The size and the structure of the industry

• How many production sites

• Average size of a production site

• Direct labor and total number of employees involved

• Status of manufacturing technology

4. How manY AC-units have been produced during the last ten years (specific

data per year; also import and local data)

5. What is the production target for the year 2000 (as well as estimates for

import data)

6. How much refrigerant (types, HCFC-22, CFC-12, 500 or CFC-11) is used in

equipment manufacturing (first charge; whether it concerns domestically

produced refrigerant or import)? What is the charge used in typical products

(indications as to size)?>

7. How many units have been installed (domestically produced or import)

• Distribution with respect to the age of the product (10-20, 5-10 and

0-5 years old)

• Typical charges of these units

8. Engineers involved and their education level, some information on

• Education level of engineers

• National engineer societies (education level)

• Training courses

9. What is future trend expected in manufacturing this equipment

• Manufacturing technology change

• Types and typical volumes

• Size of production sites

10. (Optional) Which standards are applied in tests (ISO, NF< DIN, own...)
- 11 -

• Inner and ambient temperatures applied

Which responsibility belongs to the National Manufacturer Organization(s)

B. Components (compressors) Manufacturing

1. Are components (like heat exchangers -and valves, not the compressors)

made in-site/locally or bought from external suppliers

• Information on the type of heat exchangers

• Information on manufacturing techniques

2. Are compressors made in-site/locally or bought from external suppliers

(abroad)

In case of domestic compressor production (in-site or not)

3. The size and the structure of the compressor industry

• Number of factories (licensed/joint ventures)

• Direct labor and total number of employees involved

• Installed production capacity per shift

• Age of production lines and lifetime (when installed)

• Capacities of compressors produced (cooling capacity)

4. Are compressor electric motors made in-site?

5. How many compressors have been produced during the last gen years

(import and export data)

• Separate data for each of the refrigerant types

6. What is the Mure production target (e.g., 2000)

• Quantity concerned

• Shift from/towards other types

• Shift from/towards other refrigerants

C. Servicing

1. How efficient is the service organization

• How many servicing operations per unit

• Amount of refrigerant (typicaQ used in servicing (separated to the

refrigerant type of equipment)

• The amount of refrigerant used for servicing per year compared to

the charge of the unit

• Is servicing performed via factor/brand organization

• General practice in servicing

2. What has been the amount of refrigerant used for servicing per year versus

new charging of equipment (split up to types of equipment)

, ,
- 12 -

3. What kind of engineers perform servicing

•

•

•

•

•

Education levels

Training on the job/service manuals

Service engineers organizations

Number of engineers involved

Is there a shortage/surplus of service engineers

f .

, -

i _

j -

t ,

4. Which are typical aspects of servicing and the critical parameters

• Which components fail, leak detection available, etc.

5. Disposal

• What is average lifetime of a unit

• How many units are being disposed of/future expectations
- 13 -

V. AUTOMOTIVE/MOBILE AIR-CONDITIONING

A. General Information

1. A short description of the history of Auto-AC; are cars normally equipped

with AC units?

2. Which are the critical parameters for the country (comfort, humidity, etc.)

3. What is the number of cars equipped with AC:

• Tendencies in recent years

• Expected for the near future

• What is the lifetime of a car and what is the average lifetime of the

fleet equipped with air conditioning

4. Is there a significant amount of buses, railway carriages, etc. equipped with

AC and what is the trend for the near future (are units produced

domestically or imported)

5. Production figures

• How many cars are being produced domestically

(with and without AC)

• How many cars are being imported/exported

(with and without AC)

(some data for the last decade)

6. What is the production target for the year 2000 (as well as estimates for

import data)

7. How much refrigerant (type) is used for first charging the units and how

much is used for servicing; what is the total amount involved and is it

obtained from domestic sources.

What is the average charge used in the equipment

8. How many units are functioning (domestically produced or imported)

• Distribution with respect to the age of the unit/car (10-20, 5-10 and 0-

5 years old)

• Typical charges of these units

9. What is the future trend expected in manufacturing this equipment

• manufacturing technology change and types involved

10. In which way compressors are mounted in cars and what is the education of

the workers.

1 f
, e

- 14 -

11. Which standards are applied in tests (SAE, own...)

• Inner and ambient temperatures applied

12. How many cars are being disposed of each year (percentage equipped with

AC; can the refrigerant be collected)

B. Components (compressor) Manufacturing

1. Are components (like heat exchangers and valves, not the compressors)

made in-site/locally or bought from external suppliers

• Information on the type of heat exchangers

• Information on manufacturing techniques

2. Are compressors made in-site.locally or bought from external suppliers

3. The size and structure of the compressor industry

• Which percentage is licensed production

• Installed production capacity per shift

• Age of production lines and lifetime (when installed)

4. How many compressors have been produced during the last ten years

(import and export data)

5. What is the future production target (e.g. 2000)

• Shift from/towards other types

C. Servicing

1. Is servicing of the AC units performed·by garages (percentage of total

number of activities; do it yourself attitude)

What is the amount of refrigerant used by garages for servicing compared to

the total amount used for servicing/refilling (disposable cans)

2. Which kind of engineers perform servicing?

• Standardized education levels

• Permanent education

• Training on the job/service manuals

3. What is the amount of refrigerant used for servicing per service center

(average garage)? What has been the tendency in the years 1986-89?

4. Which are the typical aspects of servicing and the critical parameters

• Which components fail, leak detection available, etc.

5. Is there a shortage/surplus of service engineers? Is there a service engineer

organization?
- 15 -

AEROSOLS

1. Indicate the aerosol product categories manufactured in your facility and the approximate

wholesale value per unit (in local currency):

Wholesale Value

per Unit

[] Insecticides

[] Personal Products

. [] Paints

[] Medical Products

[] Household Products

[] Automotive and Industrial Products

[] Other (please specify )

2. Estimate the total number of aerosols produced in your company in 1988 and the percent

exported to other countries:

• Approximately million aerosol units were produced in 1988 and _ percent of this

was exported to _

3. Estimate the overall future annual growth rate in demand for aerosols over the next 5 years:

• The estimated annual growth (decline) in demand for aerosols is estimated at _ %

4. What is the basis for changes in production of aerosols:

[] Purchasing power of the population

[] Availability of alternative products

[] Prospects of export markets

[] Other (please specify )

5. Of the total number of units manufactured in your facility, estimate the percent containing

chlorofluorocarbons and the type of theses aerosol products:

• __ percent of the total number of units manufactured contain CFCs. The product

categories formulated with CFCs include _

6. What is the current price of aerosol-grade propellants in local currency:

CFC-11 /Kg

Isobutane IKg

CFC-12 __~/Kg

Butane __---J/Kg Propane -J/Kg

7. What would be the constraints for reformulating products using CFCs to hydrocarbon

propellants? If capital investment is required to modify existing manufacturing facilities, please

estimate the level of investment required?
- 16 -

SOLVENT CLEANING

1. Of the total amount of CFC-113 consumed in the company. estimate the distribution of solvent

use by application:

Percent of Total Use

Methyl Carbon

CFC-113 Chloroform TetraChloride

[ ] to remove flux from electronic assemblies

[ ] metal cleaning

r '

[ ] precision cleaning (e.g., cleaning of disk drives)

[ ] component drying

[ ] other (specify:

Total 100% 100%

100%

2. Which end-products are involved in the above uses:

[] Computers; [ ] consumer electronics; [ ] automotive components

[] telecommunications equipment; [ ] avionic instrumentation; [ ] military equipment;

[] other ( )

3. Estimate the number and type of solvent cleaning equipment produced every year and the

approximate value. Estimate the percent of total production that is exported and the number of

imported units (please include destination and origin of exports and imports).

Number of Units

produced annually

, , Cold cleaning

Conveyorized Vapor degreasing

Open top vapor degreasing

l " Solvent recovery systems

Value

per Unit

Units

% Exported-Destination Imported-Origin

4. Provide the number and age of cleaning equipment in service:

l.

i.

Number of Units

in Service

Cold cleaning

Conveyorized vapor degreasing

Open top vapor degreasing

Solvent recovery systems

Percent of Total Stock

1-5 years old 6-10 years 11-20 years 21 + years
. 17 -

5. Consider all major solvents currently used for electronics and metal cleaning applications. What

is the approximate distribution of consumption by solvent type?

• CFC-113 accounts for __ % of the total solvent consumption.

• Methyl Chloroform accounts for __ % of the total solvent consumption.

• Carbon Tetrachloride accounts for __% of the total solvent consumption

• Other solvents account for the remaining _ % of total solvent consumption.

6. Do you send out waste CFC-113 for recycle/recovery? If so, how much annually?

7. Are you aware of and for considering replacement processes/chemicals/technologies for the

above applications? If so, please describe.

, I
- 18 -

STERILANTS

1. For each of the following end-uses estimate the total number and type of sterilization chambers

in service and the approximate value of these units:

Hospital sterilization.

Commercial/industrial sterilization

R&D laboratories.

Other (please specify) _

Number of Units

in Service

Value per Unit

2. Indicate the approximate number of sterilization chambers purchased every year and the

expected growth in future sales:

Number of Units

Purchased

Hospital sterilization.

Commercial/industrial sterilization

R&D laboratories.

Other (please specify) _

3. What percent of the local market is supplied domestically: __ percent.

Sales Growth

4. What percent of local production is exported: ___ percent.

5. Of the total volume of sterilant gases used, roughly estimate the percent associated with

mixtures containing CFC-12: percent.

6. What other sterilization methods are used for heat-sensitive devices:

[ ] Pure ethylene oxide

[ ] Formaldehyde

[ ] Ethylene Oxide and Carbon Dioxide

[ ] Other ( )
- 19 -

FOAMS

1. Quantities and types of foam products manufactured and imported, blowing agents used,

and extent to which CFCs or other blowing agents or product substitutes are now

employed.

a. Polyurethane Foams

Rigiq Appliance Insulation

Rigid Insulation: building, piping, slabstock, etc.

Flexible·

Packaging and Other

b. Extruded Polystyrene

Packaging

Insulation

c. Phenolic

d. Polyolefin

2. Projected foam demand by year until 2000

Basis for growth in demand

Domestic Consumption

Exports

Projected sources for meeting future demand

Expanded domestic production

Increased imports (possible sources)

Infrastructure requirements for expanded manufacturing and/or production

Possible sources of technology

Possible quantum of capital

Government/private/international agency participation in expansion

3. Sources of current raw material for production

Domestic production

Imports and country of origin

4. Current domestic manufacturing facilities

Size and structure of industry (number of employees, sales, etc.)

Age and expected life time of production facility

Is the facility under a licencing agreement/joint venture

Source and type of technology used

5. What are the critical parameters, factors of the product that are essential to the country.
I _

i _

t -

( .

,

t.

- 20 •

6. Characteristic of unorganized industry in the country

Small plants

7. Identify near term substitutes

Chemical substitutes

Process modifications or alternative technologies

Product substitutes

8. Availability of near term substitutes

9. Identify longer term options for both chemical substitution or process change.
• 21 -

HALONS

1. Is there a government agency or trade association responsible for fire protection? If so, list

name, address, phone number and fax number.

·2. Are there any pieces of national legislation or regulations on fire protection that require

halon? If so, please list.

3. Imports/Halon

When did you first import halon?

How much halon is currently being imported?

- bulk

- in equipment

How much has been imported each year from initial date of import?

- bulk

- in equipment

4. Production/Halon

If there is any production facilities in your country, please estimate volume.

5. Production/Equipment

Does your country manufacture any fire protection equipment intended to contain halon? If

so, identify manufacturer, location, capacity and whether manufacturing

- 1301 systems

- 1301 portables

- 1211 portable extinguishers

- 1301 systems

- 2402 in any type of equipment?

6. Estimate bank of halon by examining use sectors. Specify use of ·1301, -1211, -2402 within

each sector.

- Transportation

- Communications

- Utilities

- Financial services

- Primary industry

- Manufacturing industry

- Natural resource industry

- Petro/chemical

- Government services/military

Health care

- Other

TOTAL
- 22 -

To check estimated bank, compare total to quantity imported from date of initial import.

6a. What percent of halon applications are in areas where a fire would pose direct threat to

human life and a large sector of your society and where no other extinguishing agent could

be used effectively?

7. How much halon is used to:

Fill new installations

Recharge existing installations

Testingltraining

1301 1211 2402

.,

( .

1.. _

8. What major projects has your country committed to that will require halon?

8a. Provide a S-year forecast of halon needs/commitments.

9. What national plans, if any, exist for reducing halon dependence?

10. Please provide any other information/suggestions for needed assistance.
r •

r •

APPENDIX
I •

r '

j ,

Replacement of CFC-113 in

Industry

Author:

Brian N. Ellis

(Protonique SA. 1032 Romanel-sur·Lausanne)

Published by:

Federal Office of Environment, Forests and Landscape

3003 Berne

January 1990
( "

1 .

, '

Preface

To protect the global ozone layer, the production and consumption of

a series of chemicals, such as chlorofluorocarbons (CFCs) and halons,

must be phased out. The great majority of industrial enterprises using

CFCs and halons are prepared to renounce them, but there is an obvious

lack of infonnation on how to achieve this in practice. This booklet

contributes towards filling in this gap. The author is a renowned expert

in industrial cleaning and is recognised in the relevant international

professional circles. He has actively participated in the evaluation of the

possibilities for the substitution of CFC-113, within the framework of

the United Nations Environmental Programme (UNEP). The Federal

Office of Environment, Forests and Landscape is convinced that, by

supporting this publication, an important contribution to the

accomplishment of CFC replacement is being made.

Federal Office for Environment,

Forests and Landscape,

The Director

Professor Dr. Bruno Bohlen
French executive summary

£5-2

I .

l .

, .
{ ,

Executiv ,~mmary

This boolclet is intended primarily to guide Swiss

Industry away from the use of chlorofluorocarbon

(CFC) and other polluting solvents, giving suggestiorts

as to how these products may be replaced by less

polluting ones, For the most pan. it is a resume of the

Solvents Technical Optiorts Committee Repon of the

United Natiorts Environmental Programme. modified

to suit the Swiss context. Its structure follows a logical

sequence.

The first chapter is an introduction giving brief

indications as to why it is necessary to replace

CFC·solvents, touching on both the technical and the

legislative aspects with. obviously, a cenain emphasis

on the Montreal Protocol, as well as the official Swiss

position, as defined by the Federal Council and

probable future legislation. The mechanisrrts of ozone

depletion and the greenhouse effect are also briefly

discussed.

Chapter two examines most of the practical products

that may be used for industrial cleaning, indicating their

individual advantages and disadvantages. The first

section discusses the two solvents which are restricted

under the current (1979) provisiorts of the Montreal

Protocol, CFC·ll and CFC·ll3. The next section

examines those solvents that are not yet restricted even

though there is every reason why they should be,

namely, carbon tetrachloride, l,l,l·trichloroethane

(methyl chloroform), CFC·ll2 and ceMain HCFCs. All

of these will probably be included in the next revision

of the Protocol, scheduled for June 1990. Section 3 of

this chapter looks at other halogenated and

non· halogenated organic solvents. The last section

exposes water·based cleaning methods, with and

without diverse types of additives.

As CFCand other halogenated solvents become more

difficult to obtain, and more expensive, it will become

increasingly imponant to practIce conserv3t:o:c. :: .,

shown in the third chapter that savIngs of.u]·90'C o( :~:

consumption are usually pOSSible by s:~:J::.

common·sertse measures, panicularly for the S:7'.2.::~~

establishmentssuch as are common in SWI tze ~i3 ~c. ;~:

most imponant of these measures IS 10 ~3;;e ~O:~

management and the operator aware of t~e ?~()h::~".

but simple machine modificanons and en~3r.c;~;~:;

are equally described. These conservatIon ~e:~cc:s ~~:

obviously applicable to all volaule solvents. '.' ~::~~~

CFCs or not.

The final chapter gives specific recom..rr.e:;cat:or.s ~s

to how to go about substituting less·pollu:::cg ?~oc,~:,;

for halocarbon solvents in various appltca::or.s. C·.:~

half the chapter is devoted to defbx:ng .:': :~:

electronics industry, this being the pnncI;Jie ·.:.s~c:'

CFC·ll3 in Switzerland. Six substItute rr.e:hoCs ~~:

discussed, namely, the use of Ouxes that do not ~:~ _~:

cleaning, water cleantng of water-soluble ::·,\C'.

saponifier and water cleaning of ~os:n :: .:\:S.

hydrocarbon/surfactant and water c!eancng .:>:' :".-.

fluxes. hydrocarbon and derivative (e.g. J.~~.~.;: ..

cleaning of rosin fluxes and. finally. the :..se of J :':'.,

permitted halocarbon solvents for rosin r;ux ~~~O\~:

Funher applicatiorts that are discussed are :r.c'.:.s:~:.,

degreasing, precision ..::Ieaning, dry:ng by so;\ :~,:S.

textile dry cleaning. particle rernov:!l. 17'.:-:.,-,.

applicatiorts and, finally. the use of such solv~~:s -', -'

vehicle for lubricants and adhesives.

The booklet is completed by an appendix 1:5·.:~~ .. ~.:

usual halocarbons, with cenain propenies. t~.3t ~JY :--c

found in industry, a list of references for those \> :s~:~ Emore detailed information and some lists of Jd';,;SS~5

of organisatiorts that may help industry to e!iml:'Jt~ t~.:

use ofCFC-ll3. Acomprehensive table of con:e~:s ~~..:

index is provided.

£5-1
.~. talian executive summary

ES-4

! .

\ .

f •

I.
r •

1

f ".

l.

i

I .

German executh ,~-nunary

ES-3
Chapter IV. Substitution

IV. 1. Genera! .....

IV. 2. Specitlc appUcatlons .

IV. :. 1 ·l•..uxing ....

f\!. 2. 1. Industrial def1JJ.xing

TV 2. J. J. J The "no-clean" solution

IV 2 J. J. 2 Wa/L'r cleanlng with water·soluble fluxes

rv 2. J. J. J Rosin flux aNi sapoflifier .... .

IV. 2. J. J. 4 Hydrocarbon/sur{actanJ cleaning 01rosin fluxes

IV. 2. J. J. 5 Hydrocarbon and derivative cleaning ofrosin fluxes

rv 2 J. J. 6 Permitted halocarbon blends

IV. 2. 1. 2. ATtisanaJ deflu;xing.

IV. 2. 2. Degreasing

IV. 2. 3. Precision cleaning

IV. 2. 4. Drying by solvents

IV. 2. 5. Textile dry cleaning

IV. 2. 6. Particle removal

IV. 2. 7. Medical applications

IV. 2. 8. Vehicles for lubricants and adhesives

Appendix A, Properties of Halocarbons

R. References

L. Useful Lists of addresses

L. 1. Government and official departments

L. 2. Private sector organisations

L 2. 1. Chemical Industry .

L 2. 2. Electronics industry:

L 2. 3. Precision industry:

L 2. 4. Dry cleaning:

L. 3. Experts • • • • • .

Index .

.... IV-I

. IV·I

IV·l

IV-I

[\/.]

.IV· 2

IV-4

.IV·6

.IV-8

IV-B

IV·lO

.IV-ll

.IV-II

.IV·11

.IV·12

.IV-12

.IV-12

.1V·12

,IV·13

.APP.A·l

.R·l

.L·1

L-l

L-l

L·I

Lol

Lol

L·2

L-l

... IND·1

"

1 .

i .
Table of Contents

Preface by Dr. B. Bohlen . . . . . . . . . . . . . . . . . . . . .1

f •

Executive Summary (in English, Frenc. ";,nnan and Italian)

D. Dermitions .

Chapter I. Introduction

I. 1. Why? .

I. 2. Historical background . . . . . . .

I. 3. The Montreal Protocol . . . . . . .

I. 4. The Helsinki Declaration, May 1989 .

I. 5. Solvents Technical Options Committee

1.6. Future Decisions ofthe Parties to the Montreal Protocol

I. 7. Swiss legislation . . . . . . . . . .

I. 8. The Mecbanism of ozone depletion . . . . . . . .

1.9. Greenhouse effect . . . . . . . . . . . . . . . .

Chapter II. Products under question and others . . . . . . . . . . . .. . . II. 1. Restricted solvents according to the Montreal Protocol (state of 1989) .

II. 1. 1. CFC·113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II. 1. 2. CFC-II .

11.2. Ozone-depletlng solvents not yet restricted according to the Montreal Protocol (state or 1989)

II. 2. 1. Carbon tetrachloride .

II. 2. 2. l.l,l-trichloroethane .

II. 2. 3. CFC-112 .

II. 2. 4. Hydrochlorofluorocarbon solvents (HCFCs)

II. 3. Otber organic solvents .

II. 3. 1. fluorinated solvents .

II. 3. 2. Chlorinated solvents .

1I. 3. 2. 1. PrQ&ticaJ aspects ofchlorocarbons Q1Id hydrochlorocarbons

II. 3. 3. Non-halogenated hydrocarbOns and their derivatives

II. 3. 3.1. Hydrocarbons .

11.3.3. 2. Alcohols and other hydrocarbon derivatives . . .

II. 3. 3. 3. PrQ&tical aspects ofhydrocarbons Q1Id derivatives.

II. 3. 3. 4. Hydrocarbon/surfactQ1lt blends

II. 4. Aqueous systems

II. 4. 1. General

II. 4. 2. Water quality

II. 4. 3. Drying . . .

II. 4. 4. Pure water cleaning

II. 4. S. Water + detergents

II. 4. 6. Water +saponifiers

Chapter m. Conservation of CFC and other volatile solvents

m. 1. Genenl .

m. z. Bottoms recovery

m. 3. Equipment siting m.4. Equipment maintenance

In. 5. Molecularsieves . . . .

III. 6. Solvent bandUng

111.7. Equipment enbancement

m. 7. 1. Freeboard

m. 7.2. Lid ....

m. 7. 3. Cooling coils

m. 7. 4. Pans baskets

m. 7. S. Sprays

III. 8. Cleaning cycle

III. 9. Automatic bandUng

III, 10. Solvent type . . .

III. 11. Solvent vapour capture

III. 11. 1. Othersolvents . . .

III. 1%. Operator awareness and management

TOC·1

ES·l

. D·}

J.}

1·1

1·1

1·1

1·1

I·)

I·)

I·)

I·J

I·~

. II·}

II·l

[1-:

II- L

II·I

I1- L

[I· :

II·::

11-2

II·)

II -3

II·}

II·]

l!'~

II-4

/1.4

11-4

II-5

11·6

[[-6

[[·6

Il-7

[[.-

II·;

II-3

IlI-!

· III·1

. III· 1

. Ill·!

. Ill·!

· Ill·1

· III·1

. III·)

· Ill·)

· Ill·3

· lID

· rrr-3

· 1Il-3

. Ill·)

.III·..$

· III-4

.1Il·..$

· III·~

· III-4
D. Definitions

It is thought thatsome ofthe terms used in this booklet

may be obscure to non-specialists. In view of this, it has

been decided to include a glossary explaining the

meaning of some of them, of a fairly general

application. It has been a deliberate pollcy :0 >:~~;: :'".~

defirutions as simple as possible. to the ex:e:'.t :ha: S0:":",~

of them. while practically explairung the mea::;r:g. :":",a:-

not be correctly scientifically defined.

Chelation

Defluxing

Degreasing

Detergent

i .

Aerosol [F. a~rosol. D. Aerosol] a colloidal dispersion of a liquid or solid in a gas

Aerosolspray [F. bombe a~rosol, D. Aerosoldose, Spraydose] a loose tenn to designate a means of atOri'dS: r:g .1

liquid by pressurising it with a liquified or compressed gas in which it is soluble. It IS a mlSnO:T.er

[F. complexage. ch~lation, D. Komplexierun'g, Chelatbildung] a process whereby a substance :or.:-:s

a water-soluble complex with an insoluble compound

Chlorofluorocarbon [F. chlorofluorocarbone, D. vollstandig halogeniener Fluorchlorkohlenwassers:of:"]. (CFC:.

an organic substance where all the hydrogen atoms of a hydrocarbon are replaced by c:::on r:e ar:c

fluorine atoms

Conservation [F. conservation, D. Riickhaltung] in this context, the prevention of evaporation of J 50:\ ~r:: :\

improved housekeeping

[F. d~fluxage, D. Flussmittelentfemung, Entfluxen] the elimination ofsoldering t1ux reS1Ct;CS

[F. d~graissage, D. Entfettung] the elimination of oils and greases

[F. d~tergent, D. Wasch-, Reinigungsmittel, Detergens] a product designed to solubilise oils. greases.

etc. in water

Dobson Unil [F. Unit~ de Dobson, D. Dobson EinheitJ, (D.U.), a measure of the instantaneous t0121 c;'~a;,:;:\ );'

ozone in a column of the stratosphere expressed in the number of hundredths of a mlillme::e :'".at :r:~

total column would occupy as a layer if it was at standard temperature and pressure JrC ar:c :

annosphere). The average "ozone layer" thickness is about 300-400 D.U. or 3-4 mm

Dry-cleaning [F. nettoyage chimique, D. chemische Reinigung] the elimination of dirt from garrr:e:,.:s Jy :r:e ~e

of organic solvents, as opposed to water solutions

Flux [F. flux, d~capant, D. F1ussmittel] a product designed to facilitate soldering. Nearly all fl'.J.xes are

acid and therefore their residues must be removed or cleaned off, in many cases

Flux octivator [F. activateur (de flux), D. Aktivator] a substance added to rosin or other flux bases to ;;.creJse ,:.5

effectiveness. The most usual flux activators are either an organic hydrohalide which breaks cow;-;

atsoldering temperatures to release minute quantities ofhydrohalic acid gas or stronger orgar.Jc accs

which remain more or less intact

Global Warming Potellluu [F. Potentiel de rechauffement global, D. Globales Erwannungspotenllal]. GWP. ar:

index, referred to CFC·ll = 1, given to a substance and which indicates its potential for globa:

warming (see Greenhouse effect). In absolute terms, Radiative Forcing Potential is expressed by :~~

theoretical temperature rise in Celsius degrees per increase in pans per 109 of the subs12r1ce (?a:-..5

per milliard volume; USA. parts per billion volume)

GreenJwlLS~ effect [F. Effet de serre, D. Treibhauseffekt] a natural increase of global temperature due :0 :-ad:a::o~.

from the eanh's surface to outer space being reduced by the presence of certain gases. The e:'fec: :s

probably intensified by the presence of. principally, man-made pollutants

Halocarbon [F. halocarbone, D. Halogenkohlenwasserstoff] generic tenn for all hydrocarbons where at :east or.e

atom has been replaced by a halogen atom (fluorine, chlorine, bromine or iodIne)

Hydrocarbon [F. hydrocarbone (preferred to hydrocarbure), D. Kohlenwasserstoffj (HC) organic subs:ar,ce whose

molecule containsonJy carbon, often in chains or rings, and hydrogen. In the Swiss legislative cor:tex:.

Jhis is considered as synonymous with Voltaile Organic Compound (q.v.).

Hydrocarbon tkrivative [F. d~riv~ d'hydrocarbone, D. Kohlenwasserstoffderivat] a hydrocarbon whe:c or:e or

more hydrogen atoms are replaced by another radical .

HydrochlDrocarbon [F. hydrochlorocarbone. D. teilweise halogenierter Chlorkohlenwassers:o[fj (HCC'I .!

hydrocarbon where one or more hydrogen atoms, but not all of them, are replaced by cr~or:r:c J:O~S

D-]
Hwirochlorofluorocarbon (F. hydrochlorof1uorocarbone. D. tellwetse halogenJener F1.t;orchlorkorJe"wa.;se:>:,,(:~

(HCFC) a hydrocarbon where one or more hydrogen atoms. but not all of them. are replaced Jy

chlonne and fluorine atoms

Hydrofluorocarbon [F. hydrofluorocarbone, D. teilwelse halogenierter Fluorkohlenwasserstoffj (HFC) a

hydrocarbon wI" .~ e or more hydrogen atoms, but not all of them, are replaced by fluonne atoms

Janie contamiNJIion [F. contal....nz.ion ionique, D. ionische Kontarnination od. Verunreinigung] residues on an

electronics assembly which will ionise in the presence of water. The measure of ionic contamination

is a standard procedure to determine cleanliness

Lifetime [F. dun~e de vie, D. Lebensdauer) in this context, the time, expressed in years. required for a substance

in gaseous or vapourform to break down in the atmosphere. the decay is exponential, it is expressed

for convenience as the "folded-en lifetime, that is until there is lie times the original quantiry,

approximately 37%

Ozone [F. ozone, D. Ozon) 03, an allotrope of oxygen. In the stratosphere, where it is generated by solar

radiation, it forms a barrier to high-energy ultra-violet (UVB) radiation. In the troposphere, it is a

highly toxic gas

Ozone depletion [F. appauvrissement d'olone. D. Ozonabbau) an effect where stratospheric Olone is reverted to

oxygen by a catalytic reaction with chlorine or bromine, mainly derived from human activities, faster

than it forms

Ozone depletion pote1UiaJ [F. Potentiel d'appauvrissement de la couche d'ozone, D. Olonschichtabbaupotential]

an index, referred to CFC-ll = 1, given to a substance, indicating its potential to deplete ozone in the

stratosphere. It is calculated by means of a small number ofmathematical models from about rwelve

parameters and is necessarily approximate as there are other undefined parameters involved

Ozone hole [F. troud'olone, D. Ozonlochj a loose term to describe a phenomenon where a high degree of Olone

depletion occurs over the Antarctic at the end of winter. It is caused by the combination of

meteorological phenomena with, principally, chlorine atoms

Ozone layer [F. couche d'olone, D. Ozonschicht] a loose term to indicate the Olone contained in the stratosphere.

between 10 and 50 km altitude

Perchlorocarbon [F. perchlorocarbone, D. Perchlorkohlenwasserstoff] (cq an organic substance where all the

hydrogen atoms of a hydrocarbon are replaced by a chlorine atom

Perfluorocarbon [F. pertluoroearbone, D. Pertluorkohlenwasserstoff] (Fq an organic substance where all the •

hydrogen atoms of a hydrocarbon are replaced by a fluorine atom

Petroleum ether [F. ~ther de p~trole D. Petrolatherj a mixture of hydrocarbon petroleum distillates with boiling

points from 40" to SO"C, often selected over a narrow range

Petroleum spirits [F. essence de ~trole, benzine D. Benzin, Petrolspiritus) a mixture of hydrocarbon pelroleum

distillates with boiling points from SO" to lSO"C. Also used as a generic lerm for all fracllons from

about 30" to 300'C

Precision cleaning [F. nettoyage de p~cision, D. Prazisionsreinigungj cleaning of ultra-precise components or

assemblies to defined limits

Product [F. produit, D. Produktj a mixture ofchemical compounds, often of a commercial nature, frequently

of indeterminate orsecret composition

Rosin [F. colophane, D. Kolophoniwnj a mixture of natural organic acids obtained from pine trees used

extensively as a soldering flux. Its fluxing action is weak and activators are usually added

Soldering [F. soudage, brasage tendre, D. LOtenj the joining of two metals by a third, usually of low melting

point, wbereby a chemical bond is formed at the interfaces by the formation of interrnetallic

compounds_ Soldering requires clean surfaces, hence one of the reasons for fluxes

Solvent [F. solvant, D. LOsungsmittelj in this context, but notstrictly correct, a liquid substance or a product

designed to dissolve specific contaminants

Stoddart solvent a type ofwhite spirits used for dry-cleaning gannents

Substance (F. substance, D. Stoff] a single chemical compound of a specific composition. as opposed to a

product

Surface insulalion ruistDnce [F. resistance de I'isolement de surface, D. Obertlichenwiderstandj (SIR) one of the

qualities of a good insulator is a high SIR. the presence ofcontamination may reduce the SIR, the

measure of it is a standard procedure to determine cleanliness

Surfactant [F. agent de surface, D. obertlAchenaktiver Stoff) a substance with long molecules, one end of which

is lipophilic and the other hydrophilic. Surfaetants reduce the surface tension of water with which,

they are mixed and they fonn micelles which can emulsify many oils and greases. Surfactants are the

principal constituents of most detergents

D-2
Terpenes

Terpenoid

Tox~ity

(F. terpenes. D. Terpene] a family of volatlle. odonferous. cyclic hycrowr::or..s ... :n :~.~ ~~.~. -, ..

formula CIOHl6- There are tens of types of terpenes wllh vanous solve:1t qualities. T::e ~,,,'I :.~~.

is alpha-pinene. the princIpal ronstituent of turpentine.

(F. terpine; D. Terpenederivat] a derivative of a terpene (see hydrocarbon denvatlvej

(F. toxicite D. Giftigkeit. ToxiziLlitJ a measure of the harm that a sub: _e ,l1ay cause to J~.y ::"'0:

species. Acute toxicity applies to the effect of a single dose. whereas ' .....OluC toxiCity applies :0 :.-.;:

effect of repeated doses-over a period of time. As far as man is roncemed. the major access pa::-..s ..<

toxic substances are oral. respiratory and cutaneous

Volatile organic compound [F. compose organique volatil (COY) D. fliichtige organisehe Veroindung] (vee

loose term to designate a rompound whose vapours will react with pollutants and oxygen. in :~.~

presence of light, to form atmospheric ozone. In the rontext of Swiss custom. the term mea:-.5 <1::.

organic compound that is easily vaporised. synonymous with hydrocarbon (q.v.)

Water-solubleflw: [F. flux hydrosoluble. D. wasserlosliches Flussmiuel) a soldering flux. not necessar.iy

containing water, but whose residues after soldering are easily removed by a simple .....ater .....ash

White spirits [F. white spirit, sangayol D. white spirit) a mixture of hydrocarbon petroleum distillates .....l!h bOI:I~g

points from 120· to 220·C

D-3
ThJs page :s :Jlank:.

D-4
Chapter I. Introduction

I. 1. Why?

This booklet is a short resume of why Swiss industry

must reduce its consumption of an environmentally

dangerous product, CFC-1l3, a chlorofluorocarbon or

CFCand popular as a cleaning solvent (plussome other

uses not relevant to this work). It is meant as an

introduction for industrialists as to means and methods

of substituting relatively harmless products for

CFC·1l3 with a brief discussion of the pros and cons

for each, as applied to each broad industrial sector. A

further utility will be to warn industry ofwhat may well

become future problem areas, so that any substitution

methods adopted are chosen. as far as possible. from

those which are least likely to cause other problems of

an environmental nature.

I. 2. Historical background

In 1974, two American scientists. Molina and

Rowland. pronounced a hypothesisl that CFCs could

provoke destruction of the ozone layer in the

stratosphere. This layer is one of the detennining

factors for global climate and protects the biosphere

from intense UVB radiation and, without it, life could

not be supported on the earth's surface. It is very thin:

if all the stratospheric ozone in a column of a given area

was brought down to the earth's surface. it would form

a layer of an average thickness of 3-4 mm at

atmospheric pressure (30~00 Dobson Units).

However, this danger appeared at the time very

theoretical and only a few persons took it really

seriously. The first resultant measure was that the

Environmental Protection Agency ofthe USA was able

to instigate legislation. passed in 1978. forbidding the

use of CFC propellant gases in most aerosol sprays.

Only a few other countries, notably Sweden. Norway

and Canada. followed suit within a year or so and no

other application was restricted.

In the mid 19805, a British Antarctic SurveyZ

discovered that the.. ozone layer was rapidly and

progressively diminishing at the end of each winter.

The immediate reaction ofscientists was to revive the

theory that CFCs3,4 may be responsible for the ozone

hole which was later confirmed independenUyto existS.

In 1987, an international meeting inMontreal, underthe

auspices of the United Nations Environmental

Programme (UNEP), agreed on a Proto<:ol6 which

defined the most dangerous products which were

known to be causing a degradation of the ozone layer.

/-J

their respective potential for such depletion. J;.c.:

programme for the reduction of their produc:lon J;.-:

consumption. Up to mid·1989, tIDS was Signed jv

nearly 50 nations and ratified by over 30 of t~e:::

(including Switzerland) piUS the European Ecor:o:::lc

Cornmunity en bloc. It entered into force on ::Je :s:

January 1989. Since 1987, much effon has been :::ace

to confirm that the ozone layer is dlmlnls:-'lr.g .:-:

thickness and not only over the Antarctic and :~at :::e

main cause of this depletion is mdeed the ch:o:-::-:e

resulting principally from the decomposItion or CFCs

and other industrial chemicals in the stratosphere. l:".;s

has now been scientifically proved and conrlrr::cd :-\

independent methods. Equally, it has been shown ::-':l:

the situation is even more serious than was 1:-':::.1:: ..

believed and that the prOVisions of the Protocoi :l~~

woefully inadequate to stop future degradalwn. eve ncr:

a long time scale (Figure 1-1).

As a result. a meeting was held In The HJg-~er:

Autumn 1988, at which it was deCIded :0 se:~J

international committees of experts :0 s::';c:. :::~

situation and its evolution and who would report 0J :~.e

state of the art to UNEP and the memoe:-s 0[ :::~

Montreal Protocol. Tl1ese committees wou:d cove~ :l.:

applications of CFCs and simllar cherrucals ar.d s~.o""

how to implement changeovers from these proC:';ClS :0

other types of materials as painlessly as poss:b:e.

identifying which substances and products are :::e

principal "culprits" and whether any others should :-e

restricted. These committees were formed ve,y raplc:y

and produced their reports in the record !lme of s:'(

months. nus is an indication of the urgency of :~.e

situation.

In Spring 1989. the British Prime Mimster. \1:-s. \1

Thatcher, responding to "green" pressure. cailed :lr:

informal international conference of scientlsts ar:d

ministers at which it was confirmed that the sltuat:or:

was grave. During the address pronounced by 5.... 1S5

Federal Councillor Mr. Flavio Colli. he gave a wamlr.g

that Volatile Organic Compounds (VOCS) would not

be the most satisfactory substitutes for CFCs beC2L:.Se

of the problems caused by them In the lowe,

atmosphere. At the same time. he announced :::J:

Switzerland would substantially elimInate CFC a~.d

halon usage by 1995 (85-90% reduc!lon).

I. 3. The Montreal Protocol

A3 stated earlier. the Montreal Protocol dc:: r.es t:-.e

substances subject to restrictions and dangeroL:.S ,'or :~.:
U .• I

·U

ill t." oj

•

·

•

,... I

•

••

• ,...

a.1I

1."

Fig. 1·1. Forecast for Stratospheric CIx Progression

Key to Figure [-1

The above figure demonstrates the different scenarii. calculated according to the best information available and 10 possible

reduction programmes ofchlorine· COIItaining substances. The Y-axis is in parts per milliard (U.S.A parts per billion) of total ax

concentrations in the azone layer. As in all predictions, the premises on which the calculations are based can not be considered as

infallible. but they are sufficiently accurate to give a broad visual representation.

Curve 1. CFCs(all types) reduced 00 a global scale according to the current provisions ofthe Montreal Protoeol and no increase

in production of carbon tetrachloride, 5()<jf, of the CFC market being replaced by HCFCs with an average OOP of 0.08.

Curve 2. As for curve 1. except for a total phasc-out of all CFCs by year 2000.

Curve 3. As for curve 2, except for a total phase-outof carbon tetrachloride.

Curve 4. As for curve 3, piUS no iocrease in production of 1,1,I-trichloroethane.

Curve 5. As for curve 3, except for a total phase-out of l,l,l-trichloroethane.

Curve 6. As for curve 5, except for replacement 0(2()<Jf, only of the CFC market by HCFCs with an average OOP of 0.08.

Curve 7. As for curve 5, except for replacement of 35~ of the CFC market by HCFCs with an average OOP of only 0.02.

Source: adaptedfrom a presOltOlion m.tUk byt~ U.S. EPA to tkParties oft~ MONreal Protocol Ol Helsinki (1989).

ozone layer and a programme for the reduction oftheir

production and consumption. It is a long and complex

document and only the essential points, as applied to

solvents, will be discussed here. Only two CFCs

mentioned are usable as SOlvents, crc·n with an

Ozone Depletion Potential (ODP) of 1 and CFC~1l3

with an ODP of0.8. The first-named is only rarely used

for cleaning purposes due to a very low boiling point.

It is estimated that at least 99.~ of the CFC solvents

are products based on the substance

1.1.2-trichloro-1.2.2-trifJuoroethane, CzF3Q3,

abbreviated to CFC-1l3. These two substances are

included in a "basket" with other CFCs which arc used

for other purposes. This "basket" was agreed to be

subject to a reduction of the production and

consumption according to the following programme:

1July 1989: reduction to the 1986 consumption

level, a de ftxto reductio" ofabOut

21%

1 July 1993: reduction to 80% of the 1986 level

1July 1998: reduction to 50% of the 1986 level.

/-2

Further clauses in the Protocol permit revision of the

list ofsubstances and the timetable of reductions.

It is therefore clear, as Switzerland ratified the

Protocol on the 28 December 1988. that Swiss industry

is committed to reduce its consumption of CFC-l13.

In May 1989. the UNEP organised the first meeting

of the parties to the Montreal Protocol in Helsinki at

which it was agreed that funher restrictions were

inevitable.

I. 4. The Helsinki Declaration, May

1989

In substance. the Helsinki Declaration officially

recognised that the Montreal Protocol was inadequate

and it has paved the way to forcing the introduction into

it of other substances that research has shown to be

ozone depleters and to tightening the programme to a

complete phase-out of CFCs by the year 2000. It has

also foreseen the difficulties that under-developed

countries may experience in reducing their

consumption of the substances in question and IS

i ;.
forc:ng :-esearch Into means of tow-cost ,ech.noiogy

transfer Into these nauons.

I. 5. Solvents Technical Options Committee

The main task of the committee. formed as a result of

The Hague meeting, was to determine how to substitute

less environmentally harmful substances or products

for CFC solvents. This involved an examination of the

secondary implications, such as the cost of capital

equipment and exploitation. as well as the primary ones,

such as the environmental impact. As far as possible,

the objectives were to study all the known applications.

The second task was to scrutinise solvents that were not

restricted in the Montreal Protoall but were known to

be ozone-depleting and to determine whether and

where these, too, could be replaced by more benign

products.

The committee was formed in January 1989 under the

chairmanship of Dr. Stephen O. Andersen of the U.S.

Environmental Protection Agency. Twelve persons

(with three substitutes) contributed to the work of the

committee, from Canada. Japan. Sweden. Switzerland.

the United Kingdom and the United States ofAmerica.

The combined experience of the members of the

committee covers nearly every possible usage of

CFC·113 solvents and theirsubstitutes. Their report is

being published in 1989after five meetings7. Copies (in

English) will be obtainable through the Federal Office

of Environment, Forests and Landscape. It is an

imponant work: the chapter headings are: Glossary.

Executive Sumrnary, Introduction/Worldwide Use of

CFC-113, Electronics Industry Applications, Precision

Cleaning Applications, Metal Qeaning Applications,

Dry Oeaning Industry, OtherSolvent Uses ofCFC-113

and l.l,l-trichloroethane, References and Appendices.

Two accompanying documents include reprints ofcited

technical papers and commercial documentation

concerning products and machines which may be

considered for CFC-1l3 substitution purposes.

TItis booklet represents a shortsummary of the report

of the Solvents Technical Options Committee. as

applied to the Swiss context.

I. 6. Future Decisions or the Parties to

the Montreal Protocol

It is obviously impossible to forecast what the Parties

will decide in the future. What is known at the time of

writing is that the next Ordinary Meeting of the

contractual parties will be held in London in June 1990

with the firm intention of tightening the provisions of

the Protocol. As announced in the Helsinki Declaration.

it is almost inevitable that a complete phase-out of

CFCs by the year 2000 will be decided. What is

probable is that furthersolvents will be restricted in one

way or another, inclUding carbon tetrachloride,

1.1.l-trichloroethane, other CFCs, including CFC·112.

and some HCFCs.

1-3

I. 7. Swiss legislation

It is clear that pollutlOn knows no ?Oll:IG" :';or.::~:-;

Switzerland, a small country With an a~.:'._~.

consumption of CFC-1l3 of less than 2COJ lOr.~.~S.;

not a major polluter but It has taken a tirm s:.:J~.c~ .:'.

favour of reducing this to a minimum. as part 0'- 1

general programme towards a clean enVtronmer.t. .-\s

stated above. the official poSition is quite c:eJ~: 1

reduction of all CFC and halon usage by 1995 :0 a

minimum (at least 85-90% phase.down plUS a Vlrt:.:.:Ji

phase-out by 2000). Any permitted exceptions to the

complete elimination will be clearly defined and based

on sound technical reasons, as opposed :0 pure:;.

economical or commercial ones.

Obviously, no specific legislation has yet beer.

introduced concerning CFC solvents. A FeJ~~J:

Ordinance is intended, but it is Unlikely that It WI!! be

approved before 1991. It will mainly cover ~a~e

restrictions and recovery obligations.

In addition, a funher point that should not be :gr.o~e::

is that some substitute solvents, notably hydrocarbor.s

and their derivatives classed as Volatile Org3r.:c

Compounds (VOCS), are equally under attack for be::'.5

causal of tropospheric pollution by their vapot:rs bc:r.~

subject to photochemical reactio ns WI th 0 the

pollutants and oxygen. creating a risk of exceSS1V~

ozone levels and smog under unfavourable weathc~

conditions. Whereas legislation governing S'~C:-'

emissions of Volatile Organic Compounds IS stili :'l ::.s

infancy, industry should be aware that S\ICh p~ob:e::-.s

exist and that it is planned that polluters WIll be mace

to pay for the pollution they cause. Ifit is enVisaged :~.Jt

a substitution process will use such a \/OC (~.g.

hydrocarbons, halocarbons, alcohols. terpe:les.

petroleum spirits. etc.). it would seem wise to Inc; ;.;ce

in the cost calculations a figure for some form of :3X c:-'

unaccounted substances and products and the cost 0:'

means to prevent the errussion of such VOCs lr.tO the

atmosphere.

It is clear that any substitution method to replace the

CFC solvents must not engender any other :ega:

prOblems such as may be covered by other. ex:s::r.g.

laws, notably the Federal Ordinances on water

effiucnts8, onsubstances9 and on toxic productsto.! 1. fn

addition. it must conform to the requmme:lts ot

industrial hygiene as laid down by the Swiss :\atlor.Ji

Accident Insurance Fund. The appropnale Olntor.al

services should be consulted for further informatlon or.

all these requirements.

I. 8. The Mechanism of ozone

depletion

It is not always clear why the presence of CFC

molecules in the stratosphere is so damagIng. One of

the most frequently asked questiOns is why. if most of

the CFCs are ustd in the Northern HemIsphere. are the

most severe manifestations close to the South Po!e~ A

very short explanation is felt to be necessary to ~.e:?
readers grasp the fact that the phenomenon is. indeed.

a global one.

If a CFC or a similar molecule reaches the

stratosphere intact by diffusion and global convection

currents. the ultraviolet radiation from the sun breaks it

down. liberating one or more of the atoms of chlorine.

Each of these aclS as a catalyst (Le. it enters into a

reaction without ilSelf being destroyed) in such a way

that any atom of ozone it meets will break down into

oxygen and chlorine oxide. Two molecules ofthe latter

will break down, by radiation or contact with other

types of molecules, to fonn another molecule of

oxygen, thereby releasing the chlorine to restan the

cycle. It is estimated that each atom of chlorine will

destroy, on an average, 100,000 molecules of ozone

before it diffuses back to the troposphere where it will

be washed back to the earth by rain. How can a

substance whose vapours are much heavier than air

. diffuse into the stratospbere? Why, if it does reach

there, has it manifested itselfnear the SouthPole, which

is the farthest point from where it is used the most?

These are valid questions and difficult to answer injust

a few,simple words. First, time is on the side ofthe CFC

molecules. Unlike most other chemicals, this type of

solvent is remarkably stable. This means that it does not

break down readily when it encounters other

substances: it is exactly this quality that renders

CFC-1l3 so non-toxic. It is estimated that the average

"e-folding" (exponential decay) lifetime ofCFC·1l3 is

nearly 100 years. This means that, if 1 kilogramme of

CFC·1l3 evaporates in 1989, about 370 grammes will

still be intact in 2089, 135 grammes in 2189 and so on.

It is also estimated that the whole of the tropospheric

air mass only takes about a year to circulate vertically

from ground level to the bottom limitofthe stratosphere

and down again, the mechanisms being diffusion,

winds, storms, convection etc. It takes about five years

to circulate horizontally over the whole of the global

surface. Penetration into the stratosphere takes typically

tens of years. The reason for the problem having been

discovered initially at the South Pole is because of a

particularmeteorological pbcnomenon, called the polar

vortex12, which, over the few months of the polar

winter, prevenll any admixture of renewed air and

allows the temperature to drop to very low levels. The

two phenomena together, combined with the presence

of nascent chlorine, result in massive local ozone

depletion. From an average ofabout 300 Dobson uniII,

one observation post at a latitude of 76·S has measured

a diminution to about half this figure over the last

twenty-five years. The figures are even worse as the

pole is approached. This explanation is very simplistic

and reference may be made to an excellent description

of the problem for those wanting more scientific

explanations of these phenomena 12. In any case, it has

now been shown beyond all empirical doubt that the

"ozone hole" is not confined to the Antarctic. The

whole ofthe ozone layer is depleting, various estimates

having been made at approximately 0.2% per aMum at

temperate latitudes, averaged over the last twenty

1-4

years 13, The least depletion IS In the :TOpICS. where :::e

more intense radiation tends to re·lOnlse deple:ed

oxygen back into ozone more readily. ,

The above explan~ti('\n has been given to show the

mechanism when' .:. solvenlS. along wllh other

CFCs and similar ~neulicals. which we use almost

without heed, have created the problem for which the

Montreal Protocol was elaborated to provide an answer.

I. 9, Greenhouse effect

Let it be quite clear. There is no scientific proof that

the so-called greenhouse effect has caused or is causing

any global climatic changes. There are, on the other

hand, strong suppositions that the earth is wanning and

that this warming may be attributed to the greenhouse

effect. If this is so, then measures should be taken to

reduce it•

The media have published all kinds ofalannist figures

"proving" that the sea level will rise by up to 8 metres

and that at least halfthe land surface will be desertified

before the end of the next century. If the greenhouse

effect is proved to be real, there is no proof that these

scenarii will take place, even if there may be an element

of truth in them. The mathematical modelling of

climatic changes is so complex that no algorithm exists

that permit any but very approximate predictions. If

such an algorithm did exist, it would probably take the

fastest and most powerful computers longerto calculate

them than the actual changes themselves!

What is the greenhouse effect? The sun may be •

considered as a black-body radiator with a temperature

of about 5.3OOK. At anyone moment, half the earth's

surface is receiving the sun's radiation and is absorbing

itat an average energy ofabout 1 kW/m2

• the rest being

reflected back to space. This causes the surface

temperature of the earth to rise, the average being

approximately 287K. The earth can be considered as a

partial black body radiator and the temperature balance

is achieved by the difference between the incoming and

outgOing radiation (first approximation, ignoring

geothermic and other terrestrial heat sources). The

incoming radiation is at short wavelengths which

penetrate most gases with very little attenuation.

Because of the low surface temperature, the outgOing

radiation is at long wavelengths. These are readily

absorbed by many atmospheric gases and. if this

happens, the energy can not be radiated out to space but

is absorbed in the troposphere in the form of an increase

in air temperature. From there, the tr3nsfer to water and

earth is evident.

The gas that is most frequently accused of this is

carbon dioxide. the balance of which may be upset by

the combustion offossil fuels, deforestation, etc. Fossil

fuel combustion can act in two ways. First, there is the

direct production of the gas in large quantities,

Secondly, there are certain quantities ofacid·promoting

sulphur- and nitrogen-oxides which combine with ram

to form quite low pH precipitations. If these fall on

limestone or dolomitic rocks, these will break down to
;Jroduce even larger quantltles of C4rbon clOx.de. It ,s

esumated that about 98% of global carbon L5 held In

such rocks. The volume percentage of C4rbon dioxide

in the atmosphere is about 0.034% but It is Increasing

and it is to this increase that the theory of greenhouse

warming is ascribed:

It may be asked what all this has to do with solvents.

The answer is simple: CFC·1l3, along with all other

CFC gases, is an extremely powerful greenhouse gas,

stopping much radiation from the earth's surface. One

molecule of a CFC gas is estimated to have the same

effect as about 14,000 molecules of carbon dioxide.

varying slightly either way according to the

composition. In terms of weight. it is even more

dramatic: 1 kg ofCFC-12. for example. is equivalent to

8 tOMes of carbon dioxide l4. In other words. it is

sufficient to have a concentration of 0.034%/14,000 = 0.024 ppvm to reach the same effect as carbon dioxide.

In places. this figure has almost been reached and the

global tropa;pnenc aver-age os c;)r..s:~~:·,,: .:. <'> '.: .. -

only one order of magrutude [rom it. [1'. Ot::e~ '.. 0:-':5.:

the greenhouse effect IS Indeed shown to be .;;1·.:.s:1'.,,:

increased global warming, CFCs would be ~espon5 :b.e

for well over 15% of it. Although a secondary ,ease:;.

it is yet another valid one why their producuon sho~.J

be reduced.

Many other solvents. halogenated or not. are a,S0

hypothetically contributory in greater or lesser degrees

10 this effect. One notable exception :s

l,l.l·trichloroethane whose vapours have J

comparatively small effect on radiation at l~e

wavelengths concerned. Care should be taken that any

substitutes. including those under development. Will

not be greenhouse gases. HCFC·141b. for example.

which is one of the candidates for substitute solver.LS.

has a relatively low, but not negligible. radiatlve forc::;g

potential.

Here in Switzerland. we can perhaps observe the etrcc:ts of local climatic change better than in most other countncs, by

noting the changes in glaciers. As one example. over the last hundred years the bottom edge of the Furk.a gl~cler has risen

from the level of the village of Gletseh to higher than the Furk.a hotel. It is emphasised thaI this example docs not Ind,Cl:e

thaI the causal conditions are n~ly global.

[-5
This page is blank.

1-6

i. ,
Chapter II. Products under question and others

II. 1. Restricted solvents according to

the Montreal Protocol (state of 1989)

11.1.1. CFC·1l3

This substance is the base for many popular solvent

products used in many branches of industry. The pure

substance is also used in some cases. In nearly all cases.

the commercialised products are sold under trade

names, the most well-known being Arklone, Delifrene,

F1ug~ne, Freon, Frigen. KaUron etc. (alphabetical

order). There are also a number ofspeciality chemicals

manufactured in smaller quantities containing a certain

quantity of CFC-113. These can often be identified by

the figure 113 somewhere in the designation or some

other indication on the label.

It is frequently blended with alcohols, ketones and

other halocarbon solvents. Depending on the chemical

composition ofthe blend and the use to which it will be

put, the manufacturers also add stabilisers, such as

nitromethane.

The ozone depletion potential has been calculated at

a value of 0.8. This means that, if one kilogramme of

the substance will destroy 8/10 of the weight of ozone

that one kilogramme ofCFC-ll or CFC-12 would, but

possibly on a different time scale. It is not possible to

visualise the importance of this ozone depletion from

such figures. It has been calculated, as a graphic

indication, that if one kilogramme of CFC-113 is

allowed to evaporate. it will destroy over a period of

time enough of the stratospheric ozone layer to cover

the surface area of a football field.

11.1.2. CFC·l1

As stated earlier, CFC-ll is occasionally used as a

solvent for a few specific applications. It is somewhat

betler than CFC·113 for solvency and wets more

surfaces than its heavier brother. It is fairly mild

towards most thermoplastics. Its principal disadvantage

is that its boiling point is as low as 23.8·C, which makes

storage and transpon problematic.

Its atmospheric lifetime is lower than that of

CFC-113, almost eighty years. Its ozone depletion

potential is 1.0 (in fact, the reference value), higherthan

CFC-113 as it ContaIns more chlorine per mole.

CFC·ll is a solvent whose high vapour pressure

makes it almost impossible 10 use withoul considerable

losses, even if precautions are taken 10 prevent

emissions. It is therefore to be highly discouraged.

[[-J

11.2. Ozone.depleting solvents not 'Ht

restricted according to the :\tontreal

Protocol (state of 1989)

II. 2. 1. Carbon tetrachloride

Carbon tetrachloride is another solvent whIch ,5 a

heavy ozone depleter, even worse than CFC-1lJ a::C

CFC-11, as its ODP is about 1.18. However. liS :.;s~ :s

very strictly limited in Switzerland and the res: of :~~

Western industrialised community, because It ,s a

known carcinogen and liver poiSOn. It has :he:efor'C

come as a surprise when analyses of gas samples f:or::

the stratosphere have revealed thatsome 70.COO :0 r_-:e s

per annum are being released into the atmospr.e:e,

creating asignificant pan ofthe depletion. It is sum1iSeC

that this cheap. easy-to-manufacture. solveD{ IS S::::

being used in a few under-developed countr:es as we.:

as in some Eastern European nations. It IS unilkel y :~,:::

it would be possible for this substance :0 be used as :l

substitute for CFC-113 in Switzerland as tr.e :ndus:;.:!:

hygiene reguiations 1S are so stnct as to e:Tec::\e:y

preclude its use. Nevenheless it is good to me::::on ::

specifically to explain why it will probably be Inc: 'lee::

in the next revision of the Protocol.

Carbon tetrachloride is used extensively as an

industrial feedstock in chemical manufacture, Losses

from this usage are believed to be very low. ces?l:e

production figures in the USA and Europe :n :~e

hundreds of thousands of tonnes.

II. 2. 2. 1,1,I.trich/oroethane

Although l.l.l-trichloroethane (also kn0,l,n 3S

methyl chloroform) bas a relatively low ODP. var.ous:y

quoted at values from less than 0.1 to 0.18 (usual:y

taken as 0.15). the vast quantllies used and emitted a:e

the cause for a total depletion in absolute .... elg:H

approaching that of CFC-113. For this reason. there IS

pressure being applied to have its production and

consumption either limited to current levels or even

more restricted.

Most ofthissubstance is sold under a vanety of,rand

names (e.g. Chlorothene. Genklene. Prele:e.

Propaklone, etc.). The commercialised prodt.:c:s

invariably incorporate stabilisers. usually of the amine

Iype.and they are sometimes blended with hydrocarbon

solvents or their derivates to widen thetr dlssolunon

spectrum.

At the moment. there are not effective substltu:cs

available for all the applications of

l.l.l-trichloroethane based products. so tt would see::'.
very unlIkely that dracoruan restrictive measures will

be taken in the immediate furure. On the other hana. it

is likely that the production will be frozen at, say. 1986

levels. so that expansion of its use will not be possible.

For this reason, it is not considered as a valid substitute

for CFC-113. quite apart from the moral aspect of only

pamaJIy reducing the ozone depletion.

Over the last few years, both the European and global

production figures have stabilised or even dropped

slightly. This is becausca number ofhcavily consuming

processes have been modified (e.g., the development of

dry film resists in the printed circuit industry) and

equipment using it is better designed to reduce

emissions of the vapour

16. In a few countries, this

tendency has completely reversed since early 1989

because the solvent is being increasingly used as a

substitute for CFC-ll3. This is exactly what the

Solvents Technical OptiOns Comminee has feared may

happen and why they have made it quite clear in their

repon that they do not consider 1.1,1·trichloroethane to

be a valid substitute for CFC-ll3.

Another factor that it would be wise to consider

seriously before using or continuing to use

1,l,1-trichloroetbane is that some industrial hygienists

are posing serious questions regarding its safety. uke

all other hydrochlorocarbons and chlorocarbons, it may

cause liver lesions (cirrhosis) or can. at least, aggravate

the formation of such lesions if the worker is

predisposed towards them either through heavy

drinking of alcoholic beverages or from a genetic

history. Itwouldseem likely that this solvent may attack

the central nervoussystem. particularly if blended with

methanol. There is also some discussion as to a possible

carcinogenicity, even though this docs not seem likely

according to available evidence. The TLV in various

countries has been progressively reduced from about

500 ppm some twenty years ago to S0-3S0 ppm today

(Switzerland, 200 ppm) with tendencies to funher

restrictions in the offing.

Users of 1,1,l-trichloroethane would be well advised

to stan thinking in what measure they can reduce their

consumption. This can be done by two methods:

a. conservation (reduction of evaporated solvent)

b. SUbstitution (where possible, change to

a non-polluting cleaning method).

It is almost certain that there will be restrictive

measures, sooner or later, so that it is not too early to

start thinking about bow to go about replacing this

solvent In the meanwhile, every effon should be made

to reduce tbe emissions by good conservation practices

and recuperation (sec Chapter1m.

11.2.3. CFC·112

CFC·112 is currently manufactured only in Japan and

is used in relatively small quantities. It is rather

expensive. However, it does present excellent

properties, especially for detlwdng applications. The

only reason that it has not been manufactured and sold

on a wider basis is a question of price, typically 2-3

times that of CFC·1l3 but, as the price of the Jailer

Increases. demand for the former may aiso inc~as<:.

causing the price to drop. At least one senes of ?rod\;c:s

containing 1l has been sold In Switzerland (Alpha 1000

senes). .

The OOP ofCFC-ll2 is not known but an estimauon

puts it at about 0.7. slightly less than that of CFC-l13.

It was not included in the original Protocol "basket"

because the usage was so small. but concern is now

expressed because it will become more competitive.

For this reason, it is probable that the Panics to the

Montreal Protocol will include it in the next revision in

June 1990.

11.2.4. Hydrochlorofluorocarbon solvents

(HCFCs)

There are hundreds of possible HCFC compounds of

which about ten may be applicable to solvent cleaning.

Molecularly, these substances are similar to CFCs.

except that one or more of the parent hydrocaroon

hydrogen atoms has not been replaced by a halogen

atomor, more simply, they are not perhalogenated. This

has a number of effects: firstly, the substances break

down more readily in the troposphere. forming

substances such as hydr()(:hloric acid which are washed

to earth by rain (another problem!); secondly, by the

same token, they break down more readily in the body,

so are inevitably more toxic; thirdly, no matter how

shon theirlifetime, asthe decay is exponential. a certain

numberofmolcculcs will reach the stratosphere. so that

they are all ozone depleters, but usually much less than

pureCFCs.

For the moment, no HCFCs have yet been

commereialised for solvent applications. About ten are

being investigated in the hope of finding a "drop-in"

replacement forCFC·1l3 which will have all iIS virtues

and none ofits vices. This is a pious hope because. even

if a product is found that is technically and

toxicologically acceptable, the purchase cost will be at

least three times higher, possibly five.

The nearest ones, to date, have just been announced

in Japan, being HCFC·225ca and HCFC-225cb 17. It

would seem that the pbysical propenies are remarkably

similar to those of CFC·1l3 in most respects. Their

OOPs bave been calculated as fairly low, certainly less

tban 0.1, possibly even O.OS. Their radiative forcing

potentials and chronic toxicities are not yet known.

Otber possible HCFCs include HCFC·141b and

HCFC·l23. These have estimated OOPs ofO.08-().15

and 0.02-0.05 respectively, so the first-named can be

considered as similar to 1,l,1·tric:hloroethane and, if it

is put on tbe market, it must not be used

indiscriminately. They have respective radiative

forcing potentials of0.037 and O.04S·C'ppvb (1 in 10\

The ideal product would be a "drop-in" replacement

• forCFC·113, that is one that can be exchanged for it in

all applications, used in the same equipment without

any modification, with a zero OOP, zero VOC

photorcactivity, zero global wanning potential and zero

toxicity. It is unlikely that such a solvent will ever

appear and it would display a remarkable optimism to

( ,

11-2

I,
walt for it! All the currently \mown HCFC candidates

as CFC·113 substitutes have ODPs in the range of about

0.025-0.15. These are too high to be able to be

considered as general substitutes. One source has

suggested that 0.02 should be the tolerable maximumt!.

This same figure has been selected as a discussion base

for the next Protocol revision.

Nevertheless, but only for those applications where

there is no better alter1U1live, these may present a

certain utility. In any case, economic considerations

must be taken into account. Even if these substances

pass all the tests necessary before they can be put into

production and are then produced at full scale, they will

cost between SFr 25.-· and 50.·· per kg to the end user,

not counting any potential taxes or recovery costs.

The acute toxicity of HCFC solvents under

consideration seems acceptable, but it will be several

years before we can learn whether they have an

acceptable chronic toxicity. This is a subject that

requires extreme prudence as the "safe" chlorinated

solvents oCa few years ago are now considered as much

more dangerous, in the light of true experience. The

symptomatic development rate of liver lesions and

cancer is often a number ofdecades,so it would be wise

not to adopt these substances widely until we have

sufficient hindsight to give them a clean bill of health,

especially as there is a molecular resemblance to

chlorinated solvents. The real question lies in whether

it is possible to determine the chronic toxicity and put

these substances into production (assuming they pass

the chronic toxicity tests) in time to replace CFC-1l3.

This is doubtful.

At least two solvent manufacturers have announced

experimental blends of HCFC solvents with alcohols.

It would seem that these products fulfil some of the

requirements of CFC·113 replacements, at least on

paper. There is a specious argument applied to them:

the cleaning qualities of halogenated solvents is related

to the quantity ofchlorine they contain. The 00P is also

in relation to the quantity of chlorine, amongst other

factors. By making the blends appear to have an overall

low OOP by diluting the high-chlorine HCFCs with

low-chlorinc ones, HFCs (and their derivatives) and

alcohols, it would appear to be, at first sight, beneficial.

What is not mentioned is that it is probable that more

solvent blend will be required to achieve similar

degreasing qualities and quantities. For this reason,

solvent blendsshould be considered as having the same

OOP as the substance in it having the highest value.

II. 3. Other organic solvents

11.3.1. FluorinaJtdso/VtnlS

Generally speaking, organic substances not

containing chlorine or bromine but containing fluorine

are considered to have zero OOP. For

hydrofluorocarbons (HFCs), this would seem

reasonable as fluorocarbons have a very small light

reactivity and hydrofluorocarbons mostly break down

II·]

In the troposphere. On the other ~.and ..: ;; ~.,'~ ~~-:- - -

whethersome peril uorinated products. c~ar:lc:e :-.;'~ -: ".

extremely high chemical stabilines With :Ife::~.es ,':

many hundred years, would not cause' atmospr.c~

damage, even if several centuries hence. On the 0:~,e:

hand. these products are generally useless as soh~~.cs

unless blended with chlorine-<:ontalmng sol\.e:-::s

Nevertheless, they are extensively used for o'~.e~

non·solvent applications, some of which overlap :~.e

. CFC·113 area.

Hydrofluorocarbons (HFCs) are generally poor

solvents and perfluorocarbons even more so. Or.e

pertluorocarbon has been proposed by an Ame~C3:l

company to replace CFC·1l3 as the secondary bla:.ke:

on vapour phase or condensation soldenng macrJ:-:es.

As its OOP is vtrtually zero and its stability higr.er. :~:s

is seen as a positive step towards the elim,nat:or: of

CFC·113 in a small application. It wlll cer.alnly :-:ot

save on cost. HFCs have been proposed to dilute o::-:~~

solvents in order to allow the blend to approach :::o~

suitable characteristics for speCific clear.:"5

applications or to render it more inert or to ar.;f;c:a:ly

lower the OOP. Others have been proposed as ~.::J

solvents for specific applications. For examp:e.

pentafluoropropanol (5FP)19, a new solvent ... :lCer

development in Japan. may have useful charac:e~s:~cs

for degreasing delicate plastics, degreaslng prec;sio~.

parts with fluorinated oils. for cleaning optlC31

components, dry cleaning and a number of o!~er

applications. Its OOP is zero and it is non-flamm30!e.

Its spectrum of application is nevertheless'narrow. J'_!

the substance may be blended with others to wicer. :!.

11.3.2. Ch/orinaJed solvents

Perchloroethylene and trichloroethylene r.ave bo:~

very low OOPs, probably less than 0.01. They (3:":

therefore be used with reasonable safety as far as ,:-:e

ozone layer is concerned. On the other hand. they a:-e

both considered as chronically toxic and an Ame~C3:1

rating as "probably carcinogenic" is under disc'.:.Ss:on.

The TLYs are low in most countries. typIcally

25-50 ppm and it is not impossible that they be placed

in a similar category to carbon tetrachloride. With 3

TLY of 10 ppm, in the future. This could be very

restrictive for future use. They are both photoreaci \

YOCs, which may cause funherrestrlctive and posslbiy

fiscal actions to be applied in the future. It would see~

to be unwise to adopt these products as a substllu:e for

CFC·113 if there is any other choice, except as a very

shorHenn palliative. If they are used. assume the worst

concerning the toxicity and protect workers to the

maximum. By conserving the solvent in the machine.

rather than letting it escape, the environment. the

workers and the company expenses are all protected :0

the maximum.

11.3.2.1. Practical aspects of

chlorocarbons and hydrochlorocarbons

As previously discussed, chlorinated SOI\enLS shou:-:

not be considered as general subsll tules for CFe. :
They are stronger solvents and have similar

applications to CFC-llJ for degreasing most metallic

parts, but they are less suitable for use on many

synthetic polymers.

All these solvents are classed as non-flammable. This

does not mean that they can not bum: a mist ofsome of

the hydrochlorocarbons in air can even be explosive,

although perchlorinated solvents do nOlSuffer from this

disadvantage.

It is to be expected that all chlorinated solvents will

become increasingly regulated in the shon and medium

terms. either because of their ozone de"pletion or

because more information is being acquired in respect

of the health and safety properties (or both). Whereas

no definitive information is yet available. it is probable

that stricter regulation will be pronounced in the first

halfofthe 1990swith some products. It would therefore

seem most unwise to expand cleaning in this direction.

II. 3. 3. Non-hlJIogenaled hydrocarbons and

their derivatives

11.3.3.1. Hydrocarbons

Ught hydrocarbons arc all toxic and flammable but

some petroleum spirits may be applicable to cenain

degreasing operations. These are generally not

substances but distillates with a range ofboiling points.

As a general rule and within anyone family. the higher

the boiling point, the higher the flash point. so that it is

possible to choose the right compromise for each

application. These mineral spirits are variously

denominated, often arbitrarily, but usually go under the

heading "White Spirits".

Heavier hydrocamons with higher flash and boiling

points can also be quite efficient solvents if handled

correctly. Their low vapour pressure which renders

them safer to use also makes drying problematic. One

way round this problem is to use them as a solvent and

then use a second, possibly less efficient, solvent but a

better, non-polluting, dryer to finish off the process.

Water is the obvious answer to this second phase.

For the lighter fractions, flame-proofing is required

on all equipment where tbey are used. Furthermore,

even ifrelatively low-toxicity types are chosen, they are

all VOCS and liable to restrictions.

II. 3. 3. 2. Alcoholsandotherhydrocarbon

derivatives

Alcohols are excellent solvents for many

applications, iDCluding certain deflwcing operations.

However. they do require enormous and expensive

precautions to be taken before tbey can be used for large

scale industrial cleaning. Firstofall, they are flammable

with flash points between 12' and 1S'C (TAG closed

cup). This implies extreme precautions against fire,

such as nitrogen-purged, all-metal machines. oxygen

detectors, in-machine sprinklers, flameproof electrics,

intrinsically safe elcctronics, double air-lock entries

and exits, special conveyor types, infallible drying of

the parts, etc. Ifthe alcohol is sprayed or jetted against

lJ-4

the parts. the rebounding Will cause :l :TItS; :l:".d .l;i

aerosol [0 be formed. If this dnfts. by any cause. t:",tO

the air, it becomes explosive. None of these problems

is insuperable but. together. they make capital

equipment expensive and a certain risk is always

inevitable if large quantities of alcohols arc deployed.

Alcohols are also considered as VOCs. so that It IS

cenain that some discouragement will be applied to

their use in the future.

Which alcohols can be used as cleaning solvents?

Methanol is far too toxic (OFSP Class 3) and is the most

flammable. Ethanol would be ideal but for the ftscal

problems, especially if it was purified by distillation.

This leaves effectively the two propanols. isopropanol

(2-propanol) is cheap. easy to obtain and not

excessively toxic. This is the natural choice. A

propanol/water azeotrope is suggested for some

applications by one manufacturer.

Other derivatives employed for cleaning purposes

include various ketones. esters and. occasionally.

ethers. These also require similar precautions to be

taken.

11.3.3.3. Practical aspects of

hydrocarbons and derivatives.

Various hydrocarbons have been used for cleaning

purposes for many years. Benzine (not to be confused

with the highly toxic benzene) is such a well-known

solvent. Others include various mixtures of aliphallc

and aromatic petroleum distillates, usually fractions •

with a narrow range of boiling points between 50' and

220·C. Most ofthem are poorly defined and can not be

classed as substances.

Some aromatic SUbstances. the best-lenown being

toluene and xylene, are also used as effective low-cost

solvents althOUgh they are more toxic than many

aliphatic spirits.

Hydrocarbon derivatives.such as alcohols, ethers and

ketones, are popular solvents for cenain applications.

Another class of derivatives are mixtures of este~

which are used in the manufacture of paint thinners and

for other specialised applications. In fact, the range of

possible halogen-free organic solvents is enormous.

It is a half-truth that all the good organic solvents are

either flammable or contain chlorine. Another

half-truth is that the better the solvent a hydrocarbon or

a derivative is, so is its boiling point and flash point

lower. A third half-truth is that the closer a solvent

molecule resembles another molecule, the more the

latter is likely to be soluble in it. Whereas these are not

inviolable rules, they contain sufficient elements of

truth to situate the usability ofsome products.

To dissolve petroleum oils. petroleum spirits are

amongst lhe best solvents, but they are poor for

dissolvinglOSin. On the other hand. the latter is soluble

in light alcohols and some terpenes. Cellulosic resins

are readily soluble in cenain esters and so on. Some

fluorinated oils and other fluorocarbons are only

soluble in fluorinated solvents. In other words. the

l ,
solvent :nust !:>e cnosen according to the nature of the

soIl: there are no uruversal solvents.

All these products are flammable, most of them are

highly flammable, often with flash points below

ambient temperatures. This means that any means of

ignition in their vicinity could cause a lire. Use of these

solvents should be governed by the utmost prudence

and only equipment designed for the solVent in question

should be used with them. In truth, it is a wonder that

there are not more industrial fires caused by the

unconscientious use of organic solvents.

Furthermore, all these substances and products are

toxic. to a greater or lesser extent. This should be even

more reason why their vapours and aerosols should be

contained, away from the nose of any operator.

GeneraJly speaking, provided that the safety problems

can be kept under control. most current CFC-1l3

applications could be replaced by some form oforganic

solvent of this nature. The solvent costs would

generally be favourable but this would be offset by the

increased capital equipment costs occasioned by the

safety aspects.

In certain cases, drying off the clean solvents at the

end ofthe process can present a problem. It is generally

undesirable to simply allow the parts to dry off in free

air, quite apart from the flammability difficulties, as the

vapours are polluting (VOCs). In addition, it is a waste

ofsolvent. Some alcohol machines avoid this problem

by vapour phase drying, in a similar way to that l1'led

for halocarbon solvent degreasers, but this is l1'lually

done in closed, nitrogen-purged, machines. Otherwise,

activated charcoal filters or water scrubbers may be

used, the latter with a separator if the solvent is

immiscible with water.

II. 3. 3. 4. Hydrocarbon/surfactant blends

If a suitable hydrocarbon or derivative can be found

to dissolve the soil and it is relatively non-volatile, it

could present certain advantages. Ifit is non-volatile. or

nearly so, at the temperature at which it is l1'led, the fire

hazards are reduced. This is possibly conditional on no

mist being formed during a spraying operation, as mists

or aerosols of all hydrocarbons could be dangerous in

the right proponions. At the same time, the reduced

vapour content ofthe air round the cleaning equipment

will reduce the toxicity problems for the operator

(assuming the product is not inherently more toxic) and

also the air pollution problem (VOCS). Obviously, there

is a price to pay for these three important advantages

and this price is that the parts being cleaned will be

contaminated by asolventthat will not readily dry off

and some means must be found to remove this solvent.

Ifthe solvent is blended with a surfactant or detergent,

then it can be washed off with water which. in itself, is

sufficiently volatile that it can be dried off or,

preferably, blasted off. This will then leave the parts

being cleaned clean and dry. There are, l1Cvenheless, a

number of provisos before such a process could be

practically admitted. The most important one is that the

rinse waters are environmentally harmless. What

1/-5

exactly does :Ius :nean' 'Xas:e ... .i:~: ·::c:~:-.:

extremely complex subject !:>l.:t. ja;,-:l,.:.

requirements are that watersent down :..~e C:-:l:::·.....

harm any bacterial water treatment p.lant ~or . .l:':~:

passage through the plant. should it harm aquatic :::-~ ,'.

make water courses chemically unsultabi~ :-0:

consumption. To achieve these critena. any :;'3\:.

metals ml1'lt be limited to extremely low levels. In :7.0;:

cases less than 1pan per mtllion (1 mg/1.). ~any r::e::1:5

are toxic to the bacteria necessary for sewage tre:l:;':".~ ~.:

and will eventually be taken up in an alimentary c~.:l.::

(e.g. the famous case of mercury in fish fror.1 L..::-:

Leman). The waste water must be neither :00 acd ~,o:

too alkaline, otherwise it. also, could destroy :::~

bacteria in waste water plants. lArge quantitIes ofve~...

hot water discharged close to a sewage farm cOt:!d 3:50

kill the bacteria cultures. Finally, and probably rr.05:

imponant of all, there is the notion of blOdegrad30::;: y

Very briefly, this means that anything sent dow:: :1

public sewer must break down into harmless subst.1,-c~;

as quickly as possible. In this case in ques::on. ~~.s~

waters from this type of cleaning process contaIn ::':~

hydrocarbon. the surfactant and probably srr.J::

quantities ofcontaminants, often heaVier hydrocarbo:-.s

or derivatives. Many hydrocarbons. such as cr"de 0::.

may take years to break down: this is why acc:de:::s

involving tanlcers are often dramatic. The fact th:lt :::~:

can be mixed with detergents so that they becorr.e

water-miscible does not cure the problem: :t 0:-.::.

displaces it to a less visible position. It IS the:e:-o:::

essential that the hydrocarbons used in t~ese ?rod:.:cs

are readily broken down by natural r.1ear,s. r::~

surfactant itself must also degrade. preferably at 300_:

the same rate as orslightly slowerthan the hydrocar:-cn.

so that there is no preferential degradation, al10w::1g :::e

hydrocarbon itself to separate and nse to tr,~ .... 3:e:

surface.

The majority of the biodegradable hydrocarbo~.s a:::

those found in nature, usually of direct vegetable or

animal origin or synthetic look-alikes. ~any mir.er:1:

hydrocarbons are almost non-degradable. ~1:1:'y

domestic detergents for floor cleaning. for exam?:e.

contain hydrocarbons such as terpenes from pine or

citrus trees. the smell of which is frequently disg:.;:scc

by added synthetic pine or lemon perfumes. T:',IS

improves the spectrum of soluble soils and the

dissolving power for greasy din. The housewife rr.:1V

believe, through poor advenising, that there 15 !e:T.on

juice in herdishwashing liquid and that thiS is an active

ingredient, but it is only the small quantities of added

Iimonenes thatare helping her(but pOSSibly not the sicn

on her hands)! These terpcnes remalO bound in Solul:on

by the detergents until they degrade. The degral.1J:lon

process is a combination of anaerobiC (In se .... :lge

sludges), aerobic (in oxygenated treatment tanks) ar.d

photochemical (daylight falling on the COntarr.:n3:CG

water) processes. It requires a certaIn quantity 0:

oxygen. The biological oxygen demand IS th~ q:.;Jn:;:,

of oxygen, expressed in milligrams of oxygen per !:::::

of waste water. required to produce aerobic bJL:e~":
I/. 4. J. Drying

Drying is the bugbear of all forms of water cleaning,

especially for precision applications. There are several

way <'.~!l as air blasting, evaporative drying, vacuum

dl1 J' ."olvent displacement and absorption, etc.

Solvent manufacturers, aiming to sell their products,

have always cited that drying is extremely

energy-consuming. hence wasteful and costly. It

certainly can be but is not necessarily so. It is evident

that the energy required to evaporate 1 litre of water at

15'C is high (about S85 kcal or 2450 lcJ). If the heat

transfer is 10% efficient. this would require nearly 6.8

kWh. One of the main problems of evaporative drying

is that, if a small quantity ofsolids remain in the water.

they will be deposited on the cleaned part. This is not

always acceptable. so that the implication is that pure

water must be used in these cases with sufficientrinsing

that no significant contaminants remain.

On the other hand, to use mechanical means to

remove a similar volume ofliquid from capillary spaces

may require only O.OHll kWh, depending on the

means and configuration. Drying is surely the most

critical area ofall types ofaqueous cleaning and should

be examined from case to case. The most usual means

of mechanical drying are by air blasting and

centrifuging, although a few other methods are

occasionally encountered. Other than the purely

energetic aspect, mechanical removal has a secondary

advantage in that any residualsolids are removed along

with the w~ter, reducing the tendency to form

"water-maries". This means that a lower quality ofrinse

water can be used than would otherwise be possible,

sometimes even ordinary tap water. Where air blasting

is used, the design ofthe air knives is critical, especially

with conveyorised machines where any single part

being dried may be subjected to the air blast for only a

second or two. The most successful systems depend on

very high air velocities with a reasonably long attack

time and variable angle attack. To illustrate the

potential deficiencies of such a system. the most

common air-knife drying encountered in everyday life

is found in car-washing tunnels. Because a car is large,

the air-lcnives are typically about 1m80 long and 25-30

nun wide. They act at about 10-1OOcmfrom the surface

being dried and usually vertically. To limit the power

consumption, usually centrifugal ventilators of a total

of 2-20 HP, the average air velocity is generally less

than 50 m.sec·1at the carsurface. As the typical sred

ofthe vehicle through the tunnel is about 2m.min· ,the

impingement time at anyone point is about 2-3

seconds, allowing for fan-out from the nozzles and

deflected blast Even underthese conditions, about 90%

of the residual water is removed for an energy

consumption averaging well under 1kWh. In industrial

drying machines, the air velocity is often 4-S times

higher, the action lasts up to 20 seconds and the angle

of attack is usually acute. Even with complex parts of

dimensions up to 500-1000 nun in the three axes,

mechanical drying up to 95-99% is commonplace. A

11-7

basket·load of assembled pnnted c;~c:~. :',,~ \~- - .

can be blast-<1ried in about 20 seco:lG.s :;) .:r-,. ,_ remainIng 3% being evaporalive. for a :ou, e~,~:;:\

consumption of S00-700 Who As such a load rna\' X

about 2 m2, the total UnIt consumption would be ajc~:

3 Whldm2

. If electncity costs are as high as 15 C.KW:~.

a standard Europa board (100 x 160 mm) wo~.-:

therefore be dried for under 0.1 centimes. [:1 a

conventional oven, the same drying would cost aJo...:

10-1S times as much in energy, not to mennon tl:T:C

Printed circuits have a low specific heat, so lIttle er:cg:-

is required for actually heating them. Massive rr.et::::

parts may require much more. so that the di[fe~c~ce

between the two techniques would become e\:en :r:ore

significant.

Provided investment is made in adequate mac~tr:e::.

as part of the overall cleaning process. drying :s r:Ol a

severe problem. It can also be stated that it IS ~ot

necessarily excessively energy-demanding. What :s

usually necessary, on the other hand, IS that the mac:-::~.c

be tailored to the job.

11. 4. 4. PUTt waitT cleaning

The spectrum ofsoHs that can be removed wilh ?i.J;-e

water is very limited. However, it is, by far. the Jest

possible solvent for water·soluble and polar SOIls. It :s

easy to use, presents no problems regarding ope~ato~

health and safety, presents few environmental probie:r:s

and is generally low cost.

Regarding the environment, it is evident that the water

itself is harmless, but the soils dissolved ~n it ~.av "--:

very harmful. It is always good advice before acopt:~g

any aqueous cleaning method to carefully exar:".:~.e ',:-:e

effluent and to check whether it is acceptable "',i1:ho~:

treatment. If not, how can it be treated? Is it econOr:1;c;:,;

(or even possible) to treat? Water clearung has the great

advantage that the effiuent is easily contalnec :';y

treatment, unlike volatile solvents.

II. 4. 5. Water +detergents

The action of detergents is well known, even If the

theory of their operation is somewhat obscure :0

non-specialists. Under the name detergent. there are

vast numbers of different types of product whose

function is to widen the spectrum of dissolulion of pure

water. Many detergent mixtures are exce!!er:t

degreasers. One document has cited that half of t:-:e

degreasingappliC3tions in Europe is already being cor:e

by aqueous methods20,

It is worthy of mention that the U.S. All' Force has

made a detailed study21 of over 250 commercial

detergents with a view to completely replac:r:g

halocarbon solvents in military aircraft maIntenance,

The reasons given for this were for envlronrne:1tal

protection, worker protection and cheaper clsposa!

costs ofused solvents. The projectwas achieved In three

phases: a performance evaluation of the var.o~

solvents used, as a yardstick; IdentlficallO:1 :l~J

evaluation of the detergents for cleanIng. coI":'os:o~,

biodegradability and the impact on waste wale~
dIgestion of the pollutants. It is usually expressed in the

oxygen requirements over five days.

The anaerobic digestion in the sewage sludge at the

bottom of the sedimentation tanks breaks the

hydrocarbons down to lighter types, often producing

large quantities of methane and other light organic

gases. The slUdge is periodically removed and a

percentage is recycled back to ensure the continuity of

the bacterial reproduction.

The organic solvents in this process must therefore

not only be hannless to the diverse bacteria, they must

also be active nutrients. All these requirements limit

greatly the range of suitable products that can be

employed as cleaning solvents. The spectrum of soils

that can be removed is therefore limited, especially if

the soils themselves must be essentially biodegradable,

as well. There exist a number of industrial terpene and

other hydrocarbon degreasing products of this type but

. their use is generally fairly specific. One such

application that has created a certain controversy over

the past few years is the removal of residues of rosin

fluxes aftersoldering.

II. 4. Aqueous systems

11.4.1. General

Under the heading of aqueous systems, pure water

and water plus additives are both treated. The term

"semi-aqueous" is best avoic1cd as it has been applied

to various techniques bearing no relation with one

another.The category ofhydrocarbonlsurfactant blends

which require a water rinse after the solvent treatment

has been partially discussed in the last section, but the

actual water rinse belongs more to this one.

II. 4.2. WaterqualiJy

Tap water is usually sufficient for the first stages of a

cleaning cycle. However, it is frequently necessary to

employ better qualities for at least the final rinse. The

main problem with tap water is the "hardness" or total

calcium and magnesium ion content. Several different

treatments arc possible to render tap water more

acceptable. The easiest is thermal decalcification. It can

only be done wbere the barc10ess is due to bicarbonates

and, to a smaller extent, hydroxides of calcium and

magnesium. Heating the water will cause a certain

proportion oftbe lime to precipitate, this being removed

by filtration. It is not very effective, but can prevent

excessive precipitation in the cleaning machine itself.

At the same time, the hot water produced can be used

directly by the machine.

Water softening is w~ll _known and consists of

replacing the calcium and magnesium ions by sodium

ones. For electrical or electronics applications,

although there may be less visible residues on the

cleaned parts, the contaminants are strongly ionic and

very dangerous. This process is therefore restricted to

non~lectrical applications. The essential point with

IJ·6

water softener> IS to regenerate them In time. r1.;S :5

usually done with simple salt which replaces the :lme

in the softener zeolites with a stock ofsodium ions.

The next process is reverse osmosis. Alihough.

strictly speaking, it is not a filtration, It appears to be

one in that impure water, applied to a membrane. passes

through as relatively pure. leaving the impurities on the

inlet side. The real mechanism is beyond the scope of

this work. Only softened and UV·sterilised water is

suitable. The purified water is usually improved by a

factor of 10-20 in a single installation. Water from

reverse osmosis is usually adequate for most

applications. including many electronics ones. For a

single cleaning installation, the capital costs are usually

too high, but the running costs are rather low.

Ion exchange is divided into two categories. Mixed

bed ion-exchange consists of a single column which is

sent to a specialist establishment for regeneration. It is

cheap to purchase, but somewhat expensive to run if

used for purifying large quantities of tap water. If used

for "polishing" reverse osmosis or separate bed

ion-exchanged water, the highest possible purity is

obtained at relatively low cost. Separate bed ion

exchange consists of two columns for removing anions

and cations separately. As it can be regenerated in situ

with low cost chemicals, it is the most economical

deionising system in the long term and it provides a

water quality adequate for nearly every application.

One question which comes up frequently is whether

watershould be used inopen or closed circuits.A priori.

it would seem attractive if rinse water could be •

repurified after use and sent back for reuse: there would

apparently be no waste water disposal problem and the

water (which may become a rare commodity)

consumption would be negligible. Unfortunately, life is

not so simple! In the first place. unless very

sophisticated purification systems arc used. it is

possible that certain pollutants in the effluent may not

be removed. This would mean that these pollutants

would accumulate until the rinse quality became

inadequate. Secondly, the pollutants removed by the

purification system may be such that they would reach

such high concentrations that they would present

disposal problems. To take one example, products

which have heavy metal contamination from cutting

oils may be degreascd in a detergentsolution. The rinse

water will have detergents and heavy metal salts

dissolved in it. Some of the detergent surfactants will

not be removed by a· separate bed ion exchange

installation, but the heavy metals will remain in it.

When it is regenerated, the heavy metal ions captured

by the column will be replaced by hydrogen ones from

the hydrochloric acid and the erouent will become

fairly concentrated metal chlorides, requiring special

disposal. Depending on the application, recycling rinse

waters should be limited to the range of 50-90% to

avoid these problems and the question must be asked

whether this partial advantage will justify the cost.
treatment plant; the third phase was a full scale

changc:<>ver at one of the eIght aircraft maintenance

plants.

The fIrst phase identified six different solvents in

regular use fordegreasing, cleaning, mask removal and

paint removal and three were used for reference

purposes.

For the second phase, samples of each candidate

product were tested for solubility and then cleaning

ability with four standardised "difficult" soils, namely,

a petroleum wax, a carbonised oil, a hydraulic

fluid/carbon mix and a carbonised molybdenum

SUlphide grease. About eighty products passed these

two tests, includingsome which passed the cleaning test

two or three times under different conditiorts of use. A

standardised test method was developed to determine a

biodegradability index, using ordinary sewer sludge

with a 6 hour retention time and a measure of the COD.

.This reduced the number of candidate detergents to 32.

Corrosion testing to a standardised method was then

done with 15 common cortstructional metals including

copper, nickel, various aluminium allOYS, varioussteels

and stainless steels, brass, inconel, monel, titanium and

magnesium. After undergoing these tests, only six

products were cortsidered usable, of which five were

suitable for all metals. Before the phase 3 testing, more

extertsive testing was done with two or three of these

detergents in order to determine how to go about the

practical work.

Phase three testing has been started and has been

running for aboutsix months at the time ofwriting. Full

reports have not yet been made aVailable, but interim

information would seem to show an overall costsaving

of the region of 10-15%, no worker health problems,

adequate cleaning quality and no special water

treatment problems. The Air Force Base concerned .

already had its own sewage treatment plant and no

interference was observed from the technical cleaning

on the biocultures.

Similar work is now starting on the paint stripping

project.

This work is in the public domain and it is probable .

that the complete database will become available at the

end of the solvent replacement project (a question of

months). It is mentioned bere as an example of the

serious approach of this project and the fact that

industrial degreasing, including precision cleaning, can

be successfully done by aqueous methods.

/1·8

Some detergents are restrlcted ::1 :he:r..;sc •..

Switzerland. there are some wluch are forbidden tor '..:Se

In household washing-up products but are. for the

moment, permitted in industrial cleaners. It .IS not

expected that this permissiveness Will continue

indefinitely as the degradation products of these

detergents, cetyl· and nonylphenoxylates, are much

more stable and toxic to some forms of aquatic life. It

is necessary to be aware that this differentiation of

applicatiorts is a legal anomaly.

II. 4. 6. Wattr +saponifitrs

Saponifiers22 are chemicals that react with diverse

fatty acids, rosins and other natural resins, etc. to form

water·soluble soaps which are themselves somewhat

detergent. Caustic soda, for example, has been used

since time immemorial to solubilise vegetable and

animal fats and oils. Commercial saponifiers are much

more complex products, often based on aqueous

solutions of monoethanolamine or ammonium

hydroxide as well as the strong caustic alkalis.

depending on the applications.

One well-tried usc is for solubilising wood roslO.

Rosin cortsists of an indeterminate mixture. of which

some ~9S% is a numberofisomeric cyclic carboxyl ic

acids, nonnally almost completely insoluble in water.

These acids are easily saponified with

monoethanolarnine and commercial saponifiers have

been available for this purpose for over 20 years. The Ir

efficiency,used underthe rightconditiorts. is extremely

good, producing residual contamination approaching

an order of magnitude better than cleaning with

CFC·113. If the rosin is used as an activated soldering

flux, the cleaning efficiency is even better as the

activators are readily neutralised and solubilised. which

is not necessarily the case with halocarbon solvents.

Used for this kind of application, the rinse waters

generally present no environmental problem. What is

more, even the actual wash waters can sometimes be

disposed of directly into public sewers under

well-definedconditiorts(see section IV·2). If not, a very

simple neutralisation is frequently the only water

treatment that is necessary.

As a general rule, saponifIers are not suitable for

mineral oil degreasing. However, saponifiers are

sometimes added to other detergents to broaden their

overall cleaning spectrum. Users are nevertheless

warned to leave such blending to the manufacturers

who, alone, are able to understand the reactions.

I.
Chapter 111 t;onservation of CFC and other volatile

solvents

III. 1. General

As a short·term measure with CFCs and a long·term

measure with all other volatile solvents. conservation is

an important point to consider. Ifconservation had been

applied to CFC usage since the beginning, the problem

today probably would never have occurred.

Conservation is equally important with other

solvents. Unfortunately, their very cheapness has not

justified money being spent on preventing evaporation.

After all, if it cost, say, SFr 50,000 to install a solvent

recovery system with returns of less than 10,000 Htres

of isopropanol per year, most economists would agree

that it was not worth it But those 10.000 litres per year

may cause untold other damage outside the factory

walls. In Switzerland, high ozone concentrations in

some towns and even in the open countryside are

becoming commonplace under certain weather

conditions and such VOC solvent evaporation is one of

the contributory causes.

In terms ofsolvent usage, various figures have been

proposed as to the fractions ofCFC solvents that could

be recovered if the· equipment was better designed,

maintained and used. The lowest is 40% and the highest

90% with an average ofabout SQ-60%2-4. These figures

seem to be borne out with practical experiences.

Consider the case of a small, open-top, vapour

degreaser equipment used for manually defluxing

printed circuits. Average CFC·113 consumption with a

medium production rate may be 40 kglweelc, of which

10 kg is recovered from the bottoms-.

III. 2. Bottoms recovery

This 10 leg in the bottoms is, at present, usually lost

as the product is either sent for incineration (causing

other pollution) or as a landfill where, sooner or later,

it will escape. If a recovery still was used, ~9.5 kg

could be recovered and reformulated for reuse. In the

case of our example, this would make typical savings

of about SFr l,500/annum including distillation costs.

If the total factory production quantities Justlfied:t, the

recovery still could be internal. One Amencan

company achieved savings of over 510.000.000 per

annum just by installing their own still and anothe~.

smaller, one reached a savings figure of $·n.ooo ?e~

annum by installing a secondary still uniquely for the

recovery ofsolvents from the bottoms of tv.'o pnrr.a:-y

stills. If not. an external recovery service could do ::::s,

In Switzerland, there is no well·organlsed

redistillationservice forsmall users available. This :r:ay

be an excellent commercial propositlOn for an

enterprising company willing to make the Investment

and set up the collection and redelivery Infraslr~c:;;~e,

On many occasions, small users have complained ::-,at

no means exist to recover used solvents. One poss:oie

method is that a company could issue on loan spec:a::y

painted 200 litre drums with the solvent type clear:y

marked. The user would undertake to put orJy :~.:lt

solvent type in the drum (if he used several so:ve,.:

types, he would have a drum for each). Wh~n the C~'~:':':

was nearly full. he would telephone the ser.'lce ·... ~.:c::

would collect it the next time there was suiTIc:e:::

rnaterialto collect in that geographical area. The whole

of Switzerland could be serviced with one truck on a:

least a monthly collection. At the same time. he wOt.:'d

be issued with an empty drum. On arm'ai at :he

recovery centre. a sample of each drum would :-e

analysed for solvent percentage and type. n.e

corresponding quantity of recovered and reconstlt'.i:ed

solvent would be delivered to him at the next dellve ..y

in his area. If it is found that solvent mixtures are. Jy

accident, in his drum. the user would have to pay extra

for recovery or destruction.

Economically, such a recovery service would

possibly nothave been viable up to 1989. but the rapidly

increasing prices of CFC·113 based products shou:d

now render it feasible. It is probable that the recove red

solvent could be sold to the users at about 90% of the

cost of new products at the 1989 prices. but this will

become increasingly attractive as prices nse further.

For chJorocarbon and hydrochJorocarbon solven:.s. the

economic viability can not be established at ct.:rrer::

- Bottoms: the residue in the boiling sump of a still or a vapour phase deaning machine comprising the maJonly of :~e

removed contamination piUS acertain amount of solvent.

IlI·J
pnces. but !l IS possible that a legal oblIgation wIll be

declared necessary.

The real problem is for the user whose annual

consumption of anyone solvent type is less than, say,

. OC ';g per aMum. In this case, the used solvent should

• ",rumed obligatorily to his supplier at the user's

expense. The costs for this service could be levied as

pan of the sale price.

III. 3. Equipment siting

All machines should be in a draught-free room,

preferably dedicated to their own use. The floor should

be level and covered with a solvent-resistant

impermeable surface, so that the solvent is not lost in

the event of spillage and can be recovered before it

evaporates. Ventilation should be by extraction at floor

level. but regulated for minimum throughput consistent

with operator safety. For large installations, the

ventilation should be equipped with activated carbon

filters. Thought should be given to transporting fresh

and used solvent to and from the room.

III. 4. Equipment maintenance

All ~uipment should be maintained on a regular

basis2S. It is possible that up to 5-10% of all CFC-113

losses are due to almost imperceptible minor leaks.

Seals and gaskets should be regularly checked and

changed at least every year. Taps and valves are

notoriously dangerous and drain taps should have

solvent-tight plugs in them when not in use.

All equipment using halogenated solvents ofall types

should be checked annually with a sniffer. This is a

small electronic device which sucks in air and indicates

whether it contains halocarbon vapours of any type. A

small flexible hose can be directed to every part of the

machine to locate even the smallest leak. Every user of

multiple or large installations should possess a sniffer.

Users ofsmall installations should ask their equipment

or solvent supplier to do an annual sniffer check ifit is

felt that the modest cost of the instrument can not be

justified.

III. 5. Molecular sieves

Most vapour degreasers are equipped with molecular

sieves for removing water from the solvent. It is

essential that these are correctly maintained, to ensure

maximum solvent life. The zeolite beads adsorb

considerable quantities ofsolvertts as well as water. A

cenain quantity of this solvent can be recovered by

Initially plaCing the filter In a c;osec ,ec:;::e~,:

Immediately on removal. Put In the new filter and ~~n

up the machine. Transfer the filter rapidly from the

recipient into the vapour phase of the machine and keep

it there until it reaches the full vapour temperature,

Transfer it to the freeboard- zone and keep it there for

several minutes to allow the vapours to "drain" from the

filter. The recipient should also be emptied back

(vapours and possible liquid) into the machine. Note

that this technique is only usable where there is a sharp

differentiation between the vapour pressures of water

and the solvent, notably with CFC-113 and its blends.

Many machines are poorly designed and spillage is

inevitable when removing the molecular sieve for

maintenance. Ifit is not possible to modify the machine

to avoid this spillage, try and recover as much as

possible.

III. 6, Solvent handling

CFC-113 s.olvents are usually delivered in 20 litres

(30 kg) cans, 200 litres (300 kg) drums or in bulk

containers. Bulk containers are of two types. Pressure

containers present no problems provided they are never

opened to the atmosphere while the pressure gauge is

indicating a positive pressure. Other bulk containers

have breather valves, often titted with desiccators. but

which let solvent vapours escape if the temperature

rises. This creates losses amounting to about 2% of the

stock per aMum. Bulk tanks should never be situated

where the sun can shine on them or where other soura:s •

of heat can cause solvent evaporation within the tank.

Drums and cans of all halocarbon solvents should

always be stocked in the coolest place possible and

never outside. When taken from the storage area for use.

they should be opened before the temperature of the

contents can rise. After use, they should be reclosed

tightly and taken back to the storage area. Never

transfer from the storage area to the usage area in an

intermediate recipient, even closed: the transfer losses

will be doubled. Drums should always be kept

venica1ly, tightly sealed, and never horizontally With a

tap.

Unless the equipment has special transfer pumps

incorporated, transferring solvents from or to drums or

cansshould only be done with special pumps without!et

pipes extending to the bottom of the recipient. This

ensures there is minimum solvent-air interface while

filling and emptying. On no accountshould solvent ever

be poured from one container into another. This applies

also when dirty solvent is removed from a sump: drain

taps are frequently placed where spillage is inevitable .

• Freeboard: this dc3aiptive nautical tenn, frequently used in thisapplicatiOll, is employed throughout this booklet to descri be

the distance between tile upper level of the vapour in the vapour phase and the level of tile upper surface: of the opening

1/1-2

i '

i J"
r

•

1. I 1 I

III. 7. Equipment enhancement

/II. 7.1. Freeboard

. A number of minor modifications of open·top vapour

cleaning machines can reduce th' "'ent losses

dramatically. Undoubtedly. the me .n'-ortant IS an

Increase of freeboard height. This is ,defined as the

venical height between the top level of the vapour and

[he lip of the machine. With most degreasers of more

thana few years age, this is woefully inadequate and

often so on more modern machines. Ifthe height is less

than tbe width of the opening, then it is essential to

increase it. If it is less than the length. or even the

diagonal, of the opening, then it is desirable to do .SO.

Various freeboard heights have been quoted as betng

ideal but the more. the bener and the diagonal would

seem to bea good compromise. At the very least, the

freeboard should be at least twice the height of the

tallest parts to be cleaned or the opening width,

whicheveris the greater. This improvement can be done

witha simple stainless steel box·form structure on all

four sides. It should be bolted down onto the original

uppersurface, not forgetting

a good gasket ina material

resistant to the solvent in use.

A water-cooled

serpentine round the interior is desirable. The wat~r

flow rate does not have to be high. so that the cost tS

only SFr 1-3/day.less thana gain of halfa kilogramme

ofsolvent. Itshould flow 24 hours/day.

7 days/week, as

long as the machine is filled. The water temperat~re

should be as low as possible and certaInly less than 15C

for CFC-113 instal1ations. If, in summer. the

temperature rises slightly over this fis,ur.e for a, day or

two, this is nota cause for alarm. but If tt consIstently

rises. refrigerated cooling may be necessary. Ofcourse.

the same applies if water-cooled condenser cotls ~re

used. these being even more critical. The machine

should never be opened until all condensers and

freeboard coolers are at their minimum temperature.

111. 7. 2. Lid

Most equipment is fitted witha lipped. lift~ff lid.

Every time this is lifted. most ofthe vapour in the up~r

half of the machine is wafted away. The onglOal ltd

should be thrown away and replaced bya sliding lid that

causes no draughts when it is opened.

A motorised lid

ofa "Venetian blind" construction is ideal. as the speed

can be regulated to ensure no vapour disturbance. the

gas-tightness can be good and it can be made to close

automatically if the operator has forgonen to shut It.

,The lid must be kept closed at all times the machine

is not in use. Ifthe lid isa !Wo-partsliding type. opening

from the middle, only the half of the machine in use at a time need be opened. These halves can be

automatically -1)pened through the controller of an

automatic transfersystem.

If the machine is equipped with additional freeboard.

it goes without saying that the lid should fit this new

top.

lll-J

III. 7,3. Cooling coils

If the machine has water-cooled or ?ia::: :~:':-;~: _:._

COIls, these should be kept cooled ~ntli all the S0,\~:,:

in the machine is cold. If .the equIpment hasJ ::el:

pump. then additional water<ooled coils srlo~':x

added for this purpose. Ifa water-cooled free:'oJr.: ,j

added (see above), then the water flow rate :i1.:ly :.e~.:

to be increased until the solvent is cool.

In all cases. it is desirable to fit flat water.cooilr:g co~:s

along the side or bottom of each sump. Tbs .s so ::::It

the solvent is cooled as rapidly as pOSSible wr-.e::

shuning the machine down and kept as cold as ?oss.b:e

until the heating is switched on agatn. The SOle:,:O.-:

valves controlling the water flow can be .nter;ocke~

with the off position of the power SWitch.

111. 7. 4. Parts baskets

It is usual for the parts to be cleaned to be placed ..,

baskets. These should be constructed of an open w::e

mesh with as high an opening:wire diameter ratlo ;lS

possible. never of perforated metal plates. The baske:.s

should be ofa size that their length and the:r v. :d::: :5

never more than two-thirds the length and w.cth at' :::e

smallest sump. to reduce the piston effect as t::ey a:e

moved in the vapour zone. When cleaning sma:l ?J~.s,

it is preferable to have only one layer in the basket. so

that vapour can circulate freely ina vertIcal d.rec::o::.

111. 7. S. Sprays

The use ofspray lances in open·top degr~asers :5 rr.o,:

undesirable. In the first place. they create t~rb~:e::ces

in the vapour phase. causing additional losses. 1;-: :r.e

second place. they depress the vapour level. draw. ;-:5,a.:

into the machine. As the vapour level nses agal:1 at:er

the spraying is finished, air is pushed out, carry:ng v.!::-:

it some vapour. In the third place, the sprayed salve:::

increases the solvent/air interface area, exa~erat:;-:~

the evaporation.

III. 8. Cleaning cycle

In most cases. the cleaning cycle should cor.SiSt or

lowering the basket containin~ the pans to be clea,r.ec

ata speed ofabout SOcm.min· directly lOto the bOli:r:g

solvent This lowering should therefore take 1-2 mIn 1:1

most machines. The parts are kept there for at least the

length oftime for them to reach the boiling point or until

the scrubbing action of vapour bubbles ensures an

adequate pre-cleaning. The basket IS then hauled

upwards at the same speed until the bOllom ISJust c;e.:lr

ofthe overflow weir. It is then displaced honzonlally Jt

lOOcm.min·! until it is over the cold dislltlate sL:rr.p ar:~

lowered in it at 50 cm.min,l. It remains there. With or

without ultrasonic agitation. until the partS are

uniformly at the same temperature as the cold solvent.

The basket is then hauled upwards agam at the sar.,e

vertical speed until it is entirely in the vapour zone over

the distillate sump. It remains there until the :nOS:

thermally massive parts reach the vapour te mpera:ure.
when the basket can be pUlled upwards again at the

same speed. unol the whole workload is in the middle

of the freeboard. For most pans. 2 minutes in the

freeboard is usually sufficient. to allow the vapour to

drop off the a...·.,.,hlies. although complicated parts

with deep. tlill ,Ies may require longer. A sniffer tcst

of the pans coming out of the machine shOuld reveal

vlr1uaJly zero solvent. It is to be appreciated that parts

such as electronics assemblies or metallic components

with small thermal masses will require a cycle time of.

say. 1 min descent, 2 min boiling sump, 112 min ascent,

1/2 min lateral. 1/2 min descent, 2 min cold sump. 1/2

min ascent, 2 min vapour phase, 112 min ascent, 2 min

freeboard, 112 min ascent or a total ofabout 12 minutes

to clean successfully with minimal solvent losses. This

compares to a typical 4 minutes in an uncontrolled

situation. It should be mentioned that the cleanliness

levels will also be better.

III. 9. Automatic handling

There exist on the market many types of automats to

manage the cleaning operation in this kind of

equipment. These are usually gantry hoists with

microprocessor control of many of the parameters.

These generally cost about the same price as the

cleaning machines themselves. If the use of one

programmed to the cycle mentioned in the previous

section can reduce the losses to half, which has been

frequently documented. then 20 kg/week can be saved

at a typical 1989 price of SFr 150.- per week. The

equipment can therefore be written offin less than three

years. especially ifsolvent prices rise even more, as is

probable. It is still therefore economical to install if a

decision to change to another cleaning method must be

deferred for a few years, for any reason. This

calculation does not take into account the labour costs

of a 12 minute cleaning cycle otherwise done manually,

bearing in mind that it is a boring job that is likely to be

skimped if it is not automated: it is based purely on

solvent savings.

III. 10. Solvent type

One manufacturer ofCFC-113 blends claims that t~e

losses are dependent on which blend is used. This is of

particular interest in cleaning electronics assemblies. It

is claimed that ethanol blends, particularly with methyl

acetate, evaporate at almost half the rate of methanol

blends. The mechanism behind this is not clear.

III. 11. Solvent vapour capture

This is the only practical methOd, other than

maintenance and handling. of being able to recover

solvent losses from large, closed, conveyorised

machines (short of completely redesigning the

machine). It consists of passing the whole of the air in

the room in which the solvent is used through a suitably

dimensioned active charcoal adsorption tilter. This is

an expensive process. as the sUbseque::: ~eco\e:; ,)f ::-:e

solvent from the filter requires a complicated steam

treatment, separation and reconstitution. IllS only llkely

to be economical if the losses are over five tonnes of

CFC·1l3 solvent per year. Even so, the cost would be

put to better use to replace the old equipment with some

other method of cleaning. in the short term.

Nevertheless. the actual cost of air extraction at floor

level and passing the air through a charcool filter is not.

in itself, costly. It is possible that this could be another

opportunity for a sound commercial operation for an

enterprising company which could provide

interchangeable filters to numbers of companies. with

one central recovery planf-. The essential minimum

requirements to make it worthwhile would be:

• to have a clientele losing a total of at least about 100

tonnes ofCFC-1l3 per year (about 5% of the Swiss

consumption)

• that each user would be willing to install [he

extraction and filter; according to the technical

requirements

• that each user would be willing to pay a few tens of

francs per filter change, inclUding collection and

servicing charges

• that each user would buy recovered solvent at, say.

5-10% offthe current market price for virgin solvent.

This could be made up into any ofthe popUlar blends.

III. 11. 1. Othersolvents

The same general remarks apply to other organic •

solvents. With the application of a little thought and a

few small investments, it is usually possible to reduce

losses dramatically. At this time, it may not be

economically sound. but neither the biosphere nor the

ozone layer have ever heard of the Swiss Franc!

111.12. Operator awareness and

management

From the foregoing, it is evident that the most

imponant gains can be made only if the persons in

charge of and operating the equipment are aware of the

problems involved and are trained accordingly.

Management involvement is not confined to deciding

on whether investments are needed: they must make all

the echelons of industry aware that the problem exists.

The ideal approach is for a corporate decision to be

made by the full board of directors to phase out CFC

solvents (and possibly other problem products) and to

appointadirector to identify all CFC lBage, to calculate

a calendar of operations and to ensure the

implementation of the decision. From there.

communications are necessary. explaining why the

decision is made and what is being done. If everyone is

aware of the problem, it is already half-solved.

This technique has been used in a number of

enterprises in North America. Europe and Asia. With

great success. The operator cooperation has often

exceeded all expectations. Some companies are even

I'

.. 11l-4
eX1e:1d.ng the :1ollon to beyond the corporate waLs J.:'.d

are already warrungsupplie~that they may be expected

to certify that their products do not contain CFCs or use

them in their production. Obviously. there are very few

Swiss companies large enough to carry the weight

~uired to force major suppliers into changing the

production methods. but preference can always b<.

given to suppliers who voluntarily state that their

1/1-5

?ioduc~ are ~3:1~.l.iac::..:red '''''',::-,0'''':: _:-.": ...; __

\1ore Important. SWiSS Ir.dust:y:s :'3C. ::C:-:~.,

towards subcontracting ;Jar,s ot :n3:-:'~:'3c:_::-;

processes. Subcontracto~ can always be, c~ose:: :':":-,,

the ranks of those who do not use CFC ~:eJ.:-::::;

"rocesses and compames proVidIng subcont'3(::;'~

services should Inform their customers that :tiey 3:0:

"CFC·free" (when they are. of cou~e !).
This page lS blank.

1I1-6
f'

l.i

Chapter IV. Substitution

IV. 1. General

Any substitution method or product must take into

account numerous parameters. Some of these are:

• Soil to be removed

• Ea,se of use

• Operator health and safety

• Environmental problems

• Cost

Each application has to be studied entirely on its own

merits. No single substitution method to replace

CFC~113 can possibly be the answer to all the current

uses of this solvent.

IV. 2. Specific applications

IV. 2. 1. Defluxing

No 2. 1. 1. Industrial defluxing

Industrial defluxing is defined as the removal of flux

residues after soldering using ad hoc equipment

designed for that purpose. This is in opposition to

artisanal defluxing which is frequently employed in

small companies and even in larger ones for special

purposes. where trays of solvent and a brush are the

usual tools.

The most popular equipment in Switzerland for

industrial defluxing is the open-top vapour degreaser

with some commercial blend of CFC·1l3 with an

alcohol. With very few exceptions. these machines are

used for removing some form of rosin flux: very

occasionally, a synthetic activated flux (type SA) may

be used but this type will almost cenainly disappear

from the market in the near future. because they were

developed to exploit crc-n3. This type of equipment

is frequently badly designed and it is probable that at

least ofthe crC-113solvent losses from the Swiss

electronics industry, which in itself accounts for

6O-70CJ, of the total losses, is derived from this usage.

In the shon term, as has been explained in the previous

chapter, it is possible to reduce these losses by at least

50CJ" but it would be betterstill if they were reduced by

lOOCJ, by simply replacing the equipment to profit from

one of the substitute methods. A brief survey of

open-top vapour degreasers in ten Swiss factories.

taken at random from both the Eastern and Western

sides ofthe country, has shown that twelve out ofa total

ofthineen machines are mOre than five years old, nine

more than ten years old and one was even 22 years old.

Funhennore. of these thirteen machines. three were

never designed for use with CFC·l13 so!vc~:;.

although they were sold for this purpose. It 11.'0(;:': Scc:':1

that this kind ofmachine is kept in operation until I! :'a::;

apart. It is therefore not very surprising that the Sw:ss

electronics industry wastes something like SFr 6--

million in solvents literally gOing mto thin air. ~ve:,:

year.

Larger factories are equipped with convevo~5~~.

in-line machines where the output flows directly ;:0:::

a wave soldering machine into the clearung r:-.J.::::~e

These machines are frequently badly maintained a::c .:

is not unusual. even WIth new ones. for them to WJS:~

quantities ofsolvent through gasket leaks. tladl yc:os:~,.;

taps or valves. etc. With this type of mac~l::e. ~::;:

average age in industry being between five a::d :~~

years. relatively little can be done to preve~t ::~~

inevitable operational wastage: the best that CJn ~c

hoped for until such time as they are replaced ':J:-

machines using other processes is that acme c~.J:C')~:

filters are used to recover most of the tosses. O..e ot '.~.~

tragedies is that this kind of machIne also g,'es C; .... :~

mediocre cleanliness results. as measured with ~,~::c:

ionic contamination testers or surface I;;Si,;:a::o~

resistance analysers.

A handful of Swiss companies. both large and S~Ji:.

have already very successfully adopted more mode:::

cleaning techniques such as aqueous and hydrocar'J0~

derivative (alcohol) cleaning. One group. renowr.ed :'0,

its quality. high-reliability products. has ':Je~~.

continually using water·soluble fluxes and aqueo·,.s

cleaning for defluxing since 1967 for most at Ie;

production. At least half-a-dozen olher SWISS

companies have been using it for over ten yea~. :>:0,.<:

of these has experienced problems in terms at

soldering, cleaning or reliability of their prodUCe;.

rather the opposite.

On an international scale. aqueous clearung has be~~

the worlchorse method for many large multinatlo~J:s

for up to 25 years. The first rnajorcompany to put It 'r.!O

production was Hewlett·Packard. followed by IB~1.

lCL, Burroughs. NCR. Olivetti. Bull and many o:hc:'5.

It is estimated that about 40% of the CS c:ec:'or.:cs

industry production is cleaned in water.

To date, relatively little hydrocarbon or denva!lvc

cleaning has been done. Three Gennan compa;;:es r.:1VC

developed alcohol cleaners but these are mostly be:~g

used for evaluation purposes. as yet. one In Sw,tze::Jr,J.

The hydrocarbon/surfactant technique has not yet r::J~c

any great penetration in Europe. Two chemical Si,;pp:Y

companies are experimenting With It J~d I~ .S

[V-]
Hydrocerbon.

etc. cleening

HycWcc:arbonlsurfectant WId we. cleening

Fig. IV-I. Schematic ofsubstitution for defluxing

We.

clea-1ing

• !

anticipated that they will both become commercially

available in Autumn 1989. It is known that two machine

manufacturers in Europe are developing equipment for

this method. The first is a French large-scale

conveyorised machine and the other a Swiss batch

machine for small and medium-sized applications (on

the same scale as open-top vapour degreasers). Several

North American companies are also developing

machinery.

There are six substitution methods27 (Figure IV-l)

open to the electronics industry and these will be

discussed in fairly full detail here, as it is in this sector

that the most imponant reductions in CFC-113 and

other ozone depleters can be made. At the same time,

this industry, which is one ofthe most modem ofSwiss

industries, is paradoxically one of the most

conservative and traditionalist, resisting change at all

costs.

The six methods are:

• 1. Not to clean (using so-called low-solids or

"no-<:Iean" fluxes)

• 2. Water (using water-soluble fluxes)

• 3. Water + saponifier (lising traditional rosin fluxes)

• 4. Hydrocarbon/surfactant +water(using traditional

rosin fluxes)

• 5. Hydrocarbon and derivative solvents (using

traditional rosin fluxes)

• 6. Permitted halocarbon solvent blends (using

traditional rosin fluxes)

IV.2.1.1.1 The "no-<lean" solution

Up to the time when printed circuits were adopted for

professional electronics, cleaningwas required onlyfor

exceptional conditions.This was because assembly was

done by soldering wires to discrete tags and both

spacing and leakage paths were long. The situation

changed dramatically with the advent of the printed

circuit and, especially, of machine soldering when

cleaning was deemed necessary for many applications.

The Germans developed a special rosin flux type for

those applications wbere cleaning was not absolutely

essential. This was adopted in DIN 8511 under the

designation F-SW32. Many users of this type of flux

made the mistake of trying to clean off the residues

using CFC-113 blends, forgening that it was designed

not to be cleaned. Not only was this difficult, even

impossible, the residues after cleaning were frequently

very dangerous.

One ofthe diffic:ulties with this type afflux, and other

rosin fluxes, was that automatic testing was rendered

difficult as the residual rosin prevented contact from

being made with the conductor panem. In 1984. a flux

manufacturer in Germany developed and patented a

variant of this type of flux with solids as low as 2-8%.

as opposed to the traditionall5-35%. Although slightly

more corrosive than the older types, these fluxes did

allow reliable contact to be made for automatic testing.

N-2
UltJ"Q nl~c_.

\1 .....=: _01

:;,

..

"d1 ci-t

j

'No-eleen' flux usoQe.

- - - - - - Flg.IV·2. Technical usage or uno-dean" fluxes

This figure and the following ones arc meant uniquely to show the technical feasibility of the various techniques. ney Jr~

neither a cost comparison nor a recommendation of one technique over another. However. if a technique is obviously too cos::y.

this fact is shown and is taken into account under the heading of current usage.

This graph is based on the following assumptions:

1. that the technical progress between 1984 and 1989 may be extrapolated to atlc:ast 1992.

2. that no unforc:sccn problems oc:cur from the use of these fluxes for medium-professional use and that correet cont.'lmi~at:c~

control is used for all professional uses.

3. that, as would appear likely. these fluxes will not be approved for any form of high-reliability eleccronics.

Since then, many other flux manufacturers have

developed various formulations of fluxes that are

variously described as "Iow·residuc". "no-cleao" and

even. untruthfully, "no-residue". Other doubtful claims

that have been made are that wave soldering washes off

all the residues or that the residues sublimate. These

fluxes all have total solids of less than 10% and are

activated mainly with strong mono· or dicarboxylic

acids. The actual rosin or, in some cases,synthetic resin

content is used as a matrix to encapsulate the dangerous

activators.This confersreasonable insulation resistance

to the residues. It must notwithstanding be realised that

none of these fluxes is harmless and all leave large

quantities of ionic contamination, measured from five

to thirty times that permissible under military

specifications (incidentally. this is another cause of

doubtful pliblicity as some military specifications are

worded in such a way that the less scrupulous flux

manufacturers have used a loophole to promote their

products).

Various mechanisms of breakdown of the old

F·SW32 fluxes are known and these can all be applied

to the newer fluxes. now mown under the designations

of F·SW33 and F-SW34. The most common is that

rosin and some other resins oxidise on air contact (this

is why that beautiful amber lump that some people used

as paperweights became covered with a whitish powder

after a year or so). When this happens. the

activator·holding matrix is destroyed and the re!eJ.Sec

acids can cause damage. Even more dangerous is ros:::

hydrolysis caused by long·term contact .....!th hurr::d ~:r

Another problem can be caused by prior contamlr.::;::c::

on the parts being soldered upsetting the matr:x.

Unfortunately, llOne of these effects is re....ealed b~

. accelerated testing, except possibly the last-named ::1

some circumstances.

The use of this type of flux is perfectly acceptable

where long-term reliability is of 1i ttle I nte rest,

particularly where the circuits are designed for l.:Se

indoors in temperate climates or in air<onc!iuoned

rooms. It is doubtful whether they can be employed :"cr

most professional applications. They should rr:ost

certainly be avoided for life-dependent applicat:o~.5

(military. aerospace. automotive, Iife-support:~.g

medical uses. etc.). They are not recommended :or

other high-reliability usage. especially If for :.;se

outdoors or in industrial locations. Figure IV-:? sho·... s

that usage of these fluxes is rising In the qu::;l:ty

spectrum. but a ceiling is being approached.

One reason sometimes quoted for cleanlng off :~:.;x

residues is that the thick, sometimes sticky. reSlcues of

the more mildly activated fluxes were unaesthe::c. T::e

newer low·solids fluxes leave residues that C.1r1 \::;f'

from visible but not especially unaesthetiC to al~o,:

invisible to the naked eye. As a general rule. :!ley J:'.:

not usuaIly sticky to the touch.

IV·]
It.. .... ... It"

(Too iI't

e~v'."'" to_ '.tee...... Itldv.''';.t.

etc· )

Lo..

(~..t, .,.10.

_",1 .... ;dIt••

etc· )

Hiqn1Qf''flce .... ..,...., JIC.

\.l.~.

etc. J

Cl i :l ..

Cl .

e

?

IJ t ... .... ~"

("''''O~aoc•. !

.... I ,to"". ,;tf........-t.

etc· )

"e~·.J I"l :qt'l

I...,t_tl.....

:_~ ~;:...~ ,ot.ll:\. c.-·

.te. I

11;0" ~,"""",~;.-,o,~

''''Oi""t.,...

c~t.f'1• ••c.......... •CII.oI." t . • te.)

these fluxes be solvent cleaned as the residues are

partiallyinsoluble. Ifnecessary,some (but not all) types

can be successfully saponifier-cleaned. Their use is

reslrieted to relatively low-reliability applications or

where a short life-time is acceptable. For fully

professional applications, they should only be adopted

with prudence and circumspection after lengthy field

tests under real operating conditions for at least the

expected life-time ofthe electronics.They should never

be used for life-dependent applications. Above all. read

manufacturers' data sheets and publicity with a

sceptical mind as many of the claims made are either

exaggerated or untruthful.

IV. 2. 1. 1. 2 WilUulaning wilh WGler-soluble

fllues

This is what most experts foresee as being the most

likely to become the popular method for professional

wave-soldering applications with small inroads into

other soldering methods. It has a long and good track

record and is thus. proven process. Its advantages are:

• very cost effective, especially for large systems

• the most reliable soldering process

• easy to obtain good ionic cleanliness levels

• machines for all sizes of lines available

• conforms 10 some military specifications

often usable with SMT

• little or no waste water treatment required (machine

dependent).

Fig. IV-3. Technical usage or water-soluble Duxes

This graph is based on the following assumptions:

1. that the military approve oftbem in DEF-STAN 00/10-3 (1986)

2. that the equipment used is suitable for 5MD cleaning

3. that some other approvals will be acecrded by 1990

The overlap area of "current usage" and "probable usage" is dependant on future approvals. At the time ot writing. these fl uxes

are not approved for general use by the U.S. military authorities, but they will possibly be approved fot limited use within a short

period.

The actual mise-OI-servi&e of these fluxes requires a

cenain apprenticeship28, as they are not "drop-in"

replacements for conventional types. In panicular,

foam maintenance and solids-contents adjustment are

difficult and differ from traditional techniques.

Machines may have to be modified. All soldering

machine parameters are more difficult to optimise. Flux

consumptionwill be greaterand, being more expensive,

the savings by not cleaning will not be as great as.

originally imagined.

Another variation on this same theme is being

proposed in conjUDClion with a new wave soldering

technique, inert gas soldering. This is similar to

ordinary wave soldering except IlIat the whole of the

inside ofthe machine is nitrogen purged. A3 the solder

itself docs not oxidise UDder these conditions, the flux

has less work to do and lower quantities are claimed to

be necessary.It is being proposed to use small quantities

of rosin-free carboxylic acids fl~ in certain cases.

This technique is interesting but cenainly notsafer: one

company (telecommunications) experimentally using

inen-gas soldering has reverted to "low-solids" fluxes

in such a machine. A3 the machines are expensive and

the running costs high, it is likely that this technique

will be reserved for special applications.

In conclusion of this section, low-residue fluxes not

requiring cleaning offer the ideal way of not causing

pollution by a cleaning process. It is also the most

cost-effective process. Under no circumstances should

N-4
On :he other ~and .•t5 dtsadvantages are:

, dryIng may be problematic. depending on mactune

design .

• effective water·soluble flux solder pasteS and wires

difficult to obtain

• cos!s forsmall users may be slightly higher than 1986

CFC·1l3 usage (probably sirrular to projected 1990

costs)

• treatment of tap water usually required

• with a few flux and substrate combinations,

degradation of printed circuit insulation resistance.

Figure IV-3 shows the increasing universality of this

type of flux.

The choice ofcleaning machines for all types ofwater

cleaning is critical. There are four basic types of

purpose·built machines available on the market:

low·volume "dishwasher" types

• high·volume professional batch machines

• low·volume conveyorised machines

• high·volume in-line machines.

The "dishwasher" types, as the name implies, uses the

principle of the domestic dishwasher modified for this

application. As a general rule. standard dishwashers are

not suitable for complete wash·and-dry cycles. For

conventional assemblies. this type of machine gives

excellent results, but very few are suitable for SM

assemblies. Their prinCipal disadvantage is that they

take typically at least 1 hour for cleaning and drying a

load of, say. 1 m2 of circuits. if they dry at all. They

present no specific pollution problems as the wash

water is completely renewed with each batch and there

is no accumulation of pollutants. It is extremely

unlikely that the wash water would ever fail to meet

Federal requirements either in terms of heavy metal

content, pH or biodegradability. On the other hand,

these machines consume large quantities of water

(typically 20-40 lIm~ which is expensive if deionised

and they are quite energy-inefficient (drying is

evaporative and the machine itself with all the residual

water has to be dried as well as the circuits). The capital

cost of a machine is typically similar to that of a small

open·top degreaser (SFr 10,000-25.000). Some

machines rinse in a closed circuit through a 01 column,

but their spray energy, hence cleaning quality, is

reduced and the cost of column renewal is high as all

the ionic rinse contaminants are ion-exchanged. On the

other band, the non-ionic contaminants are not

eliminated. The successive rinse system is more

efficient except for water consumption.

The high-VOlume professional batch machines (some

of them are of Swiss manufacture) are suitable for all

types of circuits. inclUding SM types. They are

characterised by low water and energy consumption

and extremely efficient cleaning and drying. They can

handle the fUll outputofa wave soldering machine with

typical throughputs of up to 20 m2

/h (about 5 m2/h for

SM assemblies). With water-soluble fluxes. the waste

water is never likely to present a pollution problem as

the wash water is constantly renewed by the rinse water

and goes to waste while it is still very dilute. This type

ofmac:Unege:1e:-:lilv:Jast'.jg".?~:':".?~~.c~;." ', __

2 HP). malung for emCte:ll was:u ~.g. T:~e .... .:..<~ _~-:

nose water circuits are comple:ely Indepe~.ee~.:. S~ ..~_:

the open-circuit rinse water is totally unpoll:.:ted '~;-.::: ::

reaches the circuits being rinsed. makJl".g ':-:;;;..

rinse·water consumption (typically 5 1;, ,. ":'):':".e

machines have an opllonal feature of inJe1:ting a s:':".;L:

percentage of isopropanol in the nnse water Wi:~

several benefits. Drying with this type of mactune :$

achieved in a separate compartment or machine. Tl':e

best ones have rotary air·knife drying which blasts ove,

90% ofthe residual water from the circuits wllhln a fe''''

seconds (even from COMectors and from under SMDs1.

follOwed by an energy-conserving hot·air dr;r'lng for

removing the residual moisture. This results In the best

drying of any system. These machines are :nore

expensive than the previous type. usually wl:hl:) :~e

price range ofSFr 2O.<XXJ-60.<XXJ. but the ruMlng cos:.s

are considerably lower, as well as being able to har.e:e

many times the quantity of circuits.

The low·volume conveyorised machines can ~ot be

used in-line with a soldering machine as theIr conveyo,

speed is too slow. They are typically cagabie c;'

cleaning up to a maximum of about 10 m-,'h. The

cleaning and drying efficiencies are us uall y medioc,e.

They are frequently based on redesigned printed mc'.;;:

etching machines. One. American, deSign IS

custom·built with the conveyor inclined to gIve owe,

draining flow. Some types may present a pollutton

problem: if the wash water is in a closed ClrCUll wli~.O:;t

automatic renewal or with a low renewal ;'01 ume. :: :5

probable that heavy metals will accumulate \l1 :t :0

beyond Federal limits. In this case. the water :-:;:.:.5t :-.e

treated before it is evacuated to dram. Ii thIS :5 ~,)t

possible. then it must be sent to a speCialIst com?a~y

for treatment. The usual way of reducing :netal co~:e~:

. is by precipitating the metal hydrOXides In an alka!l~e

medium, prior to neutralisation. This Involves a !a,~e

and costly installation and often causes diffic\,;; :;es .~

eliminating the sludge. An alternative method. s~tab:e

for small plants, is by recirculating the waste llq:.:or

through an electrolytic cell until all the me tals are

deposited on a stainless steel cathode. With a

columbium (possibly titanium) anode. This method ~.as

been experimentally tried in the USA. by an EPA

sponsored project. It is claimed that up to 90% of the

metal (copper. tin and lead) is easily recoveree

(although for another application) but actual fig'..ll'es

were not reported. Capital costs could be as low as

$3'500, not counting the installation costs. The wate,

consumption ofsuch machines is vanable according :0

the design. Energy consumption is usually fairly high.

Capital costs are reasonable in absolute terms. but

perhaps high in relation to the quality of the resuJts (SFr

35.ססo-6O.000).

The high·volume in·line machines are usua!ly very

large. very expe'nsive and not always effiCIent. The

basic problem is that a large sOlderin~ machine :nay "';:1

at a conveyorspeed of,say, 2m.min· .It is obVIOUS :~.;;l

an in·line cleaning machine must run at the same speec.

N-5
lV. 2. 1. 1.3 Rosin fhu and saponi{ur

Rosin is nolsoluble in waler. If treated with a suitable

alltali, similarly to vegetable oils being treated with

caustic soda in soap making, it fonns a soap which can

dissolve in water. This process, called saponification.

has been used in lhe electronicsindustry for many years.

The alkali used is based on an organic substance called

monocthanolamine (MEA). It is sold in a concentrated

form by most of the Dux manufacture~. Oeanliness

levels obtained,withgoodequipmenl, are usually better

than those obtained with organic solvents, as carboxyIic

acid activato~ are also easily saponified, whereas their

J l t!"Oo .... ~" _)'S::.~e '"::l'5 ' ..., i' i. Lj X - '5-:':::::" e .... - ~c.: e- . "'f"'tIlIoGC •.

•• \. to,"",.

\; '. 11~f"1..

",e ,

"e~ ,,; ql"l (""'......... :".. , ......r l "41

.....t ....... ; sot.\ lIt. e_.

... , V .... ,;" , ("'=al"'~

- ,: c~la .....

- ••c"'-"'Qe ..... .Ql,I; ...."t. U elc:.. ,

V ""-diU,.

a. (TOO Cw ........t ""Qq- of\ c.~U"""

to. l.loC-.. :J' ;1'\Cfy.tr·ol.

..... etc. J

..- Low

g (""Of . -..t!iO.

0 l'f"Of. "I....

J 0 etc. )

0 HiQf\

(Off leo ••.• : ..1\41"" 'C •

l.'.........

\' otc.l

•• Low . (Too .,.iO •

'" too ".400.

etc· ,

. C laQl"'l'"Q r (_od;•• TV. u"aC'CW'O•. col

<

-- eleclranic••

8 t .....

etc:. I

l"'" aI' ".. "" 1992 199'"-

Fig. IV-4. Tecbnical usage orsaponifier cleaning

This grapb is based 011 the following assumptions:

1. the approval to MIL·P·28809 is subject to interpretatioa.

2. that extended approval 10 MIL specifications will be aca:>rclecl by 1990.

3. the approval to DEF·STAN OO/1G-3 (1986) is normal.

The overlap zoae is a function of th<: interpretatioa of current and future specifications.

If the cleaning process takes, say, 3-4 minutes, as may Another problem that sometimes occu~ with these •

be required for saponification on SM assemblies, this fluxes when using batch machines is that the wait time

means that the cleaning companments must total 6-8 m before a load is ready to be washed may be sufficiently

long, plus the rinsing and drying modules. This makes long that the solderjoints may be superficially attacked,

for extremely expensive machinery. Obviously, if the giving a matt result. This can be avoided by keeping the

conveyor speed can be reduced to 1 m.min-l and it is circuits to be washed in a tank with a dilute solution of

Icnownthatthecleaningproccsscanbeachievedin,say, a commercial chelating neutraliser based on

1-2 min, as is usually the case with water-soluble ammoniumcarbonate untilsufIicient have accumulated

fluxes, the problem can be resolved more easily. These to fill a basket. At the same time, it improves the

machines give mediocre to very good cleaning results, cleanliness ofthe circuits at very little extra cost. On the

depending on the machine designand conditions ofuse. other hand, it is probable that heavy metals may

On the otbcr hand, it is rare for the drying to be very accumulate in the neutraliser bath which should be

good and most use~ would be wise to consider it as a correctly destroyed. Cbclating neutralise~ based on

pre-<1rying. Pollution may sometimes be a problem and EDTAsaltsshould be avoided, as theymay not conform

the same remarks a in the previous paragraph apply. to tbe Federal Ordinance relating to Environmentally

The range of prices for these machines is very wide, Hazardous Substances (maximwn concentration in the

typically from SFr 100,000 10 over 500,000. as-dclivered neutraliserO.5%)

No matter which type of machine is used, one of the

potential problems is foaming. This is more likely to

occur if a water-soluble soldering oil is used in such a

way that it comes in contact with the circuit to be

cleaned. These waler·soluble oils are readily

biodegradable and are more economical than the

non-<1egradable mineral oils but it is a fact that they do

have this disadvantage. Foaming can usually be

controlled with the addition of a few drops of octyl

alcohol in the wash water (do nol use silicone based

foam-<1epressants).lf not, a tap water pre·rinse to drain

may be necessary.

JV-6
\----------- :,'Q~

\-----------J".C:T:'" .•

- --.---------- -_~ --

~; Q"

i 1"IQ ....,1"'QIIIIe c;o.-o..,tero•.

'.C"'Of'lO' IQI"o'O~"t . etc. I

I fOD DC

co-oute." . iow t, leCOtMft.

:l'Id!.IUroIQI.

,tc. )

Lo..

(D.,...,. QIl.Id:o.

ClI'O'. ,,:deo.

etc. )

~IQM

(O":ce'Q .. Qllne"Ol pc. t,leor"O""'" .

'te. I

"'........ ,., ; <:;It'!

: It.utOllCt ...e.

"""0"'1"";"" 2 "I.,eot• .., .

. 'totl l \: t, co_

Ite. )

Co..

("00 o..od:O.

too .. 'd'o.

etc. )

i I ~o... e\~~~.~·. --,~ .~~~ t i'- - - ---i__ __-_- _

... - - ~,..

i"''''CI~C •.

", .' ~:IT'V •

: •. fe ,..,,,,,orot· ItC. ,

1985 1988 19M ,992

f >

Fig. IV·S. Technical usage ofbydroearboDlsurfactants

This graph is based on the following assumptions:

1. that competitive products will become CXlmmercially available in 1990

2. that these products become approved to diverse specifications by 1992

3. that production costs will prove to be too high for any but professional applications and will be initially unde~sllm3:ed

4. that no unforeseen hazards arc discovered and no major accidents occur due to the use of hydroearbonfsurfac.:an: c;e3~e:>

solubility in solvents is limited. The equipment that can neutralising installation can be used to correc: :~~ ?rt

be used is generally identical to that mentioned in the before dumping to drain. The larger Ins:.alla:;ons \l, ::e

previous section. An imponant point to note is that up to several hundred litres of saponifier so!J:;Orl J.~

saponification is not an instantaneous reaction and used and dumped will certainly not be the subject vi

times of two minutes are typical with conventional derogations. As such solution is obligatonly Clrcula:ed

circuits and longer for SM circuits, provided that the in the machine, heavy metal levels wIll also be J

mechanical energy of the machine is high. The problem. Ifthe factory has an industrial water :reJ::T'.e~.:

equipment must be dimensioned to take this into plant, this can usually handle such waste Wlt~O'~:

account. difficulties. If not, the used saponifiershould be put :1",:0

In terms of pollution, the only major dilIerences drums and sent to a competent company for destruc::on,

between the previous case and this one are the alJcalinity This technique is fairly universal in 1:S applicabl:::Y

(PH) and the biodegradability of the used saponifier and, provided suitable machines are used. ,S

solution. This problem can be divided into two panicularly useful for cleaning circwts which ~J\e

categories, for batch machines and conveyorised been reflow soldered with a solder paste. It cov~ J

machines. Both types ofbateh machines dump about 5 wide range of applications (Figure IV.4).

IitreS of used wash solution per cycle. This solution has Use of saponifiers with polyimide substrates a~.c

a typical pH of 105-11, which is outside the Federal certain types of thick film circuits is not recomme need.

limits (from 6-6.5 to 8.5-9.5, according to local . as the alkalinity may present compatIbility proble:T'.5.

conditions). Its biodegradability is more variable and On the other hand, most commercial saporufie~ a;e

this is only regulated by the cantonal authorities, except buffered in such a way that they will not attack lig~.t

in the case ofdirect disposal in awatercourse. In reality, (amphoteric) metals or component markings. Dye~

it is extremely unlikely that direct dumping of such metal, such as cooling radiators for pow~,

small quantities of entirely biodegradable waste semiconductors, especially if conversion coated r.l:~e,

products will be the cause of any problems, and is not than correctly anodised. may lose some of the colour.n5

environmentally worse than the used wash water from maner.

a domestic dishwasher. Many cantonal authorities will The cost oftbis process is slightly hlgher than ',hat III

grant a discretionary derogation for the use of such a the previous one, the only major differences being :hat

small machine without water treatment, prOVided that of the purchase of the chemical and wJ..Ste WHr

application is made prior to its being put into service treatment, if any.

with a saponifier. If this is not the case, a small

IV-7

, '
The industrial hygiene aspects ofsaponifier cleaning

must be examined. The concentrated and diluted

products are strong irritants. so that suitable protective

clothing, including gloves and gOggles. is de rigueur

when handling lhem. MEA fumes are highly toxic, but

if the commercial products are used correctly, it is

unlikely that concentrations would become dangerous.

In any case, the smell is so unpleasant that it seems

unlikely that high concentrations would pass unnoticed.

Nevertheless, good ventilation of the cleaning area is

required.

lV. 2. 1.1.4 HydroctUbon/surfactanJ ckaning

ofrosin j1u.res

This technique is relatively new. It was first

aMounced in the USA about two years ago. Two

products have appeared on the European market in

experimental quantities. One of these is based on a

. terpene principally distilled from orange peel and the

other is another type of hydrocarbon. It is too early to

give definitive infonnation on this type of process, but

it appears to be technically very promising. There still

remain a number of unanswered questions.

Figures published by both manufacturerssuggest that

the ionic contamination levels with this process can be

up to an order of magnitude better than with straight

CFC·113 blend cleaning. Even if we discount the fact

that these figures are probably laboratory results

obtained under the best conditions. there would sum

little doubt that it is a valid cleaning process. Results

obtained by users in the USAand Japan would seem to

confirm this fact. It seems a process panicularly

indicated for SM cleaning. It will probably be too

expensive for usage on mass production articles and it

is expected that it will find its plac; in the upper third

of the quality spectrum (Figure IV-5). Subsequent

expansion will tend to be upwards.

What is sure is that this process is expensive. The

solvent itself is expensive. even though it can be used

for a longer time before it has to be discarded. Even

more important is the fact that machinery cost is

doubled for in-line machines and about 50% higher

(estimated) for batch systems. The overall costs would

approach the double oftbe eliminationofwater-soluble

fluxes. To understaDd this, it must be realised that two

distinct operations are uecessary. The filSt is the solvent

cleaning. This is tben followed by a waterrinse and dry.

The solvent cleaning machinery is divided into two

categories. The conveyorised. in-line machines are

usually provided IS two,separate modules. The solvem

module uses high pressure jets to dissolve the rosin flux

residues. As this creates a fine mist which can be

explosive under some conditions, the machines are

usually nitrogen purged (requiring a large nitrogen

supply system which may be quite expensive to run).

Various safety devices are consequently necessary. As

the solvent is a voe poJlutant, the nitrogen outlet has

to be equippedwith a waterscrubber to prevent the mist

from dissipating in the atmosphere. Batch machines.

which are currently more experimental. use an agitated

soak techruque for the solvent phase. nus eliminates

the problem of mist formation and it reduces the

flammability difficulties to zero, as the open-cup f1ash

points of these solvents are very high ('f)"-140"C) and

the volatility very low. In both cases, qu~us phase

is done in machines similar to thuse previously

described.

Other than the VOC pollution, which is easily

handled, water pollution remains a thorny problem. In

the USA-it would seem that the rinse waters are

permissible pollutants. They are not so clearly defined

in Europe. For batch machinery. the quantities involved

would be so small that there should be no difficulty (see

the previous section) and it is expected that cantonal

authorities would raise no objections (note the case is

not covered by the Federal Ordinance). For

conveyorised equipment. two problems may arise. The

filSt is that of a biodegradability of the rinse wate~

which would sum to be on the limit ofwhat is currently

acceptable, typically up to five times more severe than

human faecal matter. The second is that not all

surfactants that may be used are themselves fUlly

biodegradable. although there is no reason to believe

that the commercial products contain such detergents.

There are a number of unknown facto~ regarding the

health and safety aspects. The products used are not

common as concentrates for such industrial processes

and relatively little is Icnown about them. At least one

component is known to be an allergen in remote cases

and is an irritant. Fonunately. the smell of this

substanc; is so bad that it would seem unlikely that

dangerous quantities would accumulate in the operator

environment. It is probable that we shall have de fi nitive

allSwelS to these questions within a few months.

It would seem that this process is amongst the more

promising ofthe new ones for those cases where good

cleanliness is imponant and cost is of secondary

importance.

lV. 2.1.1. 5 HydroctUbon and derivative

cleaning ofrosin j1u.res

'This implies cleaning in volatile. flammable solvents.

Theoretically, there is no reason Why this should

present any major difficulty that standard industrial

processes do not already handle. Alcohol has, for

example, been distilled for many years without major

catastrophes happening. The real problem is that a

printed circuitwith its components is not the same thing

as the walls of a slill. It has many interstices which trap

contaminants and solvents. At least three German

manufaeturelS offer equipment for this purpose but 11

must be said that these must be considered as at least

semi-experimemaI. For this reason, it would be unwISe

to install them without adequate fire precautions

external 10 the machines. In Japan, for example, such

machines have to be installed in separate buildings With

a 20 metre fire break round them. at least for the

moment. 'This extreme case is also partially due to the

high earthquake risk.

, ,

N-B
"1ed·v....

... ...,,,;:1<:1.(:.

0 .....

'. "'-'000"\' .~:.. \

{Toa ,

COI"O.It, ,. •

. :J.... "IICO-'.

"'Ou,t .. ,ol.

etc t

" On 11'lQ .... ' __

;;CllI'O.oIt..., •

..el'lO~

'Qu.~t •

• tc f

"'.,...,j ... ' QI"I

''''ut~t· . ,..,.b-oP", .

.. .-01. .,.

'Gtlll,te eo ·

etc'

·

,

·

.. -'

w

tJ

Q.

'I'

i------------------ _.'or" ..... ~----------------- ..... Ie::w-OOO' ::

Lo",(ToG Gl.IlS.O.

too '" ,0.0 .

• tc.. I

LOw

1 of, CLod;o.

o of. .dIG.

etc I

"';Q'"(O":CIIO·.

Qlr'lI1"Q1 I'C.

t, l.aho....". etc )

· (10410. rv .

.3 "'0_ 'l.ct"'07~::: Itc:.' '-" -- --.......- _

0 "0

e :J r 0

E·

e

".

'"

191'" ,... 1'" 19lj2

I-f;Qn

(1'10,,",'~

eo""",,,,,,,,,,.

'.CI"IGt1QI '.'1 ;o--,.t.

etc. ,

I Too '-C

.:o....t.""'. to.. t.lec.....

''''''''r'ol . • to. I

Lo..

,,,"',. ~je.

(I"tl • .,;....

etc. )

loti9'"(O',:c•••.• O.,..rol P'C. t.l.-...•. etc. I

Verv "":Qh( ....to_t;"•• 'Iwb-o,,. ;....

....o.ot• .,... . • ote t I ; t, co....

nc.1

U l t rOo ,..;~"

I ....o.ooe•. 777/7/'7/'7/'7/'7/"7:"7':"7':"7':7"77"7777777777/7/'7/'7/'7/"7':'T77777777:-"-'" Ill. \ .1.0""

l; II 'uaoort, etc. )

·

·

o

3eI- ..

-'

U

III

Q.

111

:J'

...,

Low

(T_ too ........a;o.I ,.-•. .::::.~=============1

I.

I etc.) r-

~============================~,.Qf"I "'Q

,~_3 ....- .l.Ct~ICll. "tOCl;••.!\C.)

t .... TV, '--_- ~============================== __-- --_-__--__- __- - __---..".C:)"Of" ~=-

Fig. IV·6. Technical usage or alcohol cleaning

This graph is based on the following assumptions:

1. that alcohol cleaning is approved to diverse specifications by 1992

2. that no major ~dents oocur. due to the use of alcohols

3. that the casts will be initially underestimated.

Usage rosin flux + CFC-ll3 & l.l.l-TCA

Fig. IV.7. Technical usage orozone-depletlDg solvents

This is the reference diagram. bawd on the wrinen standards and norms usual for indUSlry up lO 1986.

This graph is based on the following assumptions:

1. the price of CFC·1l3 will rise considerably from 1989 onwards

2. that ei ther economic or legal considerations will enforce a tk facto phasc-out by 1995

3. that industry will not react fast enough after CFC·113 cleaning becomes economically non~mpelitive to prevent ex.;:cs.s< 'C

cleaning COlts

IV-9

t

i "
IV. 2.1.1. 6 PermitUd Iullocarbofl bknds

As already discussed, none of the available

halocarbon blends. not currently regulated by the

Montreal' ProtOCOl. can be considered as a long-term

solution at this time (Figure IV-7). They are based on

blends of 1,1,I-trichloroethane and perchloroethylene

with various alcohols or other derivatives and

, ... s,:..:;e -::'5 - -' '.J It.-a OM - ( .....O'DCIC••• ~-~~" , .'.=00;_ .. , : ; to ..... :

l;'_ ' ..""0,",,, 1

'J . ." I ,

'e ..... ~'Qn .~ I Arr,ut ...\, ..... i ,......,.;~ ,J - ......,..... tOt. t lite

etc. --,)

.. 'Q'"

:; I ,..'"~."....

" eo_ter,.

••C1"lGt'lq•

•Q""O"'"' . c.J etc. )

IIJ Med;ulll

0. If.. "t JI'l c:OllDwt ..... ,

l.w t.l.co..... :J' "CII",,,t"';Q{ • .., etc. I

Lo..

0 '~1"'Q' . CIIoICIIlo.

0 < ....' "ideo.

:l ,~ etc. I

Cl : "4;0"IO"ic. 011- •

.: Q."."Ol IIC.

e loloaf'\Of'W••

9- _U.I

'e Lo.. . (roo oucHoo

'" ... .... 4•••

etc. )

r C leQrl '"Q

; llto4lo. TV. ........eo..o ... ,eol

.

e '- eloct'''cu'':c•. t~... U ote. ,

191"

'"" l"t '9" ,992 199\0.

Fig. IV-S. Technical usage or HCFC solvents.

This grapb is based on the following assumptions:

1. that suitable HCFC blends become commercially available by 1994

2. that their cost is likely to be ~S times that of CFC-113 (1989 price)

3. that they will be permitted legally (wbicb is Dot certain)

4. that the toJci(X)logical aspects will render them as cuy to use as CFC-113

S. that they will be permitted Cot use fot military cleaning

6. that the ODP of the substances be lea than 0.05. preferably less than 0.02

It must be realised that all tbese assumptionsreadertbe practical usage ottbis kind oholvent hypothetical, alleast foe the moment.

The most popular soivent is isopropanol which Because the process imposes imponant means with

dissolves most components of freshly soldered rosin reasonable-to-high costs, its usage will mainly be

flux residues very well. Isopropanol is a VOC and may confined to mass-production applications (Figure

become subject to aspecial tax in the future. One ofthe IV-6). In the case of mixed products, the attainable

machines uses a water azeotrope ofpropanol. 71.7% by quality is sufficient for it to be used for high-reliability

weight ofthe alcohol. This raises the boiling point and applications. as well.

reduces the flammability but the price to pay is very Simplermachines are also likely to become available,

high: the solubility of tbe rosin is very much reduced but it is not yet certain that they will meetsafety critena.

because of hydrolysis. Then: seem to be thn:c types of Itsbould always be remembered that the flash point of

principle involved in these machines. The most isopropanol is 13'C and other alcohols in the same

advanced one issimilar to the machines CUl1'Cntly ~ed region. 'This means that any ignition source, including

for conveyorised cleaning using CFC-1l3, with static discharges, will ignite alcohol at room

pumped liquid phase aod vapour phase cleaning and temperature in the presence of air. An alcohol fire. as

drying. The machines must be equipped with extensive such, can be easily controlled if, by accident, such

security devices such u nitrogen purging, oxygen arises. What can not be controlled is the explosion that

detectors. automatic water sprinklers. water scrubbers alcohol vapours or mists can provoke if ignited. Any

for the outgoing nitrogen. etc. The capital cast ofsuch machine that sprays alcohol on to a pan is as effective

systems must obviously be very expensive. as such as a carburettor at producing such a mist. CaveaJ

sophisticated safety precautions. including completely emptor.

explosion-proof eleetrics. must be added to the price.

Running ,costs for the solvent are not expensive if an

external distillation unit is added to the equipment. On

the other hand. the consumption of nitrogen will

certainly add a considerable sum to the running costs.

It would seem very unlikely that the total casts will be

less than any othersystem but this is unconfirmed at the

time of writing.

!V-lO

. ,
,

.

st<lbliisers. On :he whole. ~he clear,Jng qt.:a!:ty oo~alned

is probably not qUite as good as with CFC·113 blends.

butsufficient for many appliC4tions. Their high activiry

may C4use damage to some components. This type of

solvent blend is sometimes used as either an anisanal

(see next section) cleaner or for cold cleaning in "kiss"

machines (underbrushing). Those solvents based on

1,1,1-trichloroethane can also be used for vapour phase

tlux removal but the high temperature makes the

solvent very aggressive towards many synthetic

polymers. Wherever possible, it is recommended to

avoid using these solvents asa replacement for

CFC·113 and the more they are used for this, the more

likely they will become subject to severe restrictions

within the Montreal Protocol.

However, it is possible that some HCFC blends may

be usable withina few years for special applications.

The most promising ones, at the moment, would seem

to be based on HCFC-225ca or HCFC·22Scb, but it is

unlikely that blends containing these substances will be

available before the mid-I990s, assuming that the

toxicity testing passes without problem (Figure IV-8).

It is therefore utopian to defera decision to change from

CFC·113 type solvents beC4use another similar one

may become available in the indefinite future. In any

case, all halocarbon solvents will, sooner or later,

disappear from the market and all the new ones will be

very expensive. Ifit is felt that no alternative exists for

CFC-l13 or any other halocarbon solvent fora specific

application, ask for confirmation from an expen before

thinking about applying fora derogation. It is very

likely that an alternative exists for defluxing.

IV. 2. 1.2. Artisanal defluxing.

Hand cleaning printed circuits is not easy under the

best conditions. Fonunately, very few companies have

used CFC-113 for this as the costs are so high because

of the extreme volatility of the products in open trays.

More popular are the chlorinated solvents blends, but

the use of these also must stop within the shon- to

medium-term for reasons of either the environment or

toxicity (or both). isopropanOl is an effective and cheap

substitute for this type of cleaning, provided that it is

executed, including the drying, in an efficient

flameproof fume cupboard. The best method is

probably saponification followed by water rinsing, but

this, also, should be done in

a fume cupboard but not

necessarily flameproof. As the products used are hot

and irritant, it is necessary to protect the operator from

accidental contact with them by supplying adequate

protective clothing.

IV. 2, 2. Dtgrtaring

General degreasing can be replaced by aqueous

degreasing, using one or more of the hundreds of

detergents on the market As each type of soil may

requirea fairly specific type, it is better to consult

suppliers for advice before startinga frantic race to try

to find the "best" one. See the section on detergents in

Chapter II.

For degreaslr.g WI th soi ve r.~0 :::e: ·r.~r. -::c -::

same general remarks apply as for ':e::.;.x:r.;;. :\,,-

that saponifiers are not appliC4ble ~o :e:i:ov:::~ rr.. r.e:...

oils and greases. See the general dISCUSSion in C:J:J·.:~

n.

IV. 2. J. Precision cleaning

This can be defined as cleaning to :T'~lC:-Ol"':"',e:re J:'

angstrom cleanliness levels. ThiS can be :::

ultra-precision mechanics, optical applicatior.s. e:c

Precision cleaning, as opposed 10 degreaslng. IS aiwa\s

done in clean-room conditions. Traditionall y. CFC-1 :.3

has been considered for many years as the Ideal solve::t

for precision cleaning, although there has beena ~rend

away from it in recent years for some appl1ca~IOr.s.

Unfortunately, there are hundreds ofprecLSion cleaning

applicatiOns which would be too long to enumera:e

here. Each one has its panicularities which renders :~.e

choice of CFC substitutes more difficult.

Also traditionally, precision cleaning has o[;e:l been

done with small bench-top ultrasonic tanks. presen:;::g

the worst conditions for CFC emiSSIOns. Any chanse

must therefore involve not only the solvent. but also the

method. It may transpire, for example. thatsome spec:Ji

applications may require the use of HCFCs as an

alternative to CFC·1l3. These will be too expensive :0

simply let evaporate ina bench-top cleaner.

Many, probably the majority, of the applicatior.s :i:a,

be replaced by some form of aqt:eous clearung. '~i::g

detergents. This may require systems Wi:::

uUra-fiItration on incoming 18 megohm·cm ..... a:e~ Wi::: a special distribution network. •

One example ofthe success of replacing (FC·':3 :;y

wateris with hard disc drives.A large man ufac:ure: has

done this very successfully with even better resuiLS ;::3:1

obtained before. Inenial guidance and navlgatIor,a,

systems for aircraft have also beensuccessfuliy cleaned

with aqueous systems. not only wtth better c!ear,l:ness

but also faster results.

For particulate contamination. filte~ed.

contaminant-free air has been found as effecuve as

CFC·1l3 for semiconductor reticle masks. cathode ~JY

tube shadow maslcs and electron guns. All these

examples have been aq:omplished with cost savl:1gs.

Optical parts have also been successfully aqueously

cleaned before vacuum coating or other operallons.

However, some glasses may be degraded by pure wa~e~

or alkaline detergents. Tests are therefore essential.

Drying ofoptical partsis often critical and CFC·113 has

been the preferred method (see next section).

Many other applications have been convened f~or.'1

CFC·1l3 to some other method but there area :ew

others for which no replacement technology eXISts, as

yet. For these, exceptional cases, it IS hoped that one of

the new HCFCs or SFP may offer the solutIOn or

solutions. In the meanwhile, CFC·113 will conllnue :0

be used provided that utmost measures are :al<en :0

minimise losses.

Forfuller details of the applications me~·

.ned in :h;s

section and other precision cleaning ~~?IICaU0r,s.

IV-ll
reference can be made to the Summary Report of the

UNEP Solvents Technical Options Committee.

lV. 2. 4. Drying by solvents

CFC-1l3 has been used in two ways for precision

drying. The ti~t is by pumping pure CFC-113 upwards

over the article to be dried. Any water will be displaced

upwards and will flow over a weir into a separator. The

second method uses a CFC-1l3/sunactant mixture

which emulsifies the water ioto a mic:ellic solution. In

both cases. the drying is completed by passing the part

through a conventional CFC·113 vapour phase

degreasing process.

Hot air blasting has replaced these successfully in

many applications. including the disc drive cleaning

mentioned in the previous section. It is applicable also

to drying some optical parts.

Another mechanical method which can be very

. effective without high energy requirements is by

centrifuging. Small mechanical parts with an intricate

shape, including blind holes. can usually be very

succ:essfully dried in suitable equipment. The cost of

centrifugal drying is extremely small.

Evaporative drying is also useful but is costly and

energy-consuming and may leave drying marks on

ultra-precision parts.

There are two methods of chemical drying which are

successfully applied. They are analogous to the two

CFC-113 methods. The first is to use a downward

current ofcertain aromatic hydrocarbons in a tank with

a perforated false bottom. The water is washed off and

carried downwards where it can collect under the false

bottom and periodically drained via a tap. This is

followed by a second, possibly a third. similar tank,

from which the water-free part can be taken out and

plac:ed in a drying compartment which will collect the

solvent vapou~. This method is frequently used to

prevent oxidation of base metals after a chemical

cleaning operation, where a water-wet part on exposure

to airwill cause almost instantaneous reoxidation. Itcan

also be used to lacquer cbemically cleaned parts as a

temporary protection barrier: it is sufficient to add a

small percentage of compatible lacquer to the final

solvent bath. The most popular solvent for this

application is tolUCDC, but only pure grades should be

selected. Many commercial toluenes contain

considerable quantities of other hydrocarbons ~hich

may be more hydrophilic, destroying the water

displacement properties.

The other metbod is to use two or three successive

baths ofisopropanol. The water will dissolve readily in

this alcohol. The problem is, as in the case of

CFC-113/surfaclant method. how to remove the water

from the solution in ordtr to continue using it. The

amwer is to pass the alcohol continuously through a

narrow-range zeolite molecular sieve which will

selectively adsorb the water. The sieve will require

frequent regeneration and replacement.

Both these methods have the dIsadvantage :::3:

low-flash point flammable solvents are used and the

appropriate safety measures must be taken.

IV. 2. S. Textile dry cleaning

This is a difficult situation for which there is no

ready-made answer. Most dry-cleaning is done today

using perchloroethylene. Anyone entering a

dry-cleaning shop must be aware, from the smell, that

the operato~ are exposed to solvent vapours. Questions

are being asked as to the toxicity of these vapou~.

A few, modern, machines use l.l,l·trichloroethane.

which has a high OOP and is also under question for its

toxicity.

Some garments, notably suedes, leathe~ and very

delicate textiles, can only be cleaned in CFC-1l3.

whose OOP is unacc:eptable. or a few mild hydrocarbon

solvents.

The latter method uses a petroleum distillate known

as Stoddard solvent. This is a white spirit which IS

reasonablyelIectiveand usable for most garment types.

Its major disadvantage is its flammability.

It is possible that one or more of the new HCFC

solvents may present some hope for special cases but

the question must be asked whether the public will be

willing to pay the price of cleaning with them. unless

new dry.to-dry machines can be designed with

quasi-zero losses. Another factor that must not be

ignored is that many operato~, especially in smaller

establishments. try to increase the throughput by

removing clothes from the machines before they are •

dry. New machine designs should have an interlock

preventing such misuse. It must not be forgonen that

these new solvents. if they become acceptable with a

very 10wOOPand a low toxicity, may cost twenty times

the pric:e of perchloroethylene.

It is recommended that all garment manufacturers

should be made aware of these changes that will be

expected to take place over the next decade,so that they

can adjust to the requirements of how their products

may be cleaned.

As stated at the beginning of this section there is no

ready-made answer: even less is there a miracle answer

and both the cleaners and the public must be reconciled

to a forced change in their habits and probably increased

costs. .

IV. 2. 6. Partie" rtmo~aJ

Because of its high density. CFC-1l3 allows

non-metallic particles to be floated off parts. Excellent

results have been obtained with good cost reductions by

simple high-velocity ultra-filtered air jets. See section

lV.2.3.

IV. 2. 1. Mtdical applications

The most important medical application of CFC·113

is cleaning needles before sterilisation. Short. wide bore

needles present no specific problems if they are one of

the all-metal Luer lock or slip types; almost any

cleaning method is usable. Plastic hub throw-away

, .

lV-I 2
r'

types must use 3 clearung method compatible with the

plastic used. This rules out stronger orgaruc solventS.

The aspect ratio ofsome needles is most unfavourable.

There is no difficulty in causing an aqueous cleaner to

enter such needles. The capillary effect will do it

automatically. The problem is how to rinse it out

afterwards.

One suggestion is to robatise a system which takes

each needle individually, after bulk cleaning of the

exterior, and mounts. it on one of a series of Luer lock

receptacles through which a high pressure detergent

solution is passed. This is replaced by high pressure,

pure water in sufficient volume to ensure that no

detergent remains in the bore. Finally, clean, hot air is

blown through the bores to remove the water after

which the robot removes the needles for the next

process stage. This technique could not be applied to

slip needles unless a retention jig holds them in place.

as the pressures involved would shoot them off the

adapters.

Other medical cleaning with CFC·113 is performed

to many surgical implants. implements and

instruments. In most cases. there is little reason for this

choice other than simple convenience. However, where

certain plastics are used. notably plasticised flexible

pipes. there is a certain concern that inherently

solvent·soluble plasticisers may leach into vital fluids.

For this reason. CFC-1l3 flushing is used, this solvent

being unlikely to degrade the polymers themselves. It

has been found that a 50% by volume alcohol

(ethanol)/water mixture will do the same work. A

subsequent rinse with pure or 90% alcohol will aid

drying by warm air. The resultant pipes will be

sufficiently sterile for most applications if the outside

is treated at the same time. Ethylene oxide sterilisation

ofplasticised polymers is usually undesirable.

Ethylene oxide is a popular sterilising compound. It

is a gas at room temperature (boiling point variously

given at lOS and 13.2·C) and forms a very explosive

mixture with air. It issoluble in mostsolvents but, being

highly reactive, it is difficult to conserve iL For this

reason, it is sometimes used in mixture with an

ultra-pure grade of CFC-113 which acts as an inert

liquid vehicle. Water can also act as a vehicle. but it

must be ultra-pure and neutral. Ethylene oxide will

react with many acids and bases so that small

excursions of pH are inadmissible. It is foreseen that

pertluorocarbon and hydrofluorocarbon vehicles.

which are generally inert to vital fluids. could replace

CFC-1l3 for this application, these having zero OOP.

For gaseous sterilisation, carbon dioxide is a good

vehicle.

lV. 2.8. Vehiciesforlubricanlsand.:u1h ~sl\ "

CFC·l13 IS occasIOnally used as 3 veh:c:e :'::

lubricants or as a corrosIOn inhJbltor dunng c-.;t::~.';

operations. One example is for the lubncatlon (' t

ultra·miniature ball beanng assemblies used :'or

instrumentation. The penetration of even a trun all c::-:

not be ensured. so that the oil is dissolved ::1. J

pure-grade. inert solvent. CFC·113 is the usual choice.

The ball race is sprayed with this mixture wh;c:J

penetrates to leave a microscopic oil tilm on all the

surfaces after the solvent has evaporated. .\1a;;~

solvents could be used for this purpose. For space

applications. low vapour pressure Oils are essential and

these are perfluorinated lubricants which are insolub~e

inall the usual non·fluorinated solvents. It is hoped that

one of the HCFC or HFC products in development Wi::

be able to replace CFC·113 as a vehicle for this spew:c

application.

As one example of a cutting aid, during dniling 0:

blind rivet holes in aircraft manufacture. :hey a~e

sprayed with CFC·1l3 to flush out posslb~e

corrosion-causing products and to cool the cumng :ooi.

The rivetslug is inserted while the hole is sllit we:. It ;s

probable that the CFC-1l3 may be able to be replaced

by an HFC solvent or an HFC/HCFC blend, both of

which will be even more non-reactive.

CFC-1l3 is occasionally used for the manufac:-.;re of

speciality self-adhesive tapes, although It IS :00

expensive for extensive use. l,l,l·tnchloroethane :s

more commonly used but this is also ozope·deple::;;;

and can only be used for applications where adeC;l..a:e

ventilation and solvent recovery can be ensured. \Va:e~

based systems have been developed for most tape types

but suffer from the disadvantage ofslower prod :':C::0n

rates. For ordinary adhesives. resins. lacquers 3"d

paints. it is rare for halocarbons to be an essential

vehicle and there is a distinct tendency towards

solvent-free orwater·vehicled systems. This is a rapIdly

advancing area oftechnology and it is foreseen that very

few applications will obligatOrIly req:'lIre

ozone-depleting vehicles by the mld·l990s. \\11at is

more is that far fewer will require VOC solventS. either.

Another vehicle application IS for Single page

deacidification. Books which must be conserved for

over, say, 100 years. may be mass treated using a

suspension of suitable chemicals in liqUid CFC·l:.

Single pages are more easily treated with such amixt:.::-c

in CFC·113. As the major quality required With such a

vehicle is complete inertness. it is easily envisaged that

one of the perfluorocarbons would be Ideal for thiS

purpose.

N-13
nus page IS blarUc.

JV-J4

, !
Appendix A: Properties of halocarbons.

The following table gives the most up-to-date would seem to be the same infonnation from diffe~e~.t

estimations of the boiling point, the ozone depleting sources. In practical tenns. these differences are

potential, the global warming potential and the folded negligible. as the premises used in malung the models

e lifetime of the principal halocarbons relating to are not a1wa~ very clearly defined.

r ' cleaning and similar applications. Boiling point apan, If no figure is given in the following tables. It means

these figures are calculated from theoretical principles that the information is not available. lfa figure IS glve1

using mathematical modelling. It should be noted that between round brackets 0, it means that tlus fig:Jr'C :5

there are several algorithms used for such models and an estimation. between square brackets []. It means t:-'ar

the results do not always agree. It is therefore possible tlus figure is little bener than an Inspired guess and :s

that small differences may be observed between what subject to confirmation.

Desig· Formula Boiling ODP GWP ti 1 el

nation point

1. CFCs

CFC-ll CFCI3 +24 1.0 1.0 74

CFC-12 CF2CI2 -30 1.0 3 111

CFC·112 CCI2F-CCI2F +S2 [0.7]

CFC-112a CCI3-CCIF2

CFC-113 CCI2F-CCIF2 +48 0.8 1.3 100

CFC·113a CCb-CF3 +46 0.85

2. HCFCs

HCFC-21 CHCI2F +S

HCFC-22 CHCIF2 41 0.05 0.35 20

HCFC-l22 CCIF2-CHCI2 +72

HCFC-123 CHCI2-CF3 +29 (0.02) 0.02

HCFC-132b CH2CI-CCIF2 +47

HCFC-141b CH3-CCI2F +32 (0.1) O.OS

HCFC-225ca CF3-CF2-CHCI2 +51 [0.05]

HCFC-225cb CC1F2-CF2-CHCIF +56 [0.05]

HCFC-226 CHF2-CF2-CCIF2' +21

3. Halon.

1211 CF2BrCi 0 3.0 25

1301 CF3Br -60 10.0 110

4. Other halocarbon.

1,1,1-trichloroethane CCI3-CH3 +74 0.15 0.024 7

Carbon tetrachloride CCI.4* +n 1.2 0.35 60

Chloroform CHCI3** +60

Perchlorethylene CCI2=CCI2** +121 [<0.01]

Trichlorethylene CCI2=CHCI** +87 [<0.01]

I . * Known carcinogen

*'* Suspeded carcinogen

APP.A·l
R. References

1. Molina. MJ. & Rowland. F.S.• 'stratospheric Sink

for Chlorot1uoromethanes: Chlorine Atom-Catalysed

Destruction of Ozone', Nature. 249, pp 8.10-812

(1974)

2. Fannan. J.C.• Gardiner. B.G. & Shanklin. J.D.•

'Large Losses of Total Ozone in Antarctica Reveal

Seasonal aox NOx Interaction', Nature. 315, pp

207·210 (1985)

3. McElroy, M.B., Salawitch. RJ.• Wofsy, S.L. &

Logan, J.A, 'Reductions in Antarctic Ozone due to

Synergistic Interactions of Chlorine and Bromine',

Nature, 3:%1. pp 756-762 (1986)

4. Sanders, S.P. & Friedl R.R., 'Kinetics and Product

Studies of the CIO and BrC Reaction: Implications

for Antarctic Chemistry', Submission to Geophys.

ResearchLell. (1988)

5. United Kingdom Stratospheric Ozone Review

Group, 'Stratospheric Ozone 1987', Her Majesty's

Stationery Office, (1987)

6. UNEP, 'The Montreal Protocol on Substances which

Deplete the Ozone Layer', (September 1987)

7. UNEP Solvents Technical Options Committee,

Summary Report. (1989)

8. Ordonnance sur Ie deversement des eawc usees.

814.225.:%1 (1975, rev. 1985)

9. Ordonnance sur les substances dangereuses pour

I'environnement, 814,013 (1986 rev. 1988)

10. Loi federale sur Ie commerce des toxiques, 814.80

(1969 rev. 1985)

11. Ordonnance sur I'interdiction de substances

toxiques, 814.839 (1971, rev. 1984)

12. United Kingdom Stratospheric Ozone Review

Group, 'Stratospheric Ozone 1988: Mechanisms for

Generation of the Antarctic Ozone Hole', pp. 11-20.

Her Majesty's Stationery Office, (1988)

13, Brune, W.H,. Toohey, D.W., Anderson, J.G.,

Danielson, E.F. &: Starr, W., 'In-situ Observations of

ao in the Wintenime Northern Hemisphere: ER2

Aircraft Results from 21'N-61'N Latitude', Polar

Ozone Worlahop, NASA Conference Publication

10014, Washington, D.C. (1988)

R-J

14. United Kingdom Stratospher.c Ozone R~\:~'~

Group, 'Stratosphenc Ozone 1988: The G~ec:'c.":o.;.s~

Effect of CFCs and Substitutes' p 49, Her \fajcs:\ ';

Stationery Office (1988)

15. See 11.

16. European Chlorinated Solvent AsSOCla:10:1. '.-\

Review of 1,1,1-trichloroethane (me:~y;

chlorofonn)' (July 1989)

17. Asahi Glass Company Ltd, Press release 0:;

Substitutes for CFC-113 (February 1989)

18. US EPA James Hemby (see Fig. 1-1)

19. Daikin Industries Ltd. DatJ S:~e~:.

Pentafluoropropanol, (1989)

20. See 16.

21. Carpenter, C. 'Biodegradable Solvents'..-\.ir Fo~,;:

Engineering and Services Cen:e~, HQ

AFESCIRDVS. Tyndall Air Force Base. F1. i: 9S9i

22. Ordonnance sur I'evaluation de la degradabil::e ces

agents de surface contenus dans les de:erge r.:S (:cr- rev. 1980)

23. Ellis, B.N., 'Cleaning and COntamlr.a::o:: ~:

Electronics Components and Ass~;::'i:~5·.

Electrochemical Publications Ltd. (1986) (

[also available tn German as 'Relllll~~~ ::; -:~~

Elektronik', Eugen G. Leuze Verlag (1989)i

24. See 7.

25. Directorate. Commission of the E'~r()?e~::

Communities, 'Code of Practice for n".e Des:~::.

Construction and Operation ofCFC.. 113 Degrease ~'.

EUR 9510 EN, (1984)

26. Clementson, J., 'CFC-1l3 Conser..... atlon ~r.;;

Recovery Practice in Europe', Tec~"::.,~:

Proceedings, SubsrirUJes and A/rernari\es ro CFCs

and HaloflS, Conference and Trade Fair (1985)

27. El1is, B.N.• 'Safety and Environmental Prob:e::-.5 o(

Cleaning Printed Circuit Assemblies', Tec::r.:(~:

Proceedings, Joint IPC, EIPC and PCIF Cor.fere::ce.

Future ofPCBs, Helsingor. Denmark (1988)

28. Toubin, A, 'Low Solids Content Fluxes", C:.rc:u

World. Vol. 15, No.2, pp 17..18 (1989)
L. Useful lists of addresses

L. 1. Governn :.t&1d official departments

Federal Office for Environment, Forests and Landscape (BUWAL)

HaJlwylstrasse 4

3003 Berne

Telephone: 031-61 9349

Federal Office for Public Health

Toxic Products Division

Bollwerk 27

3001 Berne

Telephone 031·61 96 40

Swiss National Accident Insurance Fund

6002 Lucerne

Telephone: 041·215111

L. 2. Private sector organisations

L. 2. 1. Chemical Industry

Schweizerische Gesellschaft fUr Chemische Industrie (SGCI)

Nordstrasse 15

8035 Zurich

Telephone: 01·363 10 30

L. 2. 2. Electronics industry:

Groupement de l'Electronique de Suisse Occidentale (GESO)

place de la Gare 10

1001 Lausanne

Telephone: 021·23 47 26

Schweizerisches Automatik Pool (SAP)

Bleicherweg 21

8022 ZUrich

Telephone 01·202 59 50

Verein Schweizerischer Maschinenindusnieller (VSM)

Kircbenweg 4

8032 ZUrich

Telephone: 01-47 84 00

L. 2. J. Precision industry:

F~d~ration de I'Indmnie Horlog~re Suisse (FH)

rue d'Argent 6

2501 Bienne

Telephone: 032·22 5911

VSM (see above)

L-t
Chapter IV. Index

cost

A alcohol cleaning [1.4. rv<']

active charcoal filter II-5, III·2, III-4. IV-I aqueous degreasing [1 ..:3

adhesives IV·13 automatic transfer system Ill·~

aerosol sprays I-I bonoms recovery [[l. :

alcohols 1-3. II-4, IV-8, rv-12 centrifugal drying [V·12

ammonium hydroxide II-8 dry-cleaning with HCFCs IV·12

.. aqueous cleaning II-6 evaporative drying [V·12

automatic handling !II-4 HCFCs [1·2

automatic PCB testing IV-2 hydrocarbon/surfactant cleaning IV-8

hydrocarbons and derivatives [1·5

B "no-clean" fluxes IV.~

benzine II-4 panicle elimination 1\(·1 :

biodegradability saponifier cleaning IV.7

detergents II-S Swiss solvent losses IV· :

hydrocarbon/surfactant blends II-5 vapour phase soldering [[·3

hydrocarbon/surfactant cleaning rv-8 water·soluble fluxes IV·4 ·IV·5

saponifier IV-7 Coni, F.,Mr. [·1

soldering oils IV-6 cutting aids [V·13

bonoms recovery !II-I cycle, saponifier cleaning IV·7

bulk containers cycle, solvent cleaning Ill·3

CFC-1l3 III·2

D

C defiuxing I!-6

carbon dioxide 1-4 aqueous rv-:

carbon tetrachloride II-I artisanal IV·1.1V-:l

caustic soda II·8 CFC-1l2 11·2

CFC·ll II-I hand IV·::

CFC·112 H·2 hydrocarbon/surfactant IV·l

CFC-1l3 H·! hydrocarbons and denvatives 1I·4. IV':

"drop-in" replacements II-2 industrial [V·l

legislation 1-3 water [\/-:

lifetime 1-4 degreasing

recipients III-2 aqueous II·7. IV·Ll

substitution by HCFCs rv·ll detergents 1I-7. r;·ll

trade marks II·1 drums and cans Ill-2

cleaning dry-cleaning IV·:2

needles rv·13 drying

water-soluble fluxes rv-4 air blasting [1.7, lV·12

cleaning PCBs by CFC·1l3 IV·12

water consumption IV-S centrifugal IV·l:

climate 1·1,1-4 chemical IV·12

communications to operators III·4 energy conservation [V·5

condensation soldering energy consumption II·'7

secondary blanket II-3 evaporative [{.7. [\'·12

conservation II·2, m·1 hydrocarbons and derivatives [{·5

CFC·1l3 recovery service III-I water [{.7,IV·5,IV-12 , recovery, Chlorinated solvents Ill·1

container venting III·2

cooling coils 1II-3

Index-t

11·3

:\.'

;.\' .,:'

1-3

I-I. I·)

!I.4. !V·W

III-1

II-2

II·S

IV-8

II·4

11-5

II-3

IV·13

[V.~

III·)

IV·II

II·I

II-3

II·S

IV-12

II·)

IV-8

1I-2

!I. I. !V-l::

IV-10

II-2

II-I

II·)

[II·l. IV-,

1-3

1-3. II-4 - II-S. IV-8

1-1

II·~. !V·12

11-7

II-5. II-7. IV-5.1V-7. IV-8

(·3

II·8

IV.4

II-5.IV-8

II-7,IV-5

[V.l, IV-4

II·4.IV-12

w

V

vapour phase soldering

secondary blanket

VOC

See volatile organic compounds

volatile organic compounds

alcohols

conservation

HCFCs

hydrocarbon/surfactant blends

hydrocarbon/surfactant cleaning

hydrocarbons

hydrocarbons and derivatives

per- and trichloroethylene

solvent vehicles for adhesives, paints etc.

U

underbrushing

water

quality

water effiuent

legislation

saponifiers

water-soluble fluxes

waterscrubbers

water treatment

water-soluble fluxes

white spirits

T

taps and valves

taxes

terpenes

Thatcher, M., Mrs.

toluene

toxic products

legislation

toxicity

carbon tetrachloride

HCFCs

hydrocarbons and derivatives

in dry-cleaning

per- and trichloroethylene

saponifiers

l,l,l-trichloroethane

l,l,l-trichloroethane

for flux removal

substitute for CFC-ll)

trade marks

trichloroethylene

surface mot.:ntlng

clearung water-soluble tluxes

hydrocarbon/surfactant clearung

water-soluble fluxes

<witching offsolvent machines

1-2

III-S

1-3

IV-l

IV-2

III-S

m-2, m-4

IV-S

II-B,IV-6

III-2, IV-I

IV-I)

I11-2

IV-7

IT-3.!V-11

II-3. !V-12

IV-Ie

II-3

II-4

III-2

II-7

1-4

IV-ll

[II.)

IV-3, IV-IO

IV-)

IV-4

II-B, IV-I, IV-3 - IV-4

s

pans bas ke ts

PCB substrates

compatibility with cle'!ners

pentafluoropropanol

perchloroethylene

for flux removal

perfluorocarbons

petroleum spirits

See also white spirits

polarsoils

polarvonex

precision cleaning

2-propanol

See isopropanol

pumping solvents

R

reliability

water-soluble fluxes

residual contamination

rosin

hydrolysis

oxidation

rosin fluxes

saponifier cleaning

saponifiers

seals and gaskets

self-adhesive tapes

siting equipment

SMT

See swface mounting

sniffer

solder pastes

soldering

inen-gas IV-4

"no-clean" fluxes IV-4

water-soluble fluxes IV-4

water-soluble oil IV-6

solvent cleaning cycle III-)

solvent cooling Ill-)

solvent filling III-2

solvent handling III-2

solvent type losses ill-4

solvent vapour capture III-4

solvent vehicles IV-13

solvents on pans I11-4

Solvents Technical OptiOns Committee 1-), II-2, IV-12

spray lances Ill-)

sterilisation IV-13

Stoddan solvent

See also white spirits

stratospheric chlorine

subcontractors

substances

legislation

substitution

electronics industry

suppliers

Index-3
r

H

II:

CFCALLIANCE

SPECIAL BULLETIN

2011 Ey. StrMt, N.W., Fifth Floor, WI.hlngton, D.C. 20008

THE NEW CFC TAX

December,1iBe

The Omnibus Budget Reconciliation Act of 1989 imposes a new excise taX on certain ozone-depleting chemicals and on impons of products made wilh or containing such chemicals. The Treuury Department and the IRS have begun the process of LOT>-

. plementing the new laX and expect to publish guidance for taxpayers on avariety of issues relating to the laX before the end of

1989.

The following is an explanation of the new tax. The explanation is based on the best infonnation currently available. Until the

IRS publishes guidance on the taX. however. a nwnber ofthe issues discussed in this paper will remain uncertain. Before makioi

business decisiQns that could be affected by the reSOlution Qf these "$u= raxpaym $hQuld seek indePendent pmfc$$iooa} advice,

1mb!c Chcmln!, Tlpb!C EYCDts

( .

The bill defmes eight chemicals as ozone-dcpleting

i chemicals and applies the new tax to them. The eight chemicals are those subject to production limitations under the

-MOnlreaJ Protocol and the implementing EPA regulations.

The chemicals are the following:

Additions to this list oftaXable chcmica1s can be made

only by Congress. Therefore if other chemicals become sub-

,ject to the Montreal ProtoCol or to other production limirations. those chemicals would not be subject to the taX unless . ,Congress takes legislative action.

The bill excludes from the defUlition of ozone-depleting

chemicals tho$C chemicals produced outside the United

States and not imponed into me United Srares. Thus. ozone-

. depleting chemicals produced outside the United Swes by a

< U.S, taxpayer are notsubject to the laX unless impon.ed into

the United States.

CFC·ll

CFC·12

CFC·llJ

CFC·1l4

CFC·US

HaIOD-UII

Halon· 1301

HalOD-2402

(trichloronuorometbaDe)

(dichlorodilluoromethaDe)

(trichlorotrilluoroetllaDe)

(I, 2.dlchloro-l, 1, 2, 1-

tetrafiuoroetbaDe)

(chloropeDtaIluoroethaDe)

(bromochlorodilluoromethaDe)

(bromotrtnuorometbaDe)

(dtbromotetralluoroetbue)

The tax is imposed in three instances:

• SIIC Qr WlC by mlpu"dUrcr. prgduccr. or Importer.

The principal taxable event is the sale of ozone-depleting chemicals aite: December 31.1989, by the manufacturer. producer. or importe: of the chemicals. The tax

also will apply where the manufacturer, producer, or imponer of ozone-depleting chemicals uses the chemicals

afte: December 31. 1989. instead ofselling them.

• Salc Qr USC Qf ImPQrted prgdudli fpr which pzgDC'

depledDI chemicals are production material In order

to reach indirect importS of ozone-depleting chemicals.

the tax applies to the sale or use by an importer. after

December 31.1989. of imported products for which any

ozone-depleting chemical is used as material in the

manufacture or production process.

• Otmcnblp or Door StoeM. The tax is imposed on

stocks of ozone-depleting chemicals owned by any per·

son (other than the manufacturer. producer or imponer

of me chemicals) on January 1, 1990 if me chemicals are

held for or for use in funher manufacture. The tax

also is imposed on stoCks oftaXable chemicw held for

the same purposes on January 1of each year 1991

through 1994 if the tax rate for such chemicals increases

on thalcWe.

These three taxable events are explained in more

detail below.

Pcnons RCQuired To Rcmlt tbe Tax to the IRS

• RCauiar tal QD salc Qr II. The producer. manufac·

turer or imponer of the chemicals is liable to the IRS for
Bye III AmoupS

Ca'c,,'adoD ot AmouDt olIU

The amount of the tax is determined under the following

formula:

The bill de dgrwes a specific base tax amount fex the

years 1990-1994 and provides for an increase of4S cents for

each year beyond 1994. The base amounts through 1999 are

as follows:

'f"-,

• j

< 1

, \

cnemlQJ.S SUDJe:, ,0 me~. -:::L;mges ill me oz:one·.Je~.ec...:n

factors can result only from Congressional acaon.

ApplicatiQQ Qf thC Tax OD Sales by the Producer

• In tt' '-e of the regular tax on sales of ozone-depleung

che, J by the producer. the bill applies the tax to the

quantity actually "sold." Thus. for example. under the

pJaJn meaning of the biJI. W1X truck heels and other

similar quantities are not waole until and unless they

are sold.

• Allbough the bill is silent on the precise calculation of a

producer's taXabJe saJes volume. the normal procedure

in lbe case of other federal excise taxes is co calculate the

volume on a net basis -- that is. gross saJes volume less

mums and adjusanents. An IRS official has indicated

informally that this nonnal calculation should apply.

• In calculating the tax. fractions of pounds of chemicals

are not rounded. The partial pounds are multiplied by

the same ozone-depletion factor and base tax amount as

whole pounds.

• The bill is silent on the issue of when asaJe is deemed to

occur for purposes of the tax. In the absence of specific

rules. general tax rules probably would apply. Under the

general rules, me IRS examines the substance. not the

fonn. of a cransaction to determine whether a saJe has oc·

cuned. In such an examination. a sale generally is

deemed co occur when lbe benefits and burdens of

ownership are transferred. not merely when paper

evidence of the saJe is executed. This sWldard also

wouJd be relevant for determining ownership of taxable

chemicals for purposes of me floor stoCks tax.

AJDOUDt X Factor X Cbeacals

Bue Tax Ozone-Depletion

Poundlor

Tax:

UIC re~Wal ..u. UlJUll UIC :>01.1C 01 u.:>C UI U1C >:nemlQlS oy

such person.

• Importcd prpdYeU· The imponer of taxable imported

products is liable co the IRS for the tax upon the saJe or

use ofsuch products by the importer.

• Floor storks The owner of the chemicals on January 1

of each applicable year is liable co the IRS·for the floor

stocks tax.

This formula applies in all insrances and to all ozonedepleting chemicals except. as described in more derail

below, balORS and chemicals used in Ihe manufacture ofrigid

foam inSulation. Thus. the formula applies in me normal

cue of the sale or ue of chemicals by the producer, in the

cue of the floor stocks tax, and in the case of imported

producu. In &be Jau.er case, me formula applies to me quantities of ozone-dep1eting chemicals used as material in the

manufacture or fIOduction of the imported products.

ApplicatjoD of the Tax QD Imported Products

1990 $1.37 1995 $3.10

1991 1.37 1996 3.55

1992 1.67 1997 4.00

1993 %.65 1998 4.45

1994 2.65 1999 4.90

02opc.Depletjga F.ctpn

Each ozone-depletion facror represents the comparative

potenlial ozone-depletion resulting from the same weiJht of a

given chemkal. The factors are as follows:

CFC·ll 1.0 HaloD 1211 3.0

CFC·12 1.0 Haloa 1301 10.0

CFC·1l3 0.1 Ha1oD%40% 6.0

CFC·1l4 1.0

CFC·115 0.6

• For imported products. the bill provides that the tax is

equal CO lbe amount of tax which wouid be imposed if

the chemicals &bat were used as material in the manufac·

ture or production ofthe products had been sold in the

United StaleS.

• To calcu1alc me quantity of chemicals used matenal

in me manufacture or production of imponed products.

the Secretary of the Treasury is directed in the bill to

choose one of three methods:

A. Data ProYided by Importer. The Secretary can

accept data the importersuppliesshowing the

volume of chemicals used as material in the production process.

B. DomCStic Ipdystry Nol'JIU. If the importer fails

to provide sufficient data. me Secretary can calculate

the chemical amounts based on standards of use in

the equivalent domestic industry.

The ozone-depletion factors designated in the stallUC are

those specified in the Moncrea1 Protocol. l.ike me list of

December 1989 Page 2
•

•

, .

t ,

C. Fiye Percent pC Appraised value, The bill also

proVldes that. If necessary, the Secretary can bypass

the foregoing procedures and impose a taX equal to

five percent of the value of the imported product.

This provision is intended to serve primarily as an incentive for importerS to come forward with evidence

as to the amount of ozone-depleting chemicals in

their products.

Treasury Department economis~ have begun work to

compile a list of imponed products for which ozonedepleting chemicals are used in the production process,

and to determine the average quantity of the chemicals

so used in each product.

The Secretary of the Treasury also is authcrized to

prescribe regulations exempting products that use de

. minimis amounts of ozone-depleling chemicals as

material in the production process. However, no such de

minimis exception applies ifthe ozone-depledng chemicals are uSed for purposes ofrefrigeration ex' air con·

ditioning, creating an aerosol ex' foam, ex manufacturing

electronic components.

Agg"gtlog pUb, Floor Stw:ks Tu

A3 swed previously, the floor stoeks tax is imposed on

January 1of each year 1990 through 1994 on any ozone·

depleting chemical owned by any person (other than the

manufacturer, producer, ex' importer) on such date and

held for sale or for use in funher manufacture. The

amount ofthe floor stocks tax is as follows:

1990: The amount of tax that would have been imposed if the chemical had been sold during 1990.

1991-1994: The excess of the tax that would have

been imposed on the sale of the chemical by

the manufacturer, producer or importer on January 1

of that year, over the tax, if any, previously imposed

on the chemicaL

The floor stoCks tax is applicable to wholesalers,

retailers, disaibutors, conD'ICtors, and any other type of

ol1Siness that holds stoCks of ozone-dcpleting chemicals

for sale or for use in further manufacture.

The bill contains no exemption from the OOCX' stOCks tax

for small businesse& or for businesses that hold de mini·

mis quantities of chemicals. The IRS is considel:ing the

possibility of instituting exemptions adminisua.tively.

The taX applies only to slOCb of chemica1s-heldiex'sale

or for use in fwther manufacture. However, the bill does

not contain a definition of the cerm "use in further

manufacture." The cerm probably is best read as denoting direct. proximate use in an actual manufacturing

process. (If the bill had been intended to have a bl"Older

meaning, it probably would have been drafted to apply

to stocks held "by" a manufacturer or simply "by" any

business.) An IRS offICial has informally agreed with

this conclusion: it is unclear, however, as to whether the

IRS will publish any detailed guidance on this issue in

the near future.

•

•

•

•

•

Plge 3

Assuming the above uue!i'ret.:lLlon of u1e telT.1 J.>C ~r.

funher manufacture'· IS correct. then, as an ex.;unple.

stocks of chemicals held for use as a solvent In J

manufacturing process probably would be taxable, as

would stocks of chemicals held by a manufactw'er of

refrigeration equipment for use as a refrigerant in (:f

ment made by the company. However. stoCks of en" 'll

cals held for use other than a direct use in a

manufacturing process -- for example. stocks of chemicals held for use in cooling systems for a factory --

probably would not be taxable. Stocks of chemicals held

for use in routine factory maintenance also might not be

taxable.

The bill is drafted to apply the floor stocks tax only to

ozone-depleting chemicals themselves and not to

products that contain ozone-depleting chemicals (in conlnLSt with the treamtent ofimports). Thus, generally

speaking, the IRS probably does not have the power to

apply the taX to such products. In administering the taJt,

however, the IRS probably does have the power to

preventllXpeyers from abusing the purpose of the floor

stocks tax through abnormal business practices.

The bill is silent as to the tax treatment of chemical

blends consisting partly of taxable chemicals and panly

of non-wable chemicals. The IRS also has not indicated any position on this issue.

The IRS is expected to publish guidance on the payment

procedures for the tloor stocks tax by the end of tJ;1e year.

A3 in virtually all other federal taxes, it is expected that

the responsibility for reporting and paying the tax will be

the taXpayer's. In other words. the taxpayer's legal

liability to pay the tax arises under the legislation and

will not depend on identification or contact of the taxpayer by the IRS. According to an IRS official. the floor

stocks taX probably will be payable on IRS form 720,

which is the excise tax renun. The IRS will revise the

form to accommodate the floor stocks taX.

The following are examples of the computation of the

floor stocks taX:

A. A dealer holds 200 pounds ofCFC-I1S for sale

on January I, 1990. The floor stocks tax will equal

S164.40 (S1.37 x 0.6 x 2(0).

B. ABC Company holds 300 poWlds of CFC·12 on

January I, 1993 for use in fwther manufacture. ABC

Company purchased the chemical in June 1992. The

floor stoeks tax will equal S294. That amount is the

difference between the taX that would be imposed if

the initial sale of the chemical had occurred on

January I, 1993. S79~ (S2.~ x 1.0 x 300) and the taX

previously imposed in 1992, $501 ($ 1.67 x 1.0 x

3(0).

C. Adealer holds 400 pounds of halon 1211 for

sale on January I, 1990. No flOCX' stocks tax is imposed because, under the bill, halon 1211 is not

treated as an ozone-depleting chemical until]anuary

1,1991.

D. A dealer holds 400 pounds of halon 1211 for

sale on January I, 1991. The floor stoCks tax will

equal Sloo. That amount is the difference between

the taX that would be imposed if the initial sale of the

December 1989
halon had occUlTed on January 1. 1991. S100 (25

centsllb. x 400 Ibs.) and the laX already imposed. SO.

E. XYZ Company holds 500 pounds of halon 2402

on January 1, 1994. XYZ Company purchased the

chemical in 1992. The floor stoe:ks taX will equal

$7.825. That amount represents the difference be- .

tween the taX that would be imposed if the initial sale

of the chemical had Occurred on January 1.1994.

$7.950 ($2.65 x 6.0 x 500) and the tax previously imposed on the sale of the halon 2402 to XYZ Company in 1992. $125 (25 cenWlb. x 500 Ibs.) Note:

No floor stoe:ks taX was imposed in January 1. 1993

because the tax rate for halons, 25 centsllb., remained

the same.

Exemptions "'9'" the TU

The bill provides five full eX' partial exemptions from the

taX, as (onows:

• Chemicais produced from recycling.

• Chemicals used as feedslocks.

• Exporu.

• Halons.

• Chemicals used in the manufacture ofrigid foam insulation.

These exemptions apply in all instances where the tax applies (i.e.• the regular taX on sale or use. the tax on imported

products, and the floor stoCks tax). The exemptions are explained below. Note that no exemption exists for sales of

chemicals to a federal. stare, or local governmental agency.

Recycljpl elemptiog

• The bill fully and 'pennanently exempts from the tax

chemicals divened or recovered in the United Stales as

part of a recyclinS process. In effect. this exemption

simply treats a recycling operation as not production or

manufacture of ozone-depleting chemicals for purposes

of the tax.

• Chemicals recovered by the original producer of the

chemicals from loading operadons. tank auct heels. and

similarsources probably do not qualify for the recycllnS

exemption (assuming such chemicals bad not previously

been taxed). Such chemicaJs II'Obably would be II'eaIed

as nonnallaJtable chemicals when soldby-the producer

thereof.

Ftcdstoc:k Enmpdop

• The bill also fully and pennanently exempts from the tax

any·ozone-deplering chemical used and entirely consumed in the manufacture or production of any other

chemicaJ.

• The bill implements the feedstock exemption by pennitting sales of chemicals for fecdslOCk use to be made cufree. The exemption applies both on direct sales from

the producer to the e"empt user and on 53les to ..l

wholesaler or distnbutor who Intends to reseU to me exempt user.

• The exemption fop of ozone·depleting chemicals

for feedstoe:k use <t. ,.it; ~s CI11x if the parties to the transactions meet registration requirements to be prescribed by

the Secretary pf the Treasury. Sec Wc scparn1C disCIlSsign of the rCiiStTaOoo requirements below.

• If taX is actually paid on chemicals used as a feedstoCk.

the user is pennitted to obtain a refund of the taX from

the IRS.

Export EumpdoQ

• The bill provides producers of ozone«p1eting chemicals with a partial exemption for exportS. The exemption consists of abase portion and an additional portion.

• The base portion ofthe expon exemption is the percentage ofthe producer's yearly production equal to the percentage of production the producer exponed in 1986.

• The percentage calculation of the base ponion is made

using ozone-depletion factor adjusted pounds. as follows:

Percentage Allqwed =

1986 Ozgnc-dep1ction faetgr adjusted pounds expoOt

1986 Ozone-depletion factor adjusted po~ produCt

• Ozone-depletion factor adjusted pounds (ODFAPs) are

calculated by multiplying the number of pounds of each

chemical (pounds cxpgncd if calCUlating the numerator,

pounds Prgduccd ifcalculating the denominator) by the

chemical's ozone-depletion factor. The ODFAPs for

each of the eight chemicals are then added together to

detennine the total ozone-depletion factor adjusted

pounds.

• The bill provides that the detennination of the level of

exports of each producer for 1986 is to be detennined

based on data published by the EPA.

• The second part ofthe expon exemption relates to

production increases destined for export. Under the

Montreal Protocol and implementing rules. the EPA is

authorized to grant additional production allowances to

U.S. producers for the explicit purpose of export. Those

exports are exempt from the cu.

• The bill indicates in a cross reference that producers of

ozone-depleting chemicals have the discretion to transfer

pan of their expon exemptions to third parties.

• Ozone-deplering chemicals used as a material in the

manufacture of products that are exponed are not exemIX from taX under the bill.

H.,Op Exemptiop

• Halons receive favorable treaUnent through 1993. After

1993, they are treated the same as all other ozone-depleting chemicals. The tteaanent for 1990-1993 is as follows:
•

•

1990: All sales and uses of halons are exempt from

tax. The tenn "ozone-depleting chemical" does not

include halon-1211, halon-l301 or haion-2402 for

the year 1990.

1991-93: Taxed at a rate of 25 cents per pound.

without adjustment for ozone-dcple,tion factor.. (Note: the bill actually exprwe3 this preferential rate

in cenns of varying percentages of each year's

relUlar tax rate. rather than as a 25-cent-per-pound

rate.)

Rlaid Foam Insulatiog Exempdog

Chemicals used or sold for use in the manufacture of

r' rigid foum insulation ~ive preferential rreaunent

through 1993.

Procedt rally. this preferential treaanent is sauctured in

precisel, the same manner as the feedstock exemption.

so that producers are permitted to sell chemicals at die

preferential tlte fa use in making rigid foam insulation.

Such sales can be made both to direct users and to

wholesalers and distributors who intend to resell to rigid

foam makers. As in the feeds"" exemption, the IRS

will impgse rciisrratiQD I'CQpircmcnt! that must be fgllOWed in order for wes to be pennissjble at the preferential Ate (Sec the disJlsmon below,) In cases where

sales are not made 11 dle preferentiall'lle. purchasers of

chemicals who use the chemicals in die making ofrigid

foam insulation are penniaed to obtain a refund ofthe

excw tax paid.

... . The preferential treatment for chemicals used in the

manufacture ofrigid foam insulation is as follows:

1990: Complete exemption.

1991-93: Taxed at a rate of 25 cents per pound.

without adjusunent for ozone-dcpletion factor.

(Note. as in the case of the halon exemption. the bill

actually expresses this preferential rate in terms of

varying percentages of each year's regular tax rate.

rather than as a 25-cent-per-pound tate).

The bill does not defme the term "rigid foam insulation."

According to an IRS official. the IRS is aware ofseveral

issues that have arisen in inlelpRting the u:rm. but has

not yet resolved the issues.

wul be put to ;l tax·prete"ed use. The ffiS Nowd

prescnbe the tonn ;lIld content oi the cenulcate ;lIlC

would requlIe that the cenuicate be SIgned under penalty

of pefJury. The purchaser would prepare and SIgn the

certificate and deliver it to the producer. .

• Once received by the producer in proper fonn. the cerufi·

tate would entitle the producer to sell chemicals to the

purchaser at the preferential tax rate applicable to the use

declared in the certUlCate. The producer would not need

to exercise judgment as to whether the purchaser was

legally entitled to the preferential rate and would not be

subject to an IRS challenge for having relied upon the

certificate in failing to collect the full tax from the purchaser.

• The purchaser would be fully subject to IRS audit to

decennine the validity of its claim for a preferential w

rate. and IRS penalties would apply in the case of improper claims.

Pa)'Jllent Schedules

• The initial payment for taxes on the sale or use of ozonedepleting chemicals and imported products is due April

1,1990.

• The IRS will issue guidance mandating a payment

schedule beyond Aprill. 1990. The likely period will

be semi-monthly with the taxes required to be deposited

within nine days after the end of each semi-month~

period.

• The floor stocks tax is due April 1of each year.

IRS Eg(o[(;emcgt

• The normal IRS tools for enforcing other wes apply to

the new CFC w. For example, the IRS will have the

authority to impose penalties ranging from five percent

of underpayments for negligence. to 75 percent of underpayments for civil fraud. and to fUles or imprisonment

for criminal fraud.

• The IRS probably will pay particular attention to policing the exemptions from the tax. In other words. the IRS

will seek to ensure that chemicals purchased w-free for

an exempt purpose are so used.

Remtrltiog Requiremegt (or Feedstock .pd

RIKid FOlm ExemptiON l ,

• • •

The IRS is expected to provide guidance by the end of

the year u to the regisuation requirement fa the

feedstock and rigid foam exemptions.

According to an IRS official. it is likely that. at least for

the sbon-Ienn. the IRS will prescribe a system of exemption certiflCates in lieu of a comprehensive system Cor actually registering producen and purchasers with the IRS.

An exemption cenificate would be. essentially. a declaration by the purchaser of chemicals that such chemicals

This document was prepared by J01M! C. Gould, a pQTlner in

1M Washington. D.C. lawfirm O/Vin.son &. ElJcin.s.

PlgeS December 19/39
lOin Co",o...

I,t StuIOIl

HOUSE OF REPRESENTAnVES RIPOIIT

101·386

December 1••

OMNIBUS BUDGET RECONCILIATION ACT

OF 1989

CONFERENCE REPORT

H.R. 3299

Pig. e

. r

. >
Cta.lllaJ NlIMMUJtMn:

tMehlerofluOroIMtluJM

dieh lorodifluoroIMthaM

IrichlerolnfluorwthaM

J.i-diehlero-J.J.i.]·l.tra·fluorwtharu.

chloro,."tafluorwrhaM

bromochlorodlfluoroIMthaM.

bromotnfluoroIMthaM

i .

"Subchapter D-O:one-Depleting Chemicals. Etc.

"Sel·. 468J. !mpo&lllon 0; la..r.·

"Sec. #8.1. Dtfinillon.s and $l'«lal rules.

"SEC. '1i.~/. !.tfPOSITIO.V OF TAX.

"faJ GE....ERAL RULE.-There is hereby imposed a tax on-

"(1) any ozone-depletmg chemical sold or used by the manu·

facturer. producer. or importer thereof. and . "(;}) any imported taxable product sold or used by the lmport·

er thereof.

"(b) AMOC:.VT OF TAX.- .'(1) OZONE-DEPLETING CHEMICALS.-

"rA) IN GENERAr..-The amount of the tax imposed by

subsection fa) on each pound of ozone-depleting chemical

shall be an amount fqual to-

"ri) the base tax amount, multiplied by

"rit) the ozone-depletion factor for such chemical.

"rB) BASE TAX AMOUNT FOR YEARS BEFORE 1995.-The

base tax amount for purposes of subparagraph fA) with reo

Bp«t to any sau or use during a calendar ~r before 1995

is the amount determined under the following table for

such calendar year: .

"C"II,..,. ,..r: Btu. tlU "molllll

/990 or /99/.............................................................................................. I/.Ji

/992............................................................................................................ J.G7

J99J or /994.............................................................................................. i.Gj.

"(C) BASE TAX AMOUNT FOR YEARS AFTER 1994.-The base

tax amount for purposes of subparagraph (AJ with respect

to any sou or use during a calendar year after 1994 shall

be the base tax amount for 1994 increased by 45 cents for

each year after 1994.

"(2) IMPORTED TAXABLE PRODUCT.-

"fAJ IN GENERAL.-The amount of the tax imposed by

subsection (a) on any imported taxable product shall be the

amount of tax which would have been imposed by subsectlon (a) on the ozone-depleting chemicals used as materlals

in the manufacture or production of such product lf such

ozone-depleting chemicals had been sold in the United

States on the date of the sale of such imported taxable

product.

"rB) CERTAIN RULES TO APPLY.-Rules similar to the

rules of paragraplu (2) and (3) of section 4671(b) shall

apply.

"SEC. tlBL DEFINITIONS A"'D SPECIAL RUUS.

Uta) OZONE-DEPLETING CHEMICAL.-For purposes of this subchapter-

"(1) IN GENERAr..-The term 'ozone-depleting chemical' means

any substance-

"rAJ which, at the time of the sale or use by the manufac·

turer, producer. or importer, is listed as an ozone-depleting

chemical in the table contained in paragraph (2), and

"rB) which i.8 manufactured. or produced in the United

Statu or enured into the United Slata for consumption.

use. or warehousing.

"(2) OZONE-DEPLETING CHEMICALS.- ..C011I"..11 NlIfIC:

CFC-JJ . CFC·J2 .. CFC·JJ3 . CFC·JJ4 . CFC-IJ5 . Hale"·/:// .. Hale"·/JO/ ..

Page 7 December 1989
OlClmber 1989

"Co",,,,o,, fla",~: ''',mjeai flom~fldat",.,:

Halofl.j!.O;!....... dlb",mottlraf1uorw,hafl~.

"rb) OZONE· DEPLETION FACTOR. -For purposes of thLS subchapter.

the term ·ozone·depletlon factor' means. wlth respect to an olone·de·

pleting chemlcal. the factor a.ssigned to such chemlcal under the fol·

lowing table: .

"Oro"...,iftt", O:OflNJ~,i~ttOfl

ell,,,,tcal.: faetor.

CFC-ll...................................................................................................... 1.0

CFC-li...................................................................................................... 1.0

CFC-IIJ.................................................................................................... 0.8

CFC-l 1.6 1. a

CFe-IJ,s.................................................................................................... 0.5

Halon·12JJ................................................................................................ JO

Halon·lJOl................................................................................................ /0.0

Holo".iJOi....,........................................................................................... Ii. a

"rc) IMPORTED TAXABLE PRODUCT.-For purposes of this subchap·

ter-

"(1) IN GENERAL.-The term 'imported taxable product' means

any product (other than an ozoM-depleting chemical) entered

into the United States for consumption. we. or warehousing if

any ozoM-depkting chemical was wed as material in the man·

ufacture or production ofsuch product.

"(2) DE MINIMIS EXCEPTION.-The term 'imported taxable

product I shall not include any product specified in regulatlons

pracribed by the SecT'f!tary as using a de minimis amount of

ozone-depleting chemicals as materials in the manufacture or

production theT'f!Of The preceding sentence shall not apply to

any product in which any ozoM-depkting chemical is used for

purposa ofrefrigeration or air conditioning, cT'f!atl1lg an aerosol

or foam. or manufacturing electronic components.

"(d) EXCEPTIONS.-

"(1) RECYCL/NG.-No teu shall be impoJtd by section 4681 on

any ozone-depleting chemical which is diverted or recovered in

the United States as part of a recycling proceu (and not as part

of the origlnal manufacturing or production process).

"(2) USE IN FURTHER MANUFACTURE.-

"(A) IN GENERAL.-No teu shall be imposed by section

4G81-

"(i) on the We of any ozone-depletin, chemical in the

manufactuT'f! or production of any other chemical if the.

ozoM-depleting chemical is entirely consumed in such

use.

"(ii) on the sale by the. manufactuT'f!r, producer, or

importer ofany ozoM-depkting chemical-

"(1) for a we by the purchaser which meets the

T'f!tluiT'f!mtn" of clause (i), or

"([1J for racle by the purchaser to a second pur·

chaser for a use by the second purchaser which

meets the f'ftluiT'f!ments of clause m.

Clause (ii) shall apply only if the manufactuT'f!r, producer.

and impotWr. and the 1,t and 2d purchaurs (if any), mftt

such reg&stration T'f!tluirements as may be pracribed by the

Secretary.

"(B) CUDIT' OR ",UND.-Untkr T'f!gulations PT'f!scribed

by the Secrrtary. if-

"(i) a taz untUr thz. subchapter WQ8 paid with reo

spect to any ozone-dcrleting chemicaL, and

"(ii) ,uch chemica was used (and entirely consumed)

by any ~,..on in the manufacturr or production of any

other chemical,

PageS
then an amount equal to the tax so paLd shall be ailou:ed

as a credit or refund IWLthout LnterestJ to such person Ln the

same manner as if Lt were an overpayment of tax Lmposed

by section 4081.

"(JJ E:CPORTS.-

"(AJ IN GENElU.L.-Except as provided in subparagraph

(BJ. rules similar to the rules of section 4662(e) lother than

sectLon 4G&2feJ(2XAXiixllJJ shall apply for purposes of thLS

subchapter.

"rBJ LIMIT ON BENEFIT.-

"ri) IN GENElU.L.-The auregate teu benefit a LlClU:·

able under subparagraph fAJ with respect to ozone-de·

pleting chemicals manufactured or produced by any

person during a calendar year shall not exceed the sum

of-- . .

"(/) the amount equal to the 198& export percent·

age of the a,gregate teu imposed by this subchap·

ter with rtspect to ozoM-depleting chemicals man·

ufactured or produced by such person during such

calendar year (other than chemicals with respect to

which subclause a/) appLiesJ. and

urID the aggregate teu imposed by this subchap·

ter with respect to any additional production ale

lowance granted to such person with respect to

ozon.e-depleting chemicals manufactured or pro·

duced by such person during such calendar year by

the EnvironTMntal Protection Agency under 40

CFR Part 82 (as in effect On September 14. 1989J.

"(ii) 198& EXPORT PERCENTAGE.--A person's 1986

aport percentage is til« percentage equal to the ozone·

dltpktion factor adjusted pounds of ozone-depletLng

chemicals manufactured or produced by such person

duri1ll1986 which wert aport«i during 1986. divided

by the ozoM~pktion factor adjU&ted pounds of all

ozoM~pktilll chemicals manufacturtd or produced

by such person during 198&. The percentage determined

under the prtCeding sentence shall be ba3ed on data

published by the Environmental Protection Agency.

"fe) OTHER DEFINITIONs.--For purposes of this subchapter-

"(1) IMPORTER.--The term 'importer' means the person enter·

ing the artick for consumption, use. or warthousing.

"(2) UNITED STATES.-The term 'Unit«i States' has the mean·

ing given such urm by section 4&12raX4).

"(fJ SPECIAL RUU3,-

"(1) FlIACT'IONAL PARTS OF A POUND.-In the ca&e of a fraction

of a pound. til« taz impaled by this subchapter shall be the

same fraction of the amount of such teu imposed on a whole

pound.

"r}) DISPOSITION OF REVENt'ES FROM PClERTO RICO AND THE

VIRGIN ISLANDS.--The provisions of subsections faXJ) and fb}(JJ

of section 7&S2 shall not apply to any tax imposed by this sub·

chapter.

"(g) PHASE·IN OF TAX ON CERTAIN SUBSTANCES.-

"(1) TREATMENT FOR 1990.--

"rAJ HALONs.--The term 'ozoM-depleting chemical' shall

not include halon-1211. halon·1301. or halon·i402 with reo

spect to any sak or use during 1990.

",B) CHEMICALS USED IN RIGID FOAM INSULATION.-No

teu shall bt impaled by section 4681-

"ti) on the lUe during 1990 of any sub8tance in the

manufacturt ofrigid foem iMulation.

Page 9 December 1989
"rii I on the sale durIng 1990 by the manufacturer.

producer. or importer of any substance-

"([) for use by the purchaser in the manufacture

ofrigiq foam insulation. or

"(IlJ for resale by the purchaser to a second pur·

chaser for su.ch use by the second pu.rchaser. or

"(iii) on the sale or U3e during 1990 by the importer

of any rigid foam insulation.

ClaU3e (iil shall apply only if the manufacturer. producer. and

importer. and the 1st and ld purchasers (if any) meet such reg·

istration requirements as may be prescribed by the Secretary.

"(2J TREATMENT FOR 1991. 1992. AND 1993.-

"rA) HALONs.-The tax imposed by section ~681 during

1991. 1992. or 1993 by reason of the treatment of halon·

1211. halon·UOl. and halon·z402 as ozone·depleting cheml'

cals shall be the applicable percentage rdetermined under

the following tabu) of the amount ofsuch tax which would

(but for this subparagraph) be impaled.

"/"UN_of:

HoUM·Illl .

HoiII"·lJOl ..

HtJUM·UOi .

FOt" tala

01'_

dunltf

1911

1.0

1.1

J.O

For saln or .....

du"ltf

lJU

;.0

U

1.j

For solft or UH

du"Olf

lJ9J

JJ

/.0

H

December 1988

"rBJ CHEMICAl.S USED 11'1 RIGID FOAM INSrJl..ATloN.-[n the

ca8e of a sau Or use during 1991. 1992. or 1993 on which no

tax would have been impoeed by reaaon of paragraph (lXB)

had such sau or use occurr«i durif16 1990. tM tax imposed

by section 4681 shall be the applicab~ percentage rdeter.

mined in accordana with tM followif16 tabu) of the

amount of such tax which would (but for this subpara·

tn'tJnn. J ,." ;m ""e"/

",,. til, ('Gil o( TI" appli('Gb/~

11./" Of' u•• dUf';II,: fWfT.,.ta~ i.:

1991........................ I,V

199J ,................................................................. 1J

/99J............................................................................................................ /0

"(;]) OVERPAYMENTS wrTH RESPECT TO CHEMICALS USED IN

RIGID FOAM INSrJl..ATION.-If any substance on which tax was

paid und~r this subchapter is used during 1990. 1991. 1992. or

199J by any pe"on in the manufactun ofrigid foam insulation.

credit or nfund (without internt) shall be allowed to such

pe"on an amount equal to the excelS of-

"fAJ tM taz paid under this subchapter on such sub.

stance. over

"rB) tM tax rif any) which would be imposed by section

4681 if,uch substance wen used for such use ~. the manu·

factunr, producer. or importer thereof on the date of its use

by such person.

"Amounts payable urukr the preceding sentence with respect to

usa during tM taxable ~r 'hall be treated as described in sec·

tion J4(a) for ,uch year unIus claim thenfor has been ti'mely

filed under this paragraph.

"rh) IMPOSITION OF FLOOR STOCKS TAXES.-

"(1) JANUARY 1. 1990. TAX.-Qn any ozoM-depLeting chemical

which on January 1. 1990. is held by any person (other than the

manufactunr. producer. or importer thereof) for 'ale or for use

in further manufactun. then is henby impotled a floor stocks

tax in an amount equal to the tax which would be imposed by

section 4681 on such chemical if the sau of such chemical by

the manufactunr. producer. Or importer thenof had occurred

during 1990.

Pig. 10
\ .

I .

l .

",}) OTHER TAX·INCREASE DATES.-

"(A) Lv GENERAL.-If. on any tax·increase date. any

ozone-depleting chemical is held by any person (other than

the man~facturtr. producer. or importer thertofJ for: sale or

for use m further manufacturt. thert is hereby imposed a

/7oor stocks tax. . "rE) AMOUNT OFTAx.-The amount of the tax imposed by

subparagraph rA) shall be the excess rif any) of-

"ri) the tax which would be imp08ed under section

4G81 on such substance if the sale ofsuch chemical by

the manufacturtr. producer. or importer thenaf had occurred on the tax·increa.se date. over

"(ii) the prior tax (if any) impoced by this subchapter

on such substance. . "rC) TAX-INCREASE DATE.-For purp03es of this paragraph. the term 'tax-incrt04e date' means January 1 of

1991. 1992. 1993. and 1994.

"(3) DUE DATE.-The taxes imt108ed by this ,ubsection on January 1 of any calen.da.r ymr shall be paid on or before April 1 of

such year.

"(4) ApPUCATION OF OTHER LAws.-All other provisions of

law. including penalties. applicable with rtSpect to the taxa

impc»ed by section 4681 shall apply to the floor ,tOCM taxes impc»ed by thil subsection. "

(b) CLERICAL AMENDMENT.-The table of subchapters for chapter

J8 is amended by adding at the end thereof the following new item:

"SUBCHAPTER D. Ozone-depleting chemicals. etc. "

(c) EFFECTIVE DATE.-

(1) IN GENERAL. - The amendments made by this section shall

talte effect on January 1. 1990.

(2) No DEPOSITS REQUIRED BEFORE APRIL 1. 1990.-No deposit

of any tax imposed by subchapter D of chapter J8 of the Internal Revenue Code of 1986. as added by this section. shall be requirtd to be made befort April 1. 1990.

(J) NOTIFICATION OF CHANGES IN INTERNATIONAL AGREE·

MENTS.-The Secrttary of the Trta.sury or h;" delegate shall

notify the Committee on Ways and Means of the House of Reprtsentative, and the Committee on. Finance of the Senate of

change, in the Montreal Protocol and of other intemational

agreements to which the United States ;., a signatory relating to

ozone-depleting chemicals.

• • •

Conference repor; langlUJge follows

Plge 11 December 1989
oecember 1989

4. ExcLSe Tax/Fee on Ozone-DepletLng ChemLcaLs

Prts~nt law

The use or manufacture of chemicals which deplete the earth's

ozone layer is not subject to specific Federal ~es or f~s.

HoUIJ~ bW

In. general

The House bill Ulesees an excise tax on the sale or use bya producer, manufacturer, or impon.r of certain ozone-depleting chemicall. The amount of tax is determined by multiplying a base tax

amount by an "cnone-depleting factor."

Chemica~ subject to taz

The specific chemica1l lubject to tu are CFC-ll, CFC-12, CFC113, CFC-114, CFC-115, Halon-120l, Halon-130l, and Halon-2402.

he t4z amount

For calendar yean 1990 and 1991, the baBew amount is $1.10

per pound of ozone-depleting chemical; for 1992 the bue tax

amount is $1.60 per pound; for for 1993 and beyond, the base tax

amount is $3.10 per pound. The bale tax amount is indexed for inflation occurring after 1989.

Ozoru-<upleting facto,.,

The ozone-depleting facton for the chemica1J subject to tax are

thOle specifiedm the Montreal protocol.

Ezemptioru and reduced rata of t4z

The HoUle bill provides ezemptioDl for feedstock chemicals, recycled chemicala, and chemicala exported subject to Environmental

Protection Aleney retU1ationa.. The HoUle bill a1Io ez.mpta from tax in 1990 CFCa u.aed in the

production of rigid foam inlulation and all halOI1.l.

The HoUle bill providell fora reduced rate of tu in 1991 through

1998 for CFCa u.aed in the production of rilid foam insulation and

all halona.

Imports

The House bill applies the tax to any ozone-depleting chemical

which is imported into the United Statell and to any product or

sublta.nce imported into the United States in whicha taxable

ozone-depleting chemical wu UIed in the manufacture or production.

Effectiw d4te

. The HoUle bill bI effective for ozone-d.pleti.ng chemicals sold or

UIed after December 31, 1989. In addition,a floor Itocb tax is impoeed on ozone-depleting chemicals held by a person other than the

manufacturer or importer on January 1, 1990. A floor stocka tax is

a1Io impoeed on each sublequent chan(e in the tax rate for any

tuable chemical. The initial depoeitl of wee due need not be

made until April 1, 1990.

&1&4" amendment

Inltrural

The Senate amendm.nt contaiDI two proviJions pertaining to the

taxation of ozone-depleting chemica1J: one reported by the Committee on Finance and the other reported by the Committee on the

Environment and Public Worka.

The Finance Committee provisionwgenerally the sameu the

HoUII bill.

The Environment and Public Worka Committee provision impoees a fee on the production, importation or diatribution of ozonedepleting chemical!. The fee does not depend upon the ozone-depleting factor of the chemical. The fee is generally related to profita earned on the production of such chemica1J.

Page 12

.1
ChemLcaLs subject to tax

The Finance Committee provision is identical to the House bill.

The Environment and Public Works Committee provision is the

st'· ..5 the House bill. In addition. the Environment and Public

Wl. _ k.:. provision permits the Administrator of the Environmental

Protection Agency to add chemicals to the list of chemicals subject

to the fee.

Ba.se ta.z amount

The Finance Committee proV1S10n impoeea a base tax amount

which is similar to the House bill. For calendar year 1990. the base

tax amount is 11.07 per pound of ozone-<iepleting chemical; for

1991. the bue tu amount is 11.12 per pound; for 1993. the base tax

amount is $1.67 per pound; for 1994 and beyond. the base tax

amount is 13.15. The bale tu amount is not indexed for inflation.

The Environment and Public Works Committee proviaion impoeeI a fee. The fee iI the i"ater of 60 cenu per pound of wed

chemical or an amount equal to the profit earned on the sale of the

chemical to the e%tent .uch profita exceed the profita earned on the

sale of.uch chemical in 1987. The Adm;niatrator of the EPA determin. the exceu profit amount by comparing total revenues generated from the sale of tued chemica1l to an allowance for revenues

pnerated from like ulee in 1987. Az1 offaet for Federal and State

iDcome tu liability is permitted. Distributors of taxed chemicals

are cruted an additional exemption of 60 centa per pound from

the exC*l profiu tu.

OzoM-depleting factors

The Finance Committee proviaion is identical to the Houae bill.

The Environmental and Public Works Committee provision does

not provide for an ozone-depletinc factor.

Exemptions and reduced rates of tax

The Finance Committee proviaion is identical to the House bill.

The Environment and Public Works Committee provision is the

same 88 the House bill with respect to exports and feedstock chemi·

cals.

Imports

The Finance Committee provision is identical to the House blll.

The Environment and Public Works Committee provision impoHS the fee on importation of wed chemicaa. but not on derivative producta.

Tru.tt fund

The Finance Committee proviaion does not establish a trust fund.

The Environment and Public Works Committee provision estatr

liahes within the Treasury an "Ozone Layer and Climate Protection Truat Fund." Fees collected are to be depoeited in the trust

fund. The ~roceeds of the fund are to be invested in interest-bearing obligations of the United States. Trust fund expenditure purpoeeI include implementation of the Montreal protocol. research

and development activities of the EPA. and to carry out the abatement and control a~i!ities of the EPA.

Effective date

The Finance Committee provision ia identical to the House bill. . The Environmental and Public Works Committee provision is effective July 1. 1989. for chlorofluorocarbons. and ia effective January 1. 1992. for halons. The Administrator of the EPA may. by regulation. change the effective dates.

Pagl13 December 1989

"W~SHINGTON REPORT"

UNEP Formulates CFC Options

\ ttAchment ';'

FEBRU1o.RY 1990

The U.S. Environmental Protection Agency (EPA), in a briefing held in

Washington for the Agency's Stratospheric Ozone Protection Advisory

Committee, reviewed the proposed amendments to the Montreal Protocol

considered recently at the United Nations Environment Program (UNEP)

meeting in Geneva.

The purpose pf the UNEP meeting was to discuss various options developed

by participating nations for additional restrictions on fully halogenated

chlorofluorocarbons (CFCs) and other ozone-depleting chemicals.

Participants attempted to refine and consolidate, where possible, existing

choices for review. A final round of negotiations will be held in London

before approval by signatory nations in June.

Currently, the UNEP Montreal Protocol, which took effect in July and with

which the United States is in full compliance places reductions on CFCs

11, 12, 113, 114 and 115 according to the following time table:

July 1989 - Cutback to 1986 production levels

July 1993 - Reduction to 80 percent of 1986 production

July 1998 - Reduction to 50 percent of 1986 production.

Halons 1211, 1301 and 2402 are to be frozen at 1986 production levels in

1992.

The Montreal Protocol also addresses other non-technical items including

special provisions related to international trade, production allotments

and special situations of the developing nations.

Additional CFC restrictions

Eileen Claussen, EPA's director of atmospheric programs, reported that a

broad consensus exists among the Geneva participants for a complete

phaseout of fully halogenated CFCs by the year 2000. Claussen emphasized

President Bush's earlier statement that the U.s. position for a phaseout

would depend on the availability of environmentally acceptable

alternatives based on the continuing reassessment of technology.

Various proposals were put forth by representatives of the attending

nations in Geneva related to additional interim restrictions on the

currently targeted CFCs with an understanding of a phaseout in the year

2000.
The UNEP parties which attended the earlier meeting in Nairobi and Cana

proposed:

1994 or 1995: Reduction to 50 percent of 1986 production

1998: Reduction to 15 percent of 1986 production.

The European Community proposed:

1991 or 1992: Reduction to 50 percent of 1986 production

1995 or 1996: Reduction to 15 percent of 1986 production.

EP~ reported that the Nordic nations with ~ustria, Switzerland, ~ustral

and New Zealand proposed:

1993: Reduction to 50 percent of 1986 production

1996: Reduction to 15 percent of 1986 production.

Japan did not support any interim reductions.

EP~ indicated that the u.s. position on any interim adjustments on the

reduction schedule in effect will be made in Spring 1990 as more

technology assessment information becomes available.

Possible HCFC restrictions

~lthough HCFCs have relatively low ozone depletion factors, world conce

over controlling additional chlorine buildup in the upper atmosphere ha

drawn attention to even the smaller contributors to the issue. HCFC 22

has a depletion factor of 0.05 (as compared to a depletion factor for C

11 or 12 of 1.0), and the new potential alternative for CFC 11 is Hcrc

which has an estimated depletion factor of 0.02. Three proposals were

placed on the table at the Geneva meeting.

As reported by EPA, the United States proposed a phaseout in new equipn

by the year 2020 or up to 2040 and in existing equipment by the year 2C

or up to 2060. The Nordic nations proposed a phaseout by the year 201(

2020 except in essential uses (which they defined as foams, refrigerat:

and medical applications); it was unclear whether "refrigeration" incl\

air conditioning. The European Community proposed the reporting of da1

on HCFC production (outside of any Protocol provisions).

As possible restrictions on HCFCs.are addressed in future UNEP negotia'

sessions, potential protocol actions may be tied to the specific ozone

depletion factor of the particular Hcrcs in question. For example,

restrictions may be applied only to HCFes whose depletion factors are

greater than 0.02.

-2-
f '

f -

i

i .

Halons

Also of interest to the ASHRAE community are halons, which have very large depletion factors (up to 10.0). Several proposals for additional

restrictions on the targeted halonswere presented. The U.S. position at

this time on halons is a phaseout by the year 2000 provided safe

substitutes are available (the phaseout may be possible by 1995 or 1996);

the U.S. supports no interim steps.

Canada proposed a complete phaseout (essential uses exempted) in the year

2000 with no interim reductions. The European Community proposal was

comprised of a 50 percent reduction from 1986 production levels in 1995 or

1996 with a phaseout in the year 2005. Japan proposed a 50 percent

cutback in the period of 1995 to 1997 with a phase out as soon as feasible

except for exemptions. The U.S.S.R proposed a 10 to 50 percent reduction

by the year 2000 with exemptions for essential uses (to be established by

each nation); EPA indicated that in order to be acceptable, exemptions

would have to be coupled to a particular list of applications.

Other chemicals

It is probable that other chemicals will be added to the Montreal

Protocol. Proposals (similar to those proposed for CFCs) were put forward

to include carbon tetrachloride and methyl chloroform. The United States,

along with the Soviet Union and Japan, proposed a freeze on carbon

tetrachloride (with feed stocks exempted) tied with a phaseout schedule

identical to that adopted for CFCs. The U.S. position on methyl

chloroform was a 25 to 100 percent cutback in production by the year 2000.

The base year for these chemicals will have to be determined.

U.S. Negotiating Strategy

Adjustments to the restrictions of targeted chemicals listed in the

Montreal Protocol requires a two-thirds approval of signatory nations

(representing at least two-thirds of the parties' production) and would be

binding on all parties to the Protocol. The addition of new targeted

chemicals (carbon tetrachloride, methyl chloroform and/or HCFCs) requires

an amendment process with a simple two thirds vote of parties in

attendance and voting.

The u.s. strategy is to package all provisions for newly added chemicals

into a single amendment. When adopted by the international body, an

amendment (which can address the addition of new chemicals or any other

topic) is subject to ratification by the individual countries. By putting

all provisions related to new chemicals into a single comprehensive

amendment, the international body may be able to avoid numerous small

individual amendments - each of which could be applicable to different

nations. Claussen indicated that "It will be a very tough negotiation

process to achieve a packaged amendment."

-3-
Series of Meetings Scheduled

The final decisions will take place when the full diplomatic conference

held June 20-29. However, there will be numerous meetings in the inter:

to· "slim-downll the number of proposals to an acceptable number from whit

a compromise hopefully can be attained in June.

The UNEP process involves factors other than the technical considerations. In working with nations with a wide spectrum of economies and

levels of industrialization, many considerations must be hammered out

particularly as related to developing nations. How will new technology 1

made available to developing nations? Should additional trade

considerations be implemented? Should funds be provided to assist

developing nations? . 1

EPA Lead Agency

The EPA serves as the lead agency on formulating the United States

negotiating position. To support the meetings at the international leVE .. the-Agency will continue with its assessments and analysis. The Adviso]

Committee is an integral part of the process.

The EPA Advisory Committee was established in the Fall 1989 to provide , Agency with "informed advice on policy and technical issues that relate

domestic and international aspects on the Mont~eal Protocol on substancE . that Deplete the Ozone Layer." The makeup of the 25-member advisory boc

is drawn from business and industry, educational and research

institutions, government bodies, non government and environm~ntal groupl . and international organizations.

-4-
! .

l .

l .

l •

•

..

,.... ""'.... : -'~4,- l',

THE DESTRUCTION OF

HALONS IN THE NORDIC

COUNTRIES

Jan BergstrOm, Raine Harju och Eva Hyden

Environmental Consultants

(MiljOkonsulterna

i 5tudsvik AB)

5-611 82 NYKOPING
SUMMARY

On behalf of the Nordic Council of Ministers' steering

committee for the halon project, Environmental Consultants at

Studsvik has studied the conditions for halon destruction in

the Nordic countries. This report investigates collection of

halons and the methods for the destruction of the halon bank

which can be put into operation within the next five years.

The halon bank is estimated at 3 000 tonnes. More than 80 %

of the halon bank consists of H 1301, i.e bromotrifluoromethane.

If the governments decide that halons must be actively

collected, this can be achieved without any technical difficulties. For this to succeed, it must be possible to reach

the end-users of halogenated fire extinguishers with information stating clearly that the fire-extinguishers must be

replaced by sending all stored halon to a specific collection

point. Collected halons can be stored pending destruction.

The cost of transporting and storing halons is insignificant

compared with the cost of destruction.

If the governments decide to initiate halon destruction in

the Nordic countries within the next five years, this would

clearly indicate the desire to set an example and a precedent.

The choice of the method of destruction would be based on

what is least hazardous to the environment. Therefore, the

cost of the destruction technique would not be the deciding

factor.

This report describes four techniques which can be put into

operation within a few years. In Denmark and Finland, halons

can be incinerated together with hazardous waste. It is

probably not possible to adopt a similar incineration

technique in Sweden since the amount of halogens which may be

supplied to the incinerator is restricted.
< f

It is our conclusion that the destruction of halons by

incineration together with combustible hazardous waste should

be avoided. Destruction techniques where aromatic compounds

occur should similarly be avoided. With such techniques, the

formation of persistent toxic organic compounds would not be

minimized. It is possible to compensate for this by adopting

more stringent requirements for flue gas cleaning and the

deposition of residual products.

There are two techniques which enable the destruction of

halons to be carried out without the formation of aromatics

such as dioxins arising from chlorine and bromine in the

process. These methods are incineration using fuel not

containing aromatics or destruction in a plasma reactor. In

both cases, the flue gases from the reactor are quenched in a

venturi cooler and the halogenated hydrocarbons are absorbed

in a multi-stage scrubber. The flue gases are then heated and

finally cleaned by a fabric filter. If the plant is sited

together with the hazardous waste incineration plant,

considerable advantages can be gained. The cost of halon

destruction is estimated at between SEK.25 and SEK 44 per

tonne.

If the capacity of the plant is adapted to the destruction of

both halons and CFCs, the destruction costs can be substantially reduced without any major disadvantages.
TABLE OF CONTENT

1 Introduction .

1 . 1 Background .

1.2 The project .

1

1

3

2 Halons

2.1

2.2

2.3

......................................

General .

The halon bank in the Nordic

countries .

Physical properties .

4

4

4

5

3

4

5

6

7

Handling before destruction ..•.............

3.1 Management of the halon bank .

3.2 Collection and storage .

Principles of halon destruction .

4.1 Halons as fire extinguishants .

4.2 Destruction of halons .

4 •3 Combustion .

4.3.1 Catalytic destruction .

4 • 4 Molten 1ron .

4.5 Plasma decomposition .

4 • 6 Reduction .

4.7 Supercritical water ...••............

Techniques ' _ .

Existing plants

New plants .

7 • 1 Capacity .

7.2 Environmental requirements .

7.3 Incineration .

7 .3. 1 Design .

7 . 3 . 2 Construction work .....•.............

7

7

8

10

10

10

12

13

14

14

15

16

17

19

21

21

22

23

25

27
, 1

, )

7.4

7.4.1

7.4.2

7.4.3

7.5

7.5.1

Molten iron .

Tests performed .................•...

P-CIG for halon destruction .

Pilot plant modification .

Plasma technology .

Design .

28

29

30

32

33

33

:

8

9

10

Economic evaluation .

8. 1 Investment costs .

8.2 Capital costs .

8.3 Operating costs .

8 . 4 5 urnrnary .

Environmental impact .

9.1 Emissions to the air .

9.2 Emissions to water .

9.3 Residual products .

Conclusions .

36

36

37

38

39

41

42

44

45

46

- I

References 48
1

1 Introduction

1.1 Background

Brominated fluorocarbons (halons) and chlorofluorocarbons

(CFCs) are the collective terms for a number of different

substances which contain chlorine, fluorine and bromine. The

basic substance is a hydrocarbon in which the hydrogen atoms

have been replaced. If halons and CFCs are released into the

atmosphere, they will partially decompose due to ultra-violet

radiation. The part of the substance that is transported to

the stratosphere is a significant contributing factor to the

depletion of the ozone layer.

An international agreement was reached under the auspices of

the United Nations in 1987, known as the Montreal Protocol,

concerning the successive reduction of the usage of halons

and CFCs. According to the agreement, the production and

consumption of halons shall be restricted to the 1986 level.

In the mid-eighties, the worl~ production of CFCs amounted to

about 1 million tonnes per year. 'The production of halons is

estimated at approximately 20 thousand tonnes per year.

Recent research has shown that despite the fact that the

amount of halons is insignificant, halons are a significant

contributor to the depletion of the ozone layer. Table 1

shows the estimated lifetime of the most common halons and

CFC compounds in the atmosphere and their ozone depleting

potential.
2

In the comparison provided in the table, the amounts are the

same for each substance. The ozone depleting potential of CFC

11 is used as a basis. The negative effect of the halons on

the ozone layer is 4 to 10 times greater than that of the

CFCs.

The halons are mainly used as fire extinguishants. Their fire

fighting properties are exceptional. One major advantage is

that human beings can usually be present in areas where they

are being used.

The quantity of banked halon is at present many times greater

than the annual consumption. There are very important reasons

why this bank should not be released to the atmosphere.

Halon can be replaced as a fire extinguishant in most fire

fighting equipment. The main area of technical difficulty is

dealing with areas where personnel must be present when the

fire extinguishant has been released. An example of such

areas is control rooms in nuclear power plants, aeroplanes

and air traffic control centers.
3

1.2 The projec~

In June 1989, Environmental Consultants at Studsvik was given

the task of evaluating the possibilities of halon destruction

in the Nordic countries by the steering committee for the

halon project of the Nordic Council of Ministers. The report

was to be presented no later than on November 15, 1989.

The objective of the study is to identify the technical and

economic conditions necessary for the environmentally safe

destruction of halons.

The report provides information on three main areas:

techniques for halon destruction.

evaluation of suitable siting for a destruction

plant.

general outline of the collection and storage of

halons.
- 1

I 1

2

2.1

Halons

General

4

.,

. j

One of the oldest halon fire extinguishants is carbon tetrachloride, CCl 4 . If combustion of CCl 4 is incomplete, the very

toxic phosgene (COCl2 ) is formed. For this reason, carbon

~etrachloride is no longer used as a fire extinguishant.

A large number of halons has been developed for use as fire

extinguishants. Table 2 shows the most common .

Table 2

Halons

Name

Halon

number

Chemical

formula Car- Fluor-Chlor- Brombon ine ine ine

Bromotrifluoromethane 1301 CF3Br 1 3 0 1

Bromochlorodifluoromethane 1211 CF2ClBr 1 2 1 1

Dibromodifl~oromethane 1202 CF2Br2 1 2 0 2

Dibromotetrafluoromethane 2402 CF2BrCF2Br 2 4 0 2

Methyl bromide 1001 CH3Br 1 0 0 1

Chlorobromomethane 1011 CH2ClBr 1 0 1 1

Dibromotrifluoromethane 2302 C2HF3Br2 2 3 0 2

Today, halon' 1~01 and 1211 are mainly used. The halons 1011,

1202 and 2402 are also used to a lesser extent.

2.2 The halon bank in the Nordic countries

Halon is not produced in the Nordic countries. The halon bank

has developed through the importation of halons from other

countries. No exact data is available, but an estimate of the
5

volume of the halon bank in the Nordic countries, carried out

by BTl (Brandtekniska ingenj~rsbyran) is presented in Table

3, ref (l).

Table 3

Total banked halon in the Nordic countries (tonnes)

Halon 1301 Halon 1211 Halon 2402 . !

Denmark 600 1000 80 - 100 10

Finland 350 330

Norway 600 - 1000 60 - 100 3 - 5

Sweden 930 - 1430 70

Total 2400 - 3780 540 - 600 13 - 15

The halon bank includes both hand-held fire extinguishers and

permanent installations.

2.3 Physical properties

The physical properties of halons used are shown in Table 4.

Table 4

Physical properties

Halon Halon Halon

3101 1211 2402

Chemical composition CF3Br CF2ClBr CF2BrCF2Br

Molecular weight 149 165 260

Boiling point (1 atm) °c -58 -4 +48

Density 20oC, fluid kg/dm3 1.6 1.8 2.2

Vapour press. at 200 C bar 14 2.5 0.35

Vapour press. at 700 C bar 42 9.0 2.0

Critical temperature °c 67 154 215

Critical pressure bar 41 42 35
, .

•- f

c J

6

The table shows that halon 1211 has a higher boiling point

than 1301. Therefore it does not vaporize as rapidly and is

more suitable for use in hand-held fire extinguishers where

an extinguishant with a good stream range is desirable.
7

3 Handling before destruction

3.1 Management of the halonbank

Halons are imported to the Nordic countries in large tanks.

These tanks are designed to withstand a pressure of 42 bars,

which is halon 1301's vapour pressure at 70oC.

The halons are taken from the tank and pressure vessels of a

suitable size are filled. The pressure vessel must meet the

stringent pressure vessel standards as regards material,

manufacturing and control.

For permanent installations, the discharge time of the

extinguishant should not exceed 10 seconds. In order to

guarantee this, the vessels are usually pressurized up to 25

or 42 bars. The pressure is selected depending on the time

required to empty the vessel. The propellant gas is nitrogen,

N2 . Nitrogen is also used as the propellant in hand-held fire

extinguishers, where the pressure is usually 14 bars.

Halons are also stored in pressure vessels by the users of

the fire extinguishers. Halon containers with a weight of a

few kilograms up to to a maximum of 250 kg are kept at

permanent installations. The halon content of hand-held

extinguishers varies from about 1 to 10 kg.

The volume of the halon bank has not been exactly determined.

It is even more difficult to obtain precise information on

the number of halon containers in existence. In order to

arrive at some estimate, it can be. mentioned that 4 730

hand-held fire extinguishers were sold in Finland in 1986.

The amount of halon 1211 contained in these extinguishers was

about 21 tonnes. Thus, each extinguisher contained on average

4 to 5 kg of halons. In Finland, halon 1211 is only used in

hand-held extinguishers. The bank of 1211 is estimated at 330

. )
·,

.., ,

· I

• !

, I

;. I

• 1

. I

· ,

· I

• I

8

tonnes. The number of hand~held fire extinguishers is thus

estimated at between 60 000 and 75 000.

When some of the major distributors of halons were contacted,

it was found that they should be able to reach more than 90 %

of the end-users of halon through their customer registers.

Halon containers are required to undergo hydrostatic testing

every fifth or tenth year. The testing is largely carried out

by the distributors. The hydrostatic testing requirement

provides a natural opportunity for contact between the

suppliers and end-users.

During hydrostatic testing, the halon containers are emptied.

There are established procedures for this. The extent of the

losses which occur in connection with the emptying of the

containers has so far been determined by the cost of halons,

not taking into account environmental considerations.

3.2 Collection and storage

If the governments decide that halons shall be actively

collected and stored, this can be achieved without technical

difficulty.

For this to succeed, it must be possible to reach the endusers of halogenated fire extinguishers with information

stating clearly that the fire-extinguishers must be replaced,

which entails sending all stor~d halon to a specific collection point. The users must be sufficiently motivated to avoid

discharging the halons, otherwise there is a risk that too

many individual users will consider that discharging the

small quantities of halons that they have is insignificant.

The premises of halon distributors can function as collection

points. The distributors must naturally be bound by contract

to provide this facility, and a fee for receiving and storing

the halons must be determined.
9

The storage of halon containers requires storage space, but

in general, no other major difficulties are associated with

this task.

The orily consequence of storing the halon bank for a long

period of time, is the cost of the bUildings used for

storage, since it is anticipated that most of the containers

will not be put to alternative use. In any case, because of

the pressure vessel classification of the containers, they

cannot be used for CO2 fire extinguishants.

The schedule for the collection of halogenated fire

extinguishants is mainly determined by the possibility of

obtaining a replacement for halons which conforms with the

safety reqUirements for fire extinguishing agents. This is

also the determining factor for estimating the volume of

storage space which must be set aside in each country or

region.

We estimate the annual cost for facilities for the storage of

halons to be SEK lSO/m2 . With certain arrangements, it should

be possible to store halons in such storage facilities at an

annual cost of SEK 400/tonne.

A general estimate of the cost of transporting the collected

halons to the destruction facility cannot be made. However,

it is clear that the transportation and storage costs for

halons are negligible compared to the cost of halon destruction.

" r

" .

r f

, " ,
, I

- ,

• I

l _

• I

, . 4

10

Principles of halon destruction

.,

_ I

. ,

, r

4.1 Halons as fire extinguishants

The fire suppression capability of halons is mainly due to

the fact that halogen radicals are released at a relatively

low temperature, 400 - SOO·C. Expressed in simple terms,

bromine steals the, OH radical which is important for

combustion. Water is formed and bromine is again released as

a radical. The chain reaction conti~ues and interferes with

combustion. If enough halons are used at the initial stages,

the fi~e will be extinguished. On the other hand, if a

moderate amount of halons is used on a blaze, this will only

result in the production of corrosive smoke.

The process is described in the following model. * is used to

indicate the radicals. Combustion occurs as follows:

2(H* + 0*

• OH*} - 20H* -~_}* + H20 + heat ( 1 )

"

- j

Halons interfere with the reaction as follows:

Heat + CF3Br - CF3 * + Br*

Br* + H* - HBr .

')

HBr + OH* - Br* + H20 ( 2 )

With halogen in the combustion gas (2) water (H20) is formed

by the hydroxyl radical. Without halogen, the hydroxyl

radical yields H20 + heat and combustion continues.

4.2 Des~ruc~ion of halons

Halon molecules can be decomposed by chemical processes or by

thermal processes, in principle, combustion. During combustion,

reaction (1) must be dominant. Enough energy must be supplied
11

at the same time that an excess of hydrogen and oxygen is

maintained.

A summary ~f the binding energies of the halons in use today

is provided in Table 5. A comparison with methane, dichloromethane and carbon tetrachloride is made. The term binding

energy refers to the amount of energy needed to decompose the

molecule into atoms.

The required energy can be supplied in very different ways.

Table 5

Binding energies for substituted methane molecules

- ,

, - .

Halon

1301

CF3Br

1211

CF2ClBr

Br

, F - C - F ,

F

Br

I

F - C - F •

Cl

Compared substance

Methane (CH4 )

H

I

H - C - H I

H

Binding

energy

kJ/mol

1739

1655

1593

. r

Dichloromethane (CHZCIZ)

H

Cl - C - Cl 1505 I

H

Carbon tetrachloride (CC1 4 )

Cl

I

Cl - C - Cl 1354 t

Cl
12

• J

4.3 Combustion

• j

• I

·,

During combustion, halons can react with hot gas with enough

excess hydrogen to decompose the halon molecules and to form

halogenated hydrogen and CO2 . The combustion process is

always controlled by the three t's, namely: !emperature, time

and turbulence. If halons are permitted to remain in hot gas

for a long time and if the mixing is good, the temperature

necessary for decomposition is not particularly high. Figure

1 shows the decomposition of methane, carbon tetrachloride

and dichloromethane as a function of temperature. The

residence time is 2 seconds.

- ]

i

- ,,

We igh t percent 1001:------1 ...----oo::::=---....... remaining

10 ,

\

\

.

01

o

G

X

\

.

methane

dich1oromethane 1

carbon tetrachloride

'00 I..-!L..-........~~~...........J...--'-~Jbo~ ............t-........~«J):::!:--'-.1--"""'--::900

,"' . ! Tempcrature-C

Figure 1

Decompostion of methane, carbon tetrachloride and dichloromethane as a function of temperature

The data in Figure 1 were obtained from laboratory experiments,

Ref 2, and therefore cannot be applied to combustion in

actual plants.

Laboratory experiments also carried out withhalons confirm

the data shown in Figure 1. The halons were passed through a
13

quartz tube filled with quartz balls. The residence time in

the reactor was two seconds. The destruction is shown in

Figure 2.

900

1301

800

2402 1211

t:

o

..-4

+J

..-4

III

o

~50 o

()

Ql

o

0'--..........

400 500 600 100

Temperature ·C

100... · -----__--:l......--~...,

Figure 2

Thermal decompostion of halons

. I

There is a sound basis for maintaining that halon destruction

by combustion in an excess of hydrogen is a technically

feasible method.

4.3.1 catalytic destruction

. I

The temperature during combustion may be reduced by using

suitable catalysts. Catalysts used in laboratory experiments

include platinum/titanium oxide and palladium/active carbon.

These experiments have shown that the fluorohydrocarbons

studied can decompose in a methane or steam atmosphere at

approximately 400 - SOO·C. The temperature can probably be

further reduced as a result of testing other suitable

catalysts.
• y

• f

1 i

" .,

. I

• r

. I

14

4.4 Molten iron

The energy needed to decompose the molecules can be supplied

by molten metal. The molten metal is a conductor of heat, and

fluorine and bromine which are released can be directly bound

as salts. Molten metal'containing sodium and iron has been

tested for this purpose.

MEFOS in Lulea, Sweden has a pressurized coal gasifier which

has also been test operated for chemical waste destruction .

Experiments with halon destruction in molten iron have also

been carried out in a smaller test furnace. The experiments

show that bromine and fluorine are released from the molten

iron in the form of dust-bound iron salts.

4.5 Plasma decompostion

The energy for the destruction of halons can also be supplied

by electricity, e.g in a plasma reactor. The amount of energy

supplied is so great that the molecules turn into plasma.

This plasma is formed in a continuous flow of an inert gas

such as argon or nitrogen, at atmospheric pressure. Plasma is

the physical state where the electrons of the molecules are

free from the nucleus. The physical states of matter are

illustrated in Figure 3.
15

.. PLASMA·

. !

1 Mio.

I >

10'000

I

I

1000 XXJroJ

TEMPERATUR£CKJ

100

I

I

10·

Figure 3

The physica~ states of matter

Laboratory experiments have been carried out by the National

Research Institute for Pollution and Resources (NRIPR), Ref

3, on the destruction of chlorofluorohydrocarbons in a plasma

reactor. These experiments show that a mixture of CC1 3F and

water in an argon atmosphere is almost fullY,converted to

CO2 , Hel and HF according to the formula:

4.6 Reduction

Halogenated hydrocarbons can be converted into hydrocarbon

(carbon) and sodium salts through reduction with sodium

naphthalenide. The reaction occurs when halogenated hydrocarbons are mixed with sodium naphthalenide in tetrahydrofuran.

In the interests of safety, it is recommended that the

pulverization of sodium and the mixing of sodium with

napthalene to produce sodium napthalenide should be done on
, ,

, ,

16

an industrial scale. skala. Sodium napthalenide must also be

handled very carefully to prevent contact with air or moisture.

The cost of the chemicals is also sUbstantial. This method

has been used for the small scale destruction of PCB.

· . 4.7 Supercritical water

· i

• 1

• J

• 1

C~emical reactions can occur very "rapidly and completely in

supercritical water. Supercritical conditions are achieved by

raising the pressure and temperature so that the liquid

assumes properties which resemble gas and liquid at the same

time. The critical point of water is 3740 C and 218 bar. The

pressure and temperature must therefore exceed these levels.

Halon destruction can probably be achieved by using this

technique. However, several years' work is necessary before

the technique can be evaluated and compared with the destruction techniques which can currently be carried out on a

commercial basis.
5 Techniques

17

Several of the methods of destruction described in section 4

require several years of development work with an investment

of several millions before they can become technically

feasible plant designs. At present, it is only possible to

evaluate thermal destruction from a technical, economic and

environmental standpoint. If halon. destruction. is to be

initiated within a five-year period at a plant located in one

of the Nordic countries, one of the following alternatives

must be chosen:

utilization of existing incineration plants for

hazardous waste.

utilization of the coal gasification facility in

LuleA.

construction of a purpose-built incineration plant

for halogenated hydrocarbons.

construction a plasma plant modified for halogenated

hydrocarbons.

If it is decided to use the incineration plants for mixed

hazardous wastes, no separate investment will be required.

Several countries have planned to considerably expand the

destruction capacity of such plants. Our assessment of the

consequences of this course of action is provided in section

6.

The other techniques would require an in-depth study of

technical, economic and environmental considerations before a

decision on investment can be made. In principle, the techniques are comparable, since they can be evaluated on the

basis of how they fulfil the need for destruction of the

halon bank in the Nordic countries alone. This comparison is

- !
• t

• I

· .

, j

. ,

18

provided in section 7. However, we assume that, in practice,

plant capacity will not only be suited to fulfil the need for

halon destruction, but also that of CFCs and other halogenated

hydrocarbons which can be gasified.
6 Existing plants

19

There are currently three plants in the Nordic countries

which receive and incinerate hazardous waste originating from

industry and the public. The destruction of combustible waste

is carried out in the same way. Most of the waste is fed into

a rotary kiln where it is incinerated. Final oxidization of

the combust.ion gases is carried out in a secondary combustion

chamber (after burner). Heat is transferred from the flue

gases in a steam boiler and the flue gases are cleaned by a

method which results in a dry residual product.

The plants are located in Nyborg in Denmark, Rihimaki in

Finland and Kumla in Sverige. In Norway, there is as yet no

facility for this purpose. There are detailed plans to locate

a plant in Mo in Rana,and in Denmark a third furnace was

recently taken into operation. Consequently, there is some

capacity which has not yet been utilized. Finland and Sweden

need additional capacity as soon as possible to avoid storing

the hazardous waste which is collected in these countries.

Finland has decided to invest in a new furnace in Rihimaki.

In Sweden, no decision has been taken as regards the siting

or financing of a new processing facility.

The combined halon bank in the Nordic countries would occupy

a small share of the plants' nominal capacity. In spite of

this, the high concentrations of halogens in halons mean

that a significant part of the destruction capacity is

affected. Since the existing plants are all equipped with

steam boilers, the corrosion conditions can also result in a

limited capacity for the halon flow.

In Sweden, the granting of a licence for the incineration of

hazardous waste has involved certain conditions which, in

practice, mean that halons cannot be destroyed in a Swedish

facility. This is due to the bromine content of halons. Only

waste which allows an instantaneous halogen load during

_ r
- I

· ,

· ,

• i

'I

. I

- r

20

combustion of less than 100 g/s may be supplied to the

furnaces in Sweden. The halogen load is defined as

(el + lOxBr) g/s. This condition has been enforced in order

to limit the production of chlorine and bromine substituted

aromatics.

The incineration of halons in furnaces where mixed organic

waste is destroyed at the same time, will, in our opinion,

lead to the substantial formation of bromine aromatics, such

as bromodioxines, bromophenols and bromobenzenes. At present,

no plant is regulated as regards acceptable emission levels

of these pollutants. We have assumed that the granting of a

licence to destroy halons in the existing plants would

involve requirements on limiting emissions which would be

more stringent than the current levels. This is mainly due to

the fact that the bromine load would increase considerably

compared to when the licences were previously granted.

It is not possible for us to estimate the cost of performing

halon destruction in the existing plants. However, if no

additional requirements on emissions control are made, it is

evident that it will be less expensive to conduct halon

destruction in the existing plants than in new, separate

plants.
7 New plants

21

It is possible to put into operation three different types

of plants for halon destruction in the Nordic countries

within a period of five years. It is uncertain when this can

be done, largely due to uncertainty as regards how soon the

decision on siting can be made.

However, if it is decided that the molten iron technique

should be used, the siting issue should be resolved. This

technique is not feasible without the substantial investment

represented by the existing coal gasifier in Lulea, Sweden.

As regards the other techniques we assume that they will be

located on the same site as an existing plant for handling

hazardous waste. Such a plant has the necessary infrastructure which would limit the need for investment. Halon

destruction involves a limited period of time and limited

quantities of waste

We have also opted for siting halon destruction facilities

together with already existing plants to en~ble a comparison

of all three kinds of plants in our cost estimate.

7.1 Capacity

The capacity of the plant is based on the assumption that

3 000 tonnes of halon will be destroyed within a period of

five years. The plant will be operated periodically or will

be capable of a day shift operation of 220 days a year. The

destruction capacity obtained on the basis of these

assumptions is 340 kg/h of halon.

The material to be destroyed is a mixture of halons and

nitrogen. The average composition of the halons is estimated

as shown in Table 6.
< 1

• 1

" ,

22

Table 6

Elemental composition of 3 000 tonnes of halon

weight %

Carbon 8

Fluorine 36

Cnlorine 3

Bromine 53

7.2 Environmental requirements

The environmental impact of the plant will be an important

factor in the choice of the destruction technique, as will

economic and technical considerations. Regardless of the

design of the plant, the surroundings are affected by transportation of materials personnel. This can affect siting but

not the choice of the process used.

In the design basis, the halon emissions from the plant are

assumed to be less than 1% of the quantity of incoming

halons. In order to reach this level, considerable effort

must be put into devising a system of handling halon

containers that prevents leakage during emptying. Stringent

safety arrang&ments are required. The total halon emission is

probably not affected by the destruction efficiency of the

processes, which should be higher than 99.99% for all the

cases.

In the design basis, it was assumed that all the techniques

would fulfil the requirements on emissions to the air, as

presented in Table 7.
23

Table 7

Emission factors

Dust g/tonne halon 20

Hydrogen chloride g/tonne halon 20

Hydrogen fluoride g/tonne halon 20

Hydrogen bromide g/tonne halon 20

Total hydrocarbons g/tonne halon 200

TCDD-equivalents ~g/tonne halon 1

Emissions to water are to a high degree affected by the

choice of technique, as well as by the amount and kind of

residual products which arise.

A reasonable, general requirement is that the technique

chosen results in the generation of a quantity of residual

products which is as small as possible, and a quantity of

substances hazardous to health and environment which is as

small as possible.

7.3 Incineration

Halons themselves do not contribute to the energy which is

needed for their destruction. Therefore, fuel is required.

The necessary excess hydrogen should also be provided along

with the fuel to guarantee the formation of HBr, HF and HCl.

The excess oxygen is controlled by the combustion air.

The carbon content of the halon mixture is low, only 8 %. If

a fuel without carbon is selected, i.e. hydrogen gas, the

risk of the formation of aromatic hydrocarbons is minimized.

However, hydrogen gas is expensive and is not a standard

fuel. A standard fuel, rich in hydrogen which is readily

obtainable is propane (LP gas).

- ,

- 1
• r

, ,

24

In order to ensure maximum safety to the environment, the

amount of excess hydrogen (H/(Fl+Cl+Br» which is supplied

during incineration in practice, must be >10. This is

probably a conservative estimate. In practice, the necessary

amount of excess hydrogen necessary in practice, may be

lower. Since this factor has a tangible effect on the fuel

consumption, it should be investigated experimentally, after

a decision to adopt incineration as a technique for destruction has been made. We do not have the resources available in

this study to investigate the issue more closely.

Fuel consumption and air requirements for the destruction of

340 kg/h halon with a large excess of hydrogen is shown in

Table 8.

Table 8

Incineration of halons with hydrogen gas or propane

Fuel rating MW

Hydrogen gas

3

Propane

6

• j

Excess hydrogen

(HI (F+Cl+Br) )

Halons

Hydrogen gas

Propane

Air requirement

mol/mol 10 10

kg/h 340 340

kg/h 90

kg/h 475

Nm3/h 2435 5900

With propane as a fuel, the thermal output of the plant is

doubled to maintain the excess of hydrogen. However, the fuel

rating of 6 MW means that the plant design is easily manageable.
25

7.3.1 Design

The plant design remains the same, regardless of the fuel

used. The reactor required is relatively small. The facility

is equipped with a propane station for the fuel supply. The

same applies for incineration using hydrogen. Propane can be

used as a cheaper form of fuel for startup, standby and

similar operating conditions. With a hydrogen gas consumption

of 90 kg/h it may be necessary to erect a separate factory

for the production of hydrogen gas if this fuel is used.

- ,

It is possible to avoid the relatively substantial costs that

this would involve if the siting is selected in connection

with a chemical industry producing a surplus of hydrogen gas.

A schematic diagram of the plant is provided in Figure 4.

Ic.cl/'UUO~

F...6tIC.

FILTER

Figure 4

Incineration plant

The fuel is burnt in the reactor, where the decomposition of

the halons is initiated. The halons remain in the secondary

combustion chamber (afterburner), for the necessary residence
, ,

- I

26

time and the mixture which is required for complete

combustion is achieved.

The necessary residence time in the reactor and the secondary

combustion chamber is estimated at four seconds. The reactor

and the secondary combustion chamber are both made of brick.

Once the gases have left the secondary combustion chamber,

they are cooled in a radiant-type cooler. The hot air

obtained is used in the plant for superheating the flue gases

before final cleaning. The flue gases from the recuperator

are quenched in a venturi cooler before the acidic gases are

removed by water in a multi-stage scrubber. The moisture can

be condensed and removed in the scrubber to limit the flue

gas flow rate. A multi-stage scrubber system for the removal

of the hydrogen halides from incineration is required, since

the quantities to be removed are considerable. The acid

effluent from the cleaning process is neutralized and filtered

before being taken to the recipient.

The flue gases from the scrubber are mixed with hot air to

attain suitable conditions in the fabric filter used for the

final stage,of the flue gas cleaning.

The composition of the flue gases from incineration is shown

in Table 9 when hydrogen and propane are used as fuels.
27

Table 9

Flue gas composition before scrubber

Flue gas

Vol %, dry gas

Flue gas flow,

H20

Flue gas flow,

nm3 jh dry gas

vol %

nm3 jh

Hydrogen

85.9

1.8

5.3

0.2

5.0

1.8

100.0

2900

24

3800

Propane

81.6

11.0

4.5

0.1

2.1

0.7

100.0

7200

11

8030

7.3.2 Construction work

It is assumed that the plant for the process described on the

previous page will be located on the same site as a similar

plant. The financial investment can thereby be limited, since

an infrastructure, in the form of bUildings, personnel,

workshops and control systems will already exist and can be

used.

In our cost estimate, we have assumed that the flue gases can

be led to a flue gas cleaning facility in an existing plant,

,thereby making'separate stacks unneccessary. We also assume

that the effluent can be cleaned together with effluent from

the already existing plant.

We have not considered unfavorable site conditions and other

factors which affect cost when assessing the scope of the

construction work.
· .

, ,

, I

· /

• l

I

- j

,

j

"I

· /

· )

• l

t

- 1

, I

28

The items in the cost estimate are shown in Table 10.

Table 10

Scope of the construction work

Halon handling plant

Construction of plant and connection to existing systems for

electricity and water and sewage

Liquid petroleum system

Hydrogen system (only for hydrogen-based technique)

Reactor

Secondary combustion chamber (afterburner)

Radiant-type cooler

Quench

Scrubber

Connection to existing water cleaning system

Connection to existing flue gas cleaning system

Power system

Control and monitoring system

Measurement instrumentation

7.4 Molten iron

Pressurized Coal !ron ~asification (P-CIG) is a process for

the gasification of coal which is injected into a slag

covered iron bath along with oxygen. The temperature of the

melt is approximately 1 4500 C. The main functions of the melt

in the process are to:

to transfer heat to the coal particles

to act as a buffer to the coal to ensure an even gas

composition

to take up and transfer the sulphur in the coal to

the slag
29

A schematic diagram of the gasifier is provided in Figure 5.

Liquic ~lag

Molten lron

Gasification zone

Nozzle

Figure 5

Vertical steel converter type gasifier

The gasifier has a lining made of brick. The molten iron can

either be supplied from an external smelting furnace or be

obtained from melting scrap iron directly in the gasifier by

gas or oil-firing.

For several years, the Swedish National Board for Technical

Development (STU) has supported the development of the P-CIG

process. At present there is a pilot plant as well as a

demonstration plant for the technique at the the

metallurgical research station in LuleA, MEFOS. The pilot

plant has the capacity for to handle 50 tonnes of coal/day

while the larger demonstration plant has a capacity for 250

tonnes of coal/day. The pilot plants would have sufficient

capacity for halon destruction.

. 1

7.4.1 Tests performed

When heated, the halogens in halons form salts easily due to

their high electron negativity. In order to check this, STU

granted funds to Interproject Service AB, Bettna, to conduct

a test campaign on the destruction of halon in an iron bath.
.. 1:

30

, ,

· ,

Experiments on the destruction of halon 1301 were carried out

during the summer of 1989 in a laboratory furnace at MEFOS.

The furnace had a capacity for 150 kg of molten iron and was

heated by induction. The halon was injected by a lance into

the molten iron.

• t

, J

• 1

Six series of tests were carried out in all, one of which was

a reference test. The measurements carried out in connection

with the tests show that bromine and fluorine are released

from the molten iron in the form of dust. A characteristic

dust formation occurs when the halon is injected into the

molten iron. In addition to bromine and fluorine, the dust

contains large quantities of iron, which indicates that the

halogens have formed iron salts. A certain amount of PAH,

Br-benzenes and Br-phenols are also released with the dust.

7.4.2 P-CIG for halon destruction

- ,

The thermal capacity of the pilot plant for coal gasification

corresponds to 15 MW. Its capacity is thereby greater than

that of the plant using a combustion technique. Figure 4 is a

schematic diagram of the pilot plant.

Fwe Q4.S SAHPuN6

CJ.E.."IN' NC:.

F£EO

Figure 6

Schematic diagram of P-CIG
31

The substance to be gasified is injected together with oxygen

through nozzles at the bottom of the reactor. Gasification is

carried out in the molten iron through the partial combustion

of coal which forms carbon monoxide. Hydrogen and iron

halides are formed at the same time. The feed material, e.g

halons, has a short residence time in the molten iron - less

than one second. Halon decomposes due to the good heat

transfer conditions and the high temperature in the molten

iron.

With the present plant design, the gas and dust from the

reactor pass through a slag separator in the gas line prior

to cooling and dust removal in a wet scrubber. The temperature

of the gas on entering the scrubber is approximately 1 ZOO°C

and the total residence time of the gas and dust in the

system before reaching the scrubber is approximately Z - 5

seconds.

Table 11 shows the calculated flow rates for the destruction

of halon 1301 using the P-CIG process.

Table 11

Flow rates for the destruction of halon 1301

, ,

Incoming

Halon 1301 (total)

of which

C

Br

F

Required 0z

Required Fe

Outgoing

FeBrZ

FeF3

Flue gases

kgjh

kgjh

"

1 000

81

537

383

78

563

726

759

407
< ,

. ,

32

As a first step, the interested parties propose that a test

compaign be carried out in the pilot plant to verify the

calculations and results obtained from previous experiments.

The test operations will comprise two test campaigns each

involving operation of the·plant for a week, destroying 10 to

20 tonnes of halons. The aim is to take comprehensive measurements during the test period. If the test operations indicate

that the technical and environmental requirements have been

fullfilled, the next step will be to modify the plant to

carry out halon destruction on a commercial basis.

7.4.3 Pilot plant modification

. r

, j

Interprojekt Service AS has expressed its willingness to

continue the development work with MEFOS and other interested

parties and modify the plant for halon destruction .

A cost estimate has been performed for the development work

and for certain specified plant modification work. The

estimate covers the replacement of the brickwork and the

addition of a ceramic liner to the reactor. The estimate also

includes the acquisition of additional instrumentation and

measurement systems as well as changes in the system for

handling the substances to be gasified. A new wet scrubber

system for the removal of dust has been bUdgeted for.

However, this does not include a fabric filter and sludge

treatment has not been specified in detail.

In the cost estimate we have taken into account certain

investments which are already known, including equipment for

handling halons, so that the emissions requirements can be

met.

The destruction of halon is estimated to be completed within

five years. It is planned that the plant will be operated

periodically, with three operating periods per year. During

each operating period, 200 tonnes of halons will be destroyed
33

in 20 operating days. -It is anticipated that the plant will

be operated in two shifts for ten hours a day.

7.5 Plasma technology

The development of plasma technology for the destruction of

hazardous waste is being carried out in many different

companies and organizations.-In-Norway, Kv!rner Engineering

and SINTEF are involved in joint work on plasma technology.

These companies are planning to put a prototype plant into

operation during autumn 1989. The plant will have an output

of 100 kW and will be used for research and development work.

It can also be used for tests on the destruction of certain

substances, for example, halons. In Sweden, SKF Plasma

Technologies AS is working with plasma technology for the

destruction of substances, including hazardous waste.

During the past year, at least two proposals have been put

forward for commercial plants using plasma technology for the

destruction of hazardous waste. Two small-scale plants have

been proposed by companies which are prepared to enter into

negotiations for a contract to construct these plants. One of

the systems- is supplied by Nutrail Corporation, Mass, USA.

The system is called the SSP process. MGC Moser Glaser in

Basel, Switzerland markets a plasma technique, known as the

MGC process, which is similar in principle. We will describe

the MGC p~ocess since we have obtained details on this

particular technique.

7.5.1 Design

The MGC process for the destruction of solid and liquid

wastes is shown in the schematic diagram in Figure 7.
, ,

< ,

34

::..1 t €::-131

30 1 cr ZOO 1 :;or~~t

~~~=aulic systere

S<.:rE\; reeder

) Direct ?lasma bur~~r

b C~ntrifugal reactcr

· ,

• i

• J

d

9

10

11

12

13-17

18

After burner/oxidation

Quench

Control station

Energy supply

Gas supply

Cooling water supply

Flue gas scrubber-Flue gas

Analysis

Plasrr.a - Ultrahigh ter:r~era,:'..:re ?"'~;:.

h. I

• J

Figure 7

The MGC process

For halon destruction, the plant does not have to be equipped

with equipment for handling drums. However, this does not

seem to have a significant effect on the total cost of the

plant.

The plasma is generated by a direct burner, which allows a

long residence time for halons in the plasma. The reactor

consists of a centrifuge where the slag is collected. When

substances wpi~h do not form slag are destroyed, such as

halons, a matrix of silica (sand, glass etc) must be

provided, since the slag is the anode in the process.

Unlike combustion, the substances in this reactor are heated

without the addition of external oxygen. Argon or helium are

used as inert gases in the reactor. Any hydrogen necessary

during the destruction process, is supplied to the reactor as
35

methane or water. Tests have been carried out using methane

• in the reactor in the aim of increasing the lifetime of the

Cu electrode. Tests with halon destruction must be carried

out to investigate whether the anticipated reactions occur

and can be checked.

When the plasma leaves the reactor, it is cooled and the

gases are oxidized with oxygen gas (02) in a reaction chamber.

The temperature in the chamber can be held at 2000°C. By

using oxygen directly, the volume of the flue gas is less

than that from ordinary combustion. However, it should be

necessary to supply air to cool the flue gases before they

reach the scrubber system. The flue gas cleaning system

handles the same flue gas components as those arising from

combustion. Therefore, the requirements for and the design of

the flue gas cleaning system are the same regardless of the

type of reactor used.

At present, we do not have the necessary information on

construction and design for a cost estimate.

MGC Mosel Glaser has stated that a plant with a capacity for

handling 7 000 tonnes/year of mixed hazardous waste would

cost MSEK 100. We have assumed that this waste would consist

of 50% organic material. With this design the plant would be

overdimensioned. We have therefore scaled down the costs to a

level that we consider applicable to a plant with a capacity

of 600 tonnes/year.

. ,
• J

< 1

· !

· I

• I

· ,

36

8 . Economic evaluation

The decision to invest in a particular plant cannot be based

entirely on the cost estimate. However, it can be used to

distinguish between the capital required and the funding

required due to other factors affecting the cost of the

destruction process.

I

• f

• 1

8.1 Investment costs

• j

. .~

When estimating the cost of the incineration and the plasma

techniques, it has been assumed that the plants will be

located on the same site as an existing plant in the Nordic

countries. The cost of determining the final site has not

been taken into account in the investment costs. With the

P-CIG alternative, it is assumed that the equipment at MEFOS

in LuleA will be used.

The costs are based on the price levels for autumn 1989.

Interest and other financing costs arising during the construction period have not been taken into account since this

requires a knowledge of the form of financing to be adopted.

Information obtained in consultation with plant and component

vendors was used as a basis for the cost estimate. For the

P-CIG technique, estimates were obtained from Interproject

Service AB. MGC Mosel Glaser submitted certain estimates for

the costing of the plasma process. In addition to this, we

used our experience from other projects of a similar nature

as a basis for the cost estimates.

The scope of the construction work was presented in section

7. The investment costs, divided into main categories, are

presented in Table 12.
37

Table 12

Investment costs, MSEK.

Combustion

Technique Hydro- Propane P-CIG Plasma

gen gas

Development 3 3 6 1 - !

Licence acc. to ML, PBL* 2 2 2 2

Plant 43 45 14 30

Uncertainty 10% 5 5 2 3

Investment 53 55 24, 36

* Corresponding legislation in other Nordic countries

8.2 Capital costs

The capital costs for all the techniques are estimated on the

basis of an assumed amortization period of 5 years. The

capital costs are calculated for the total investment in each

case, including the development and licencing costs. With an

assumed interest rate of 15%, the fixed annual instalment

factor is a • 0.3.

The capital costs for the different techniques are shown in

Table 13.
• f

38

1 , Table 13

Capital costs

1

Combustion

• 1 Technique Hydro- Propane P-CIG Plasma

gen gas

.. , Investment, MSEK 53 55 24 36

Capital cost, MSEK 15.8 16.4 7.2 10.8

8.3 Operating costs

This heading includes costs for personnel, fuel, handling of

residual products, maintenance and repair etc.

• r

The personnel requirement for both the combustion and plasma

techniques is estimated to correspond to four man years. The

cost for one man year is estimated at SEK 230 000.

The P-CIG plant is operated periodically. Interproject

estimates that the cost for personnel including preparatory,

plant operation and post operation work amounts to MSEK

3.4/year.

The operating and maintenance costs for the combustion and

plasma techniques have been estimated at a flat rate corresponding to 3 % of the investment. In addition to these

running costs, the combustion technique results in an annual

cost of MSEK 0.6 for the replacement of the brickwork in the

combustion chamber. The plasma technique involves a similar

amount for the replacement of the electrode. The fuel costs

(propane, hydrogen gas) and electricity have been calculated

according to the current price levels in Sweden.

Interprojekt has estimated the annual operating and

maintenance costs for the P-CIG process, at MSEK 8.8 MSEK.
39

The cost of the necessary replacement of the brickwork in the

reactor etc is also included.

The operating costs for the different techniques are summarized

in Table 14.

Table 14

Total operating costs, MSEK - !

Hydrogen gas

9.5

Propane P-CIG

5.0 12.8

Plasma

4.1

The operating costs for propane incineration and plasma are

relatively low because of the proposed use of these

techniques in conjunction with the destruction of other kinds

of hazardous waste. The same applies to hydrogen, but the

fuel costs are higher. The operating costs from the P-CIG

process are high due to the periodic operation of the plant

with contracted personnel and resources.

8.4 Summary

Table 15 is a summary of the costs of the different

techniques. The table also includes the unit cost of halon

destruction.

; -
. \

• I

. 1

Costs:

capital, MSEK

operation, MSEK

Annual cost, MSEK

Destruction cost,

SEK/kg

15.8

9.5

26.5

44

16.4

5.0

21.4

36

7.2

12.8

20.0

33

10.8

4.1

14.9

25

In the summary, the highest cost is obtained from the use of

the combustion techniques. This may be due to the fact that

we are more familiar with the consequences of this technique.

The other processes do not exist in the form of plants

operating on a commercial basis.
9 Environmental impact

41

, ,

. I

The economic considerations should not be the only deciding

factor in the choice of technique and siting. The environmentai impact of the plant can affect the final decision to a

large extent.

Regardless of the technique used, the environent will be

affected through the transportation of the substances.

Similarly, the halon emissions are estimated to be 1 % of the

amount supplied to the facility.

Halon destruction entails a considerable specific energy

consumption in connection with collection, storage and final

destruction. This is largely the case, regardless of the

technique used. However, it can be noted that halon destruction in already existing plants is carried out without the

need for extra energy in any measurable quanity. The destruction of halon only results in a reduction of the capacity to

handle other products containing halogen. Because of the

capacity for the destruction of hazardous waste which will be

available in the Nordic countries during the nineties this

effect may be negligible. The halon bank is very small when

compared with the quantities of chemical waste products.

The decision to destroy halons is based on the substantial

ozone depleting potential of halons. In the light of this,

the energy consumption involved in the use of the different

techniques is hardly of interest. The different techniques

use very different energy carriers.

The destruction of halons using the P-CIG process, involves a

high consumption of energy from coal or electricity since for

each tonne of halon destroyed at least half a tonne of molten

iron is used. The total energy consumption resulting from the

use of the other techniques is lower and does not vary

greatly from technique to technique.
. ,

't

• r

42

We are limiting this description of the environmental impact

to a comparison of the new techniques and the factors which

are not dependent on siting conditions, but which are

different for each technique.

The destruction of halons in the existing plants is not taken

into account, since the effect of the additional halons

cannot be specifically measured. For this to be done, the

substance which is destroyed along with the halons in the

furnaces must be defined. Neither the flue gas emissions,

residual products nor any other environmental factor, such as

noise, need be measurably affected. At the same time, it is

obvious that if halon destruction is performed by increasing

the halogen load in the combustion process, more chlorine and

bromine aromatics will be produced in the plant.

9.1 Emissions to the air

When dimensioning the plant for the different techniques, we

have taken into account general requirements concerning

emissions to the air. However, the processes involve different

flue gas flow rates. For this reason, the total emissions

will be somewhat different.

However, all the techniques are well within the limits of the

emission requirements which can be anticipated in connection

with the licencing. Table 17 is a summary of the anticipated

annual emission.
43

- ,

Table 17

Emissions to the air

Combustion

Technique Hydro- Propane P-CIG Plasma

gen gas

Flue gas flow, m

3 /h* 2900 7200 400 2900

Halon flow, kg/h 340 340 1000 340 - I

Annual halon

destruction, tonne 600 600 600 600

Emission:

hydgrogen chloride, kg/yr 5 12 0.2 5

hydrogen fluoride, kg/yr 5 12 0.2 5·

hydrogen bromide, kg/yr 5 12 0.2 5

Total hydrocarbons 50 120 ? 50

TCDD equiv. acc. to Eadon

mg/yr 0.5 1.2 ? 0.5

* 3

m dry gas with 4 % 02

This assessment of the quantities of substances emitted are

based on calculated equilibrium quantities and detection

limits when determining emissions from the plants.

Ouestion marks are used in the table for the P-CIG technique

for the same reason that the conclusion was drawn that the

emissions of. ~orresponding pollutants cannot be specified for

halon destruction in existing plants. It is not possible to

determine how any halogens released during the destruction

process substitute gasified organic substances originating

from the coal used in the process.
'f 1

· J

• 1

· ;

· ,

· ,

44

There are good reasons for assuming that the other techniques

result in very small emissions of organic pollutants,

especially of the aromatic type, since no aromatic rings are

supplied with the fuel.

It should only be possible for these pollutants to occur as

impurities in the halons or to be formed in the process.

9.2 Emissions to water

With a destruction capacity of 340 kg/h of halons with the

composition shown in Table 6, an effluent is obtained from

combustion and plasma, containing halogens, as shown in Table

18.

Table 18

Halogen content in effluent

Effluent flow rate

F

Cl

Br

6

0.5

9

gIl

gIl

gIl

· I

Total halogens 15.5 gIl

This acidic effluent can be neutralized with sodium hydroxide

and sent to a recipient as dissolved salts. If it is neutralized with lime, most of the fluoride is obtained as

sludge. Chlofi?e and bromide are sent to the recipient as

dissolved salts. The choice of method is probably wholly

dependent upon the siting of the facility.

An effluent is obtained from the P-CIG process with a high

dust content, mainly of iron. It is possible that the quantity

of effluent sent to the recipient can be lower from this

process, while the amount of sludge handled is greater.
45

The environmental protection analysis should result in the

implementation of safety systems enable detailed analyses to

be done before the effluent is released.

9.3 Residual products

Solid residual products in the form of sludge from effluent

cleaning mainly occur with the P-CIG process. The production

of sludge amounts to 6 t/h or 600 t/yr. The quoted amounts of

sludge mainly consist of iron dust. The sludge will contain

most of the halogens as iron salts. These salts can form

hydrogen bromide and hydrogen fluoride if moisture is present.

More or less the same quantity of sludge arises from combustion if the fluoride is trapped with lime.

The sludge will probably be handled as hazardous waste and be

deposited at a controlled depository which is dry and leaktight.
, !

.' -

• j

" !

" I

i

I

• J

, !

46

10 Conclusions

In the Nordic countries, there is a bank of about 3 000

tonnes of halons. This is a small share of the global amount

which" depletes the ozone layer in the stratosphere. If the

Nordic countries find reasons for coming to a decision

regarding halon destruction before any international agreement is reached on how this is to be done, this will be a

clear indication of the desire to set a precedent for the

rest of the world. Therefore, it is logical to conclude that

the choice of a method of destruction will not be based on

the cost of the technique but on what is least hazardous to

the environment.

The destruction of halons should therefore be performed so

that the conditions for the formation of persistent toxic

organic ~ompounds is minimized. The halogen substituted

aromatic compounds are greatly enriched in the environment

and can lead to unforeseen problems in the future.

The destruction of halons by incineration together with

hazardous waste should therefore be avoided, as well as

processes involving the occurrence of large amounts of

aromatic compounds which can be substituted by halogens. In

each case, it is necessary that the requirements on flue gas

cleaning and deposition of the residual products be adjusted

in plants which are to be used for halon destruction.

There are two techniques which are preferable for the destruction of halons in the Nordic countries. One is incineration in a separate furnace and the other is destruction in a

plasma reactor. In both cases, the mixture of the flue gases

will be more or less the same regardless of how the energy

for the destruction process is supplied.

A decision as regards which of the two processes is optimal

'from a technical and economic standpoint should be deferred
47

until the point of investment. At the present, the description of the environmental impact of the plasma facility is

not accepxable since there is no operating experience for

such plants. However, this situation may improve within a

year. If the decision is to be made at present, combustion

according to the process description given in section 7 is

preferable. At present, it is the only alternative which can

be defined in operational, economic and environmental terms.

Combustion using hydrogen as fuel provides maximum safety.

However, use of this fuel involves a higher risk of operational interruptions than propane.

If it is decided to destroy halons separately in the plant

for environmental reasons, hydrogen should also be used as

fuel. If it is decided that halon should be incinerated

together with CFCs and other halogenated hydrocarbons,

propane is adequate as fuel. This applies in any event, if

CFCs mixed with oil are to be destroyed in the plant.

_ t
., -

, ,

; k

48

References

, ,

· ,

· ,I

! · I

1.

2.

3.

Anvandning av halon 1301 och 1211 som slackmedel i

Norden.

Nordiska Ministerradet 1985:65

(Compiled by Brandtekniska Ingenj6rsbyran AS)

DELLINGER, B, TORRES, J L, RUBEY, W A, HALL, 0 L,

GRAHAM, J L

Determination of the thermal decomposition properties

of 20 selected hazardous organic compounds.

University of Dayton, Research Institute, Environmental Scinences Group.

KOVICHI, MIZUNO

Destruction of CFBs by thermal plasma reaction

method.

National Research Institute for Pollution and

Resources.
Week Ending

January 5

January 12

MINISTRY OF EH'VIROHJmN!1' AND FORES~S

CFCs IJf IHDIA

Avani Vaish

Director, MiDistry of Environment and Forestry

Phase I Work Plan

Tasks

1. Agreement on workplan between MOEF1 and SBB/TR/C&w2.

2. SBB briefs C&W on uses and manufacture of CFCs in India.

3. C&W prepares initial listing of technical options

relevant to India.

4. SBB finalizes C&W technical visit program.

5. Agreement on structure and content of Phase I/Interim

Report by SBB/TR/C&W.

6. TR prepares definition of "transition costs."

1. C&W program of technical visits starts.

2. TR investigates:

market structures

economic background

industry development

3. C&W expands/develops their statement of technical

options.

4. SBB completes data collection and analysis.

1MOEF is the Ministry of Environment and Forestry

2SBB, TR, and C&W are private consulting firms.
Week Endina

January 19

January 26

February 2

-2-

Tasks

1. C&W completes program of technical visits.

2. saa commences drafting Interim Report - Part A.

3. TR investigates industry structures.

4. C&W completes statement of technical options and

technical risks.

S. TR drafts Interim Report - Introduction.

6. Tr develops demand projections, with saa support.

7. TR prepares sectoral analysis for reduced use of CFCs.

1. saa completes drafting of Interim Report - Part A.

2. C&W makes technical presentation to MOEF and technical

experts on "the options for India."

3. C&W commence drafting I~terim Report - Part a.

4. TR prepares CFC production reduction analysis (and

feedstocks).

S. TR prepares "scenarios for 1111111"

6. TR commences drafting Interim Report - Part C.

7. saa presents "CFC use in India" to MOEF.

1. saa draft of Interim Report - Part A to MOEF for review

(and to TR and C&W).

2. TR presents "Targets and Scenarios" to MOEF.

3. C&W completes drafting of Interim Report - Part B.

4. Tr prepares cost implications of main scenarios.

S. TR continues drafting Interim Report - Part C.

, ,
Week Ending

February 9

February 16'

-3-

Tasks

1. TR completes drafting Interim Report - Part c.

2. Tr drafts "Executive Summary."

3. Production and internal review of draft report.

4. Draft report to MOEF for review.

1. MOEF reviews draft report.

2. Consultants meet MOEF to discuss comments/reactions/

suggested revisions.

3. Interim Report revised to take account of MOEF comments.

4. Interim Report - Final submitted to KOEF.
iJrtlltllti1JUL'

Latest News

I

1

1

Return to:

Circulation list

"arne Date

Contents

Editorial .....

Brian Ellis Honoured

Ozone Layer Protection

Thought for the Day

Letter to [he Editor

;\lew Year's Thoughts

Telex .

The Ballad of the Zone

of Ozone ....

Pr\lI\)Ol~U( ~e.. , I' J pr\Jtt::-:' "".r:::~" ,,:.,.:-..,_:~.,: .. -:~.

v{·.:h.ltge to tnlertSled p.:ll'tIC' It." :',\,(' '~' .... ..'.' ... ~.

SA re-.ef'\"e." the nght to ret"u,c JC<'J:. - ... -'.~' .'

bcln~ nel."(sso11'~ All m.!tcnJI pl,;[,j;<'c',: .~ .

PSA. lloNtJ . .lll nght.... rcscf'\.cd \'l' "t";'I.'r.·,~

fur l'plOlon, c,pre ..,ed there;;. D,,,:· ... _.

I.:l)untnc, l"lhrou~h Protooh.jue ~~~ ... >

continued on neXI pa'i(e.

Brian Ellis Honoured

by U.N.

The General Director of Protonique

S.A.. Brian Ellis. has been honoured to

receive a Citation of Excellence from the

Cnited Nations Environment Programme

"in recognition of an outstanding contribution to the protection of the Earth's

Ozone Layer".)

As most of you are probably aware. the Solvents Technical Options Comminee reponed to the United Nations Environment Programme last Summer

In view of the Helsinki Declaration. at which the Parties to the \-lontreaJ

Protocol agreed that more severe measures were necessary. ameeting wa..., held

in Nairobi starting last August at which the various Committee reports \\ ere

accepted. The Parties to the Protocol are now studying the various possibilitle'>

of revision. which will take place in June 1990.

What can we expect from this first rapidly. It would produce the rna,t rJplJ

revision.' It is impossible to forecast the reducllon in stratospheric .:hil'rlnc:

decisions but. as far as solvents are con· levels possible. Within ate.... JeCJJc:'

cerned. the situation is clear. The follow- Lnfortunately. a phase-out .... ould!:'.:

ing. under reserve. indicates the general more difficult than with the CFC '01-

lines of thought behind any reVision: vents. It seems likely that thb ,ub,tJn.:c:

.Ithe calendar may be modified. Instead may become severely restncted. but J

of a 50% reduction ofCFCs by 1998. we complete phase-out i~ unlikel:

can expect at least a 90'7c reduction (pos- .Isome new solvents rna: be Included.

sibly 100'7c) by 2000 and a 100'7c by Concern is expressed that ,orne ,1( the

2005. It is notlenown yet whether or how

these reductions will be scaled.

.Iother CFCs may be included. CFC-112

may be brought into the Protocol.

.Icarbon tetrachloride may be included.

This is amongst the worst ozone

depieters iother than halons which some

class it with) and It may be a surprise to

know that about 70.000 tonnes are still

emitted each year. despite its known

carcinogenicity. A complete phase-out

of this substance as a solvent within the

Protocol as soon as possible is probable.

.Il.l.l·trichloroethane may be included.

This substance. also known as methyl

chloroform. IS a moderate ozone

depleter but it IS used in such vast quantities that the total effect is nearly as

great as thaI of CFC-113. Due to a relatively short lifetime. if it is phased out

Editorial

When we sent out the first number of

Pmtonique ,Ve.....s. we were a little apprehensive as to how it would be received.

lt may be qualified' as a semi-success.

Those that we sent out directly to known

customers (about 5(0) were accompanied

by a reply card. Where our agents sent out

copies (about l.OOm to their customers.

we asked they did the same. We received

back -l7.jusrunderthe traditionallO'7c for

such a mailing. Of the ones we received.

three had favo~rable comments and noone made any unfavourable ones. All of

them had the square requesting a continuation of reception ticked. In a few

cases. we received photocopies of the

card. as the News was circulated amongst

several persons. About half the cards

received back requested literature on one

or more of our products. One of them has

even resulted in an important order.

On the whole. we find this good. but

what are we to think of the 90% who did

not send back the card? Does this mean

that these persons do not wish to receive

it. or does it mean the card got lost'? Worse

still for us. who have gone to such pains

to produce a short newsletter which we

have tried to make as interesting as possible. does it mean that it was relegated to

the waste-paper·basket without even

havmg been read or that it arrived on the

desk of the wrong individual? A plea! If

you receive this andyou think it concerns

a colleague, pass it on to him, please.

To try and get more feedback. we are including this time a card in all the copies

(the circulation list is currently about

1600. including those sent through

agents). Please ensure we get back as

many as possible. and especially if you

do not wish to continue receiving Protoni·

que News•. Also. to help companies who

are not sure who is the right individual. we

have drawn up a blank circulation list to

help you pass it round. If you have a col·

league who would like his own copy. there

is space for his name on the accompanying card•.

To end this self-imposed "bouquets and

brickbats" department. we have received

exactly one letter on this subject which we

have translated from French and

reproduced here. It makes us quite proud.

The person who wrote it has requested

that we do not publish his name. address

or Company and we respect thiS wish. J

" l
2 ProtonJque News Voi. 1. No.2

Schematic of available substitutes for CFC-11 3

Thought for the Day:

Many have said that ifthe summer of/989 is anything to jlid~e hy. Lon!!.

the Greenhouse Effect! But ifthe summer of/989 isjusta smull-s(ulejew('

ofthings to come...?:)

Water W.s cleaning ) Flux

It----

Saponifier Cleaning

pursued at the Nairobi Conferen,e -

first revision'ofthe Protocol. In June. ,

have to take the needs of the.,e n;.l[1

into account. but how' The lS En\ Ir

mental Protection Agency are holdln

workshop in Washington In Janua~

study such technological transfer \

representatives from sponsor

countries. technology experts ;.Ind. ;.Ib

all. top representative, from 'l'

developing countries such ,h BrJ

Egypt. India. Kenya. \1alaysla. \Ie\

China. Singapore and Venezuela

proposals are to stud~ ho\\, to Jo ,

studies for each count!!. establ"h m,

of organisation. operation and ,oop

tion and examine the economical a,p,

This will probably be one of the big

steps forward since the \-Iontreal Prot

came into force. espeCially as run

states that at least two develo~

countries are planning to construl:l I

producing plants. It must be bra

home to these countnes that. even u

the existing Protocol. they are ,au

economic disaster as the Parties I

fonn their major markets I wIII not lIT

products where ozone depleting sub

ces have entered into any manufal:tl

process. This could include such pro<

as frozen foodstuffs. optical gc

automotive components and \ehl

anything containing plastic foams. .I,

as cleaned electroOics assemblle,

onus of proof that regulated ,ubst.

have not been used mu,t Ite \\, It'

producers.':>

HydrocarbonJsurfaetant cleaning

Hydrocarbon

cleaning

from establishing an impanial data base

and we are consultants for several organisations. The largest mandate we have

,received to now has been from the Swiss

Government to wnte a booklet entitled

"Replacement ofCFC·113 in Industry" in

English. French and Gennan. This is over

50 A4 pages of closely typeset material. It

will be available in early 1990. Although

written with the Swiss context in mind. it

is a useful guide for individuals and companies in other countries. As over half the

Swiss consumption of CFC·113 is in

electronics. emphasis has been placed in

this sector with an equal accent on

methods where we have no commercial

axe to grind as those where we have. At

this time. it has not been decided by the

Swiss Authorities how this booklet will be

distributed outside of Switzerland. but if

anyone is interested in obtaining a copy.

return us the post card with the appropriate box marked. and we shall infonn you of the details within a few

weeks.

Countries "under development" present

one of the thorniest problems regarding

the Montreal Protocol. Some provisions

are included for exceptionsfor developing

countries and this has proved to be a SlUmbling block. At the Helsinki Conference.

some developing countries pointed out

that they needed aid for technological

transfer if they had to reduce their CFC

needs. Without going into the details this

was admined in principle. This idea was

(IIIlfllllleJtrlJf/1 {'n'! 1/111.1' !'Ui.!e

proposed substitute solvents. mostl~

HCFCs I hvdrochlorotluorocarbonsl.

have ozone' depletion potentials taDP)

\\, hich are 'till too high to prevent continued damage to the ozone layer. especially if they are massively adopted. It

has been proposed to introduce ceiling

values of aDP and substitution rate.

Proposed ceiling levels for the aDP

have been between 0.02 and 0.08 and for

the substitution rate between 20% and

50Clc . What does this mean'? If. for example. the Parties to the Protocol adopt

values of 0.05 and 35Clc respectively and

a nation had a total annual consumption in

19!1~ of. say 1.000.000 tonnes of all types

ofCFCs. for all applications. it will be permitted to use 35%. i.e. 350.000 tonnes. of

substitutes whose aDP does not exceed

0.05. It seems unlikely that much usage of

HCFC solvents can be envisaged and such

substances will have to be reserved for

very special applications where it can be

proved there is no other viable alternative.

In practice. it is foreseen that CFC-113

solvents will be phased out more rapidly

than is thought. In the industrialised

world. a snowball effect may occur. A

number of large consumers will make

strong efforts to reduce their consumption

as much as possible. This has started. with

a few names among many that can be

quoted: AT&T. Boeing. IBM. Northern

Telecom. Seagate. Seiko-Epson. Siemens

and at least a hundred others. Various nations are introducing or proposing legislation more severe than is required by the

Protocol. notably Sweden with a phaseout by 1991 and many who propose 85-

100% phase-downs by 1995. Taking these

cases alone. global demand will drop between 1990 and 1995 by more than 50%.

even if everybody else maintains status

quo. The price will increase by nearly

100'7c on the 1989 prices. under such a

scenario. This price increase will cause

others to stop using CFC-113 on

economic grounds. causing the price to

rise still further. Self-regulation will

create an almost complete de facto phaseout of CFC-113 by as early as 1994-5.

This is a warning to electronics companies who are adopting a "wait and see"

policy. They may be taken by surprise. If

they have not already started to examine

the five substitute methods (plus the sixth

one shown dotted in the figure). then they

may be forced to make a hasty and possibly bad decision. Stan now. if you have not

already done so.

We. at Protonique. are obviously

engaged in this matter as we can offer

equipment for three of the tive viable substitute methods. This has not stopped us
, 1

, I

January 1990

Letter to the Editor

Dear Sir.

I am probably one of the first users of a

Contammomcter. \ly employers bought

one elevc:n years ago with a Myron Conductivity \-Jeter. At that time. all the in,

slruments .,.,ere manual and were difficult

to use. as was yours. [n 1984. we decided

to replace it by a CM-2D with a HewlettPackard computer. This has given. and

still gives. good service. with only one

major problem in nearly six years: we had

to replace the cell and amplilier after three

years. Other repairs have been small: replacement of the llexible hoses twice. replacement of the resins twice and a

standard software exchange. Last year. it

was decided to purchase a contamination

tester for another department and the

choice fell on the latest CM-4 turnkey system. This was slightly dearer than X (Ed.:

the name of a competitive instrument was

put in here I. but the greater llexibility and

the fact that it was a European instrument

swung the choice in your direclion. I was

personally a little sceplical regarding

some of your claims. We received this instrument in late [988 with three software

up-dates since. Not only can [ say that

your claims were met. but that this instrument is fantastic. especially for SMD circuits. [n addition to this. the instruction

manual is exemplary: il is clear. well

presented and. above all. well indexed. so

that even someone of French mothertOnlrue can follow it.

I 'am not in the habit of writing complimentary letters and I would not have

written this one but that I received

Prorofllque News on my desk this morning. This is the mosl informative and interesting technical news sheet that I have

seen for a long time. But please allow me

to criticise it: on the back page you have

put in half a page of publicity: this is half

a page less of information! I enclose the

card asking that I be kept on your mail list.

Yours faithfully.

Name andaddress supplied

Editor's note: thank you for the compliments-we are all blushing collectively

after reading Ihis~ We have perhaps

neglected communications in the past.

Our old instruction books. for example.

have not been perfect. Over the' past two

years or so. we have made conscious effons to improve them and we think we

have made advances in the right direction.

You are the first 10 have put your comments on the new manual in writing. but

several customers have said that it is much

better than the old ones. Please be assured

.that we also know ofour other weaknesses

and we shall be making conscious effons

to improve them. as welL:)

Proton/que News Val. i. NO.2.

New Year's Thoughts

As it is planned that thiS copy of

ProrOllu/lle .\je.....s be sent out in January.

it is perhaps not too late to take stock of

what has happened in 1989 and to foresee

what is likely to happen in 1990.

This past year has. for us. been a difficult

one for mainly internal reasons. Qualified

personnel is almost impossible to lind in

Switzerland which has what is probably

now the lowest unemployment rate in the

world. The official figures. averaged over

the country. quote about 0.49c . Of course.

these do not take into account that there

are situations currently vacant of over 59c

of the total workforce. nearer 10'k- in and

near the major towns. In the Lausanne agI!lomeralion. where we are. there is a total

population of nearly quarter of a million.

The number actually officially unemployed is just over one hundred. in

about thirty communes. An unofficial estimation places the number of temporary

and permanentJobs vacant in the region at

over 10.000. One of the local newspapers

has an average of five to SIX full pages per

day of advertisements for situations

vacant plus a weekly supplement of up to

~8 pages! We were lucky to fmd a muchneeded secretary who started in December. but we are slill badly understaffed on

both the technical and commercial sides.

All this has contributed to slowing down

our development. not helped by the extra

charge of environmental studies.

On the more cheerful. positive side.

1989 was an excellent year for us with a

very marked improvement in interest in

all our product range. Our turnover has

beaten all records. This is cenainly because we have kept to the forefront ofcontamination and cleaning technology. We

should like to thank you. our customers.

for this state of affairs by the confidence

you have expressed in us through your orders.

Looking forWard to 1990. we can confidently slate that this year will not be

without interest. We shall be introducing

some new products. two of them very

shortly. We shall lift a corner of the veil

of secrecy from the first one and we are

already in a position to talk about it. although the product will not be launched

for a little while yet. It is the APL-5HS

unit. This is a module which will fit into a

standard APL-5 line for use with the new

hydrocarbon-surfactant solvents. such as

I~rpene mIXtures and similar ones.

Laboratory tests have been very positive

and a full scale preproduction test is now

planned. The price'~ It may be necessary

to count up to 50'7c more than a standard

APL·5L line and running costs will neces-

,anl\ be hl~hcr Thc ,k·!U.l: ,,"; .': .. , ..,"

109 ~in:ulh u"ln~ thl' !n~th\)J. :n":luJi!';

all running. amOrll,all''O' and rr,'du,:

COSIS. IS estimated at about t\\ II:>: th.ll ,"

C FC- I IJ 0 r 0 rdin a r: \, .I: >: r J nu

,aponifier;"'ater method,. but ~'ni\ 1",\-

thirds that oi alcohol "k..lnln~. Ie>!

throughputs of,up to 10 m-,h of e)rdin:.lr\

ClrcullS or 5 m-/h for S\ID CirCUit, T:d,

the post card if you ",ant more detall-O

The other products in the pipeline .Ire

not yet ready for announcement.

Finally. assuming it IS nOltoo late. rna:

we offer you our best'" ishes for I'NO' We

stopped sending out Greetings CJrd, Jnd

presents some eight years J~W WC 'cnd

the money thus saved to aid dl"tre"ed

children. espeCially In famine areJ' Thh

does not mean that we do not offer ,Jur Interlocutors'our best wishes. ,0:

May 1990 bring every one vfvur

readers d[tfU best in }{ea{th,

Prosperity anaJ-{appine5,>.

Telex

Important announcement

Please note that as from the end 01

March 1990. we shall no longer have

a telex machine. Please cancel our

telex number from your records.

This decision has been made because of the sharp decline in tck\

communications. Over the la.st t\\ 0

years. we have received 29 mes~agc".

of which 16 were publicity. and we

have sent out 11. This averages out at

one real message received or sent per

month. As we pay the PITa rental for

the line and machine of 0\ er

SFr 115.00 ($75) per month and a...,

vinuallyall our correspondents no\\,

have fax (quicker and cheapen. \\c

feel that our decision is entirely JUs-'

tifled for such a small volume of

traffic.

For those who wish to make "ure

that their records are up-to-date.

please note that we can be rea.:hcJ

through:

Telephone: +41 21-3823 34

Fax:+4121-382411
4 Proton/que News Voi 1. No.2. i _.... - ...

.,.) C1, C:' .'1

The Ballad of the Zone of Ozone

A light-hearted look at a seflous subject

To clean a printed Circuit. oh

How life is so unfair.

It used to be so easy. till

We found the ozone layerl

But over the Antarctic land.

A hole did find its way.

Away up in the stratosphere

To end the Winter day.

The men of knowledge looked so hard

To find the very cause.

Molina. Rowland and some more

Suggested Nature's laws.

The laws were thought to be a cinch:

A can ofaerosol,

Refrigerator. plastic foam

And nothing more. at all.

And then amongst the CFCs

One thQught of one-one-thrtl8.

But that is what is used to clean.

And we're no longer free!

In nineteen-eighty-seV8fl year,

The men ofnations met

In Montreal: they said "no moffl

And this to our fflgfflt.

Then some like Wally Rubin said.

"It does not matter much.

"Because I have a better ffux

"Ex-thirty-two or such. "

ThiS kind of flux is not to clean.

For a/I is safe and sure.

Contamination is not there

And high is SIR.

But MIL and DEF did not agree.

Too simple was this view.

"You have to clean, no matter what",

With solvents. far too few.

So Michael Hayes in Florida

DistHfed some orange peel.

And EC·seven was the way,

Orso some people feel.

Bill Kenyon, speaking for Du Pont.

An answer did release.

He felt the future must fflly

On his HCFCs.

And Colin Lea in NPL

On his white chargerrode.

In ·Circuit World" he wrote a Jot

I Ofpapers ala mode.

In EPA. Steve Andersen

I For UNEP started work.

His committee did further go

And stopped us with a jeri<.

They said that things like one-one-one

Trichloroethane were

Not the answer any m0f8.

, To clean the upper air.

The Germans said that alCOhol.

It was the only way.

But thiS IS how they mal<e the sch"aoo~

. They drink up ev·ry day

So. what is left to save the day?

Well. water does just that.

To clean both roSin and OA

It seems to be Just pat.

And what abOut the ozone layer?

Let's not forget it's there.

It we act sharp and hit the gas.

We mIght just clean the af(

But it will take some hundred years.

Before the stratosphere

Begms to get its ozone back.

And this will cost us dear.

Now let us draw a moral from

This poem. full of wit:

That future cleaning does not land

Us truly in the mud".

SNE.

·(If they can find a bener one.

are asked to improve on the las

but no prizes are offered for

one.)

The Montreal Protocol? No problem!

Clean your conventional and SM assemblies with water, the

only non-polluting solvent

Protonique S.

i

P.O. Box 78 j CH -1 032 Romanel-sut-lau

Telephone: + 4121-3823

Telex: 454144 PRTN CH

Telefax: + 4121-38 2411

The new Protonique

APL·5SMD line is in th

tradition which has rna

our aqueous cleaners

and dryers known

throughout the world

the best!

Brief Specificationa:

Typical practical throughput ISMOI 3-6 m"h

TYPIcal practical throughput (conventional) _ 5-20 m':h

TYPical Contamlnometer TM CM-4 readings:

under SM deVices <0.8 ug:cm' eQ. NaCI

general surface contamination . <0.4 uglcm' eQ. NaCI

TYPical Insulohmeter TM IRMA-' readings

under SM devices' hr after cleaning. . . . > 10'6 Of_

Idem,at400 C.95%RH " >10'50/_

rYPlcal 01 water consumption .... 4·81,m'

TYPical electriCity consumption... . .. .. 800 Whim'

r YPlcal saponifier In,ectlon loptoonafl 100·500 cm'm'

rYPlcal rinse water Isopropanol Infection loptlonall 200-400 cm' m'

The above are tnd'cat,ve under average condtflons. Without obligation