ODS ALTERNATIVES

Pete Mullenhard Senior Engineer

Navy CFC & Halon Clearinghouse

navyotone@aol.com http://home. navisoft.com/navyotone/

GEO-CENTERS, INC.

(703) 769-1 883

AGENDA

a BackgrouncVRequ i rements Overview a Brief Will Concentrate On Solvent Alternatives

o Additional Information On Refrigerant & Halon

- Will Provide Examples On How To Get Info From The World Wide Web

1301 Alternatives - Can Discuss If Interest - Slides Provided For Backup

o Open Discussion - Feel Free To Ask Questions

Page 1

ODS PRODUCTION PHASE OUT

Q Background - Production Phase Out Dates

)) Halons - 31 December 1993 u CFCs, CCI,, 1,1,1 Trichloroethane - 31 December 1995 s HCFC-141 b - 1 January 2003 )> HCFC-22, HCFC-142b -- 1 January 2020 #> All Other HCFCs - 1 January 2030

o Navy Requirements - Policy Set by OPNAVINST 5090.1 B Chapter 6

Mission Critical Applications--The Use of Class I ODSs Shall Continue For Mission Critical Applications So As To Not Jeopardize or Degrade The Safety or Operational Requirements Of The Navy

NAVY POLICY a Navy Policy

- Shore-Based HVAC&R Equipment * All Shore Based (Non-Mission Critical) HVAC&R Equipment Purchased

After 14 July 1994 Shall Use An EPA SNAP Approved Refrigerant With An ODP of 0.05 or Less.

Equipment Containing Class I ODSs Shall Be Replaced Or Converted To An EPA SNAP Approved Alternative of 0.05 or Less by 31 December 2000.

* Currently Installed Shore Based (Non-Mission Critical) HVACm

- Shore-Based Halon 1301 Systems )) All Non-Mission Critical Shore-Based Halon 1301 Systems Shall Be

Replaced By 31 December 2000. - Portable Halon Fire Extinguishers

No Later than 1 January 1996 All Non-Mission Critical Halon Portable Fire Extingutshers Shall Be Replaced.

Navy Activities Requiring ODs Solvents For Mission Critical Applications After 31 December 1995 Shall Be Supplied At The Local Level Through The Use of Recycled or Reclaimed Sources. All Activities Should Be In The Process of Phasing Out Class I Ozone-Depleting Solvent Use

- ODS Solvents

Page 2

ODS SOLVENTS

o CFC-113 (1,1,2-TrichIoro 1,2,2-TrifIuoroethane) - FreonTF - Freon PCA - Genesolv 1 13

- Chloroethene - Triethane

o 1,1,1-Trichloroethane (Methyl Chloroform)

o Carbon Tetrachloride (Tetrachloromethane)

o Products Containing The Above Chemicals - Laboratory Usage Primarily

SELECTING AN ALTERNATIVE o Know Your Requirements

- Why Must Part Be Cleaned? What Documentation Requires

- How Clean Is Clean? - Material Composition Of Parts - Soils Being Cleaned - Space Available, Ventilation, Throughput, Flammability

Cleaning?

Requirements, Worker Skill, etc.

o Don’t Be “Short-Sighted” In Your Selection

c3 Consider All Emissions (Air, Water, & Waste

o Remember. . . There Are No “Drop-Ins” Or

- HCFCs, PFCs, Or Other “Simple” Alternatives Are Only Interim Solutions

Disposal) - Don’t Trade One Problem For Another

Universal Substitutes

Page 3

GENERAL METAL CLEANING

o 1,l ,l-Trichloroethane

o Primary Replacement - Aqueous Parts Washers - Vapor Degreaser, Cold Tank, Ultrasonic Or Spray Agitation

- Implemented By Numerous Navy Activities

)) M A S (SIMA, AIMDs, CVNIASIAD) NADEPs

- Cost Ranging From $5 K to >$20K (Plus Installation) - Low Cost Chemicals, Low Toxicity, Low Environmental Hazard

- Cleaner May Be Recycled (Zero Discharge) - NAVAIR Has Developed A MILSPEC For Detergents (MIL-C-29602) - Several Manufacturers On GSA Sched (Better Engineering, Mart,

(Alkaline Cleaners)

etc.)

WIPE SOLVENTS a 1 ,I ,1 Trichloroethane & CFC-113 a Preferred Alternative - Dry, Lint-Free Cloth (CCC-C-46,

D Aqueous Cleaner (Water Rinse If Necessary)

a Heavier Soils- Low Vapor Pressure (LVP) Solvents

Class 7)

- MIL-C-85570 (Type II) Or MIL-C-87937 (Type II)

- Petroleum Hydrocarbons, Terpene Hydrocarbons, Esters, and Mixtures - Tradeoff Between Evaporation Rate And Flash Point - May Not Be Suitable For Complex Parts (Additional DryinglRinsing With Fast Evaporating Solvents (IPA, Acetone, etc.) - May Craze Some Plastics (Acrylics, Polycarbonates, etc.) - Examples Of LVP Solvents In Use By Military:

>> PF Degreaser, Electron (>140° F Flash Point) >> Breakthrough, PF-l45HP, EPA 2000 (>140° F Flash Point) u Teksol EP (112' F Flash Point) >) DS-108 (115OF Flash Point) N Prepsolv (122' F Flash Point)

Others (Axarel6100, Actrel33491, Positron, Citra Safe, Citrex, etc.)

Page 4

ELECTRICAL/VVATER SENSITIVE EQUIPMENT

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cs

1,1,1 Trichloroethane & CFC-113 Primary Replace'ment - Low Vapor Pressure (LVP) Solvents - Petroleum Hydrocarbons, Terpene Hydrocarbons, and Mixtures - Examples Of Solvents In Use By Military:

w PF Degreaser, Electron (~140' F Flash Point) w Breakthrough, PF-l45HP, EPA 2000 (~140' F Flash Point) 3) Lower Flash Point LVPs Are Used Less Frequently

If Difficult To Dry, Use Of Fast Evaporating Solvent May Be Necessary

Other Solvents In Use Include HCFC-141 b, PFCs, and Mixtures

- Primary Fast Evaporating Solvent Used Is IPA

- Only Non-Flammable Alternative - Not Recommended Due To Environmental Considerations - Use Only As A Last Resort

ELECTRONICS REPAIR

CI CFC-113 (Sometimes 1,l ,l-Trichloroethane) o Primary Replacement - Alcohols

- Already Approved And Called Out In Many MlLSPECs - IPA Is Commonly Used - IPAEthanol Mixture Also Used - Much Work Has Focused On Packaging

u Pressurized Cans With Brush Applicators (NAVAIR CID A-A-50423)

o Other Alternatives With Less Acceptance - Terpenes (Bioact) - Other Alcohols (lonox) - Aliphatic Hydrocarbons (Axarel) - HCFC-141 b (Not Recommended)

Page 5

o CFC-113 (Sometimes 1,1 ,1=Trichloroethane) o Numerous Replacements

- Aqueous Or Semi-Aqueous - Advanced Vapor Degreasing (Ester Solvating Agent With PFC

RinsdDry) - Alcohol Vapor Dryer - Low-Emission Chlorinated Solvent Degreasing (TCE, PCE, Methylene Chloride)

- Supercritical Fluid (Primarily CO,) - CO, Snow - HCFC-225 (AK 225) - Testing Has Shown Better Performance

Than CFC-113 In Several Applications - HFCs (Limited Hydrocarbon Solvency) - PFCs (Limited Hydrocarbon Solvency - High GWP)) - 3MI AlliedSignal Newly Announced HydroFluoro Ethers (HFE)

r; Shorter Atmospheric Lifetimes & Lower GWPs u Better Hydrocarbon Solvency

a Most Electronic Resources Available Via Enviro$en$e On The World Wide Web - hltp:l~astenot.inel.gov/envirosense/

o Navy CFC & Halon Clearinghouse Home Page - Mtp:llhome.navisoft.com/navyotone/ a €PA Stratospheric Ozone Protection Home Page - httpJ/www.epa.gov/docslozonel a Contact The Clearinghouse

- Help Define Problem - Review Potential Alternatives Already Identified - Suggest Possible Alternatives And Provide Info - Give NAVSEA Or NAVAIR POC

a Navy CFCMalon Clearinghouse - 1755 Jefferson Davis Hwy, #910, Arlington, VA 22202 - (703) 769-1883 - Fax: (703) 769-1 885 - Internet E-Mail: navyozonebaol.com

Page 6

REFRIGERANT & HALON I30 I ALTERNATIVES

Backup Slides

CFC- I I CHILLER RETROFIT

o Large-Tonnage (A 00 Tons) Low-Pressure Centrifugal

o Only Retrofit Alternative Is HCFC-123 o Generally Require Extensive Modifications

Compressor

- Motor Windings Not Compatible - Capacity Loss (3% - 20%) - Energy Consumption (2% -5% More) - Replace Gaskets And Seals - Possibly Other Modifications (Gearbox, Impeller, Orifices, etc.) - Lower AEL (30 ppm) - Equipment Room Refrigerant Monitor - Costs Vary Depending On Simple Retrofit To Engineered Retrofit

- Should Also Install High-Efficiency Purge ($30K - $80K)

>’ Operate At Vacuum )’ Air Leaks In And Refrigerant Is Purged With Air

Page 7

CFC - I 2 / R - 500 CHILLER RETROFIT

CI Large-Tonnage Medium Pressure Centrifugal Compressor (Some May Be Reciprocating or Screw)

CI Only Recommended Retrofit Is HFC-134a CI Not A Drop-In, Modifications Required

- Ester Oil Requires Multiple Oil Flushes - Gear Change Usually Required (R-500 May Not) - Efficiency And Capacity Similar (+5% To -5%) - R-l2m-500 Retrofit Generally Lower Cost Than R-11 Retrofft

($20K - $70K)

WHICH REFRIGERANT FOR AC?

CI HCFC-22 - Manufacturers Have Many Years Of Experience - Only Alternative For Certain Applications - Highest ODP Of Alternatives (0.05 ODP) - Production Phaseout 2020

o HCFC-123 - LOW ODP (0.02 ODP) & LOW GWP - Highest Theoretical & Demonstrated Efficiency - Production Phaseout 2030 - Lower AEL (30 ppm) - Generally Not A Problem

- Zero ODP - No Production Phaseout - Higher GWP Than HCFC-123 And Lower Efficiency

o HFC-134a

Page 8

NEW CHILLERS (FLUOROCARBON VAPOR -COMPRESSION)

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Centrifugal Or Rotary Screw Compressors HCFC-22, HCFC-123, And HFC-134a Are All Acceptable Major Manufacturers - Trane

u HCFC-123 Centrifugal n HCFC-22 Screw n Most Efficient Design = 0.50 kw/ton

8 ) HFC-134a & HCFC-22 Screw n HFC-134a & HCFC-22 Centrifugal ss HCFC-123 Centrifugal

)$ HFC-134a 8 HCFC-22 Screw 8 ) HFC-134a & HCFC-22 Centrifugal

N HFC-134a Centrifugal

- York

- Carrier

- McQuay

NEW CHILLERS (NOT- IN - KIND)

o Absorption - Direct Gas-Fired Or Waste Heat - Water Is Refrigerant - Higher Initial Cost - Lower Efficiency - Good In Remote Areas Or Areas With High Electrical Utility

- May Be Good For Use As Secondary “Peak L o a d Reducer With costs

Conventional Vapor Compression As Primary

o Ammonia - Good For District Cooling (Central Cooling Plant) Designs - Higher Initial Cost - Low Cost Refrigerant ($0.35Ab) - Zero ODPRero GWP - Flammability And Toxicity Must Be Considered

Page 9

REFRIGERATION USES _ _ ~ ~ -

6-Refrigerants Commonly Used At Facilities - CFC-12

)) Water Coolers (Hermetic - Replace At End Of Useful Life) 3) Small Appliances (Hermetic - Replace At End Of Useful Life)

Vending Machines

- Walk-In Coolers - Freezers - Refrigerators - Display Cases - R-502 (HCFC-22/CFC-l15)

)) CommercialAnstitutionaI Refrigeration

3) Ice Machines N Commercial/lnstitutionaI Refrigeration )) Environmental Test Chambers (Materials, Electronics, etc.)

3) Laboratory Uses (Medical, Fuels, etc.) )a Environmental Test Chambers (Materials, Electronics, etc.)

- CFC-13 Or R-503 (HFC-23/CFC-13)

REFRIGERATION RETROFIT (Rm 12)

CI CFC-12 Alternatives - HCFC Blends And Near “Drop-In” Blends (Example: R-401A, R-

409A) )) Low Cost Retrofit ($200-$400)

w Zeotropic Blends

)) ZeroODP )) Not A Blend )) Large Capacity Loss At Low Temperatures * More Expensive Retrofit ($700-$1200)

Highest Cost Retrofit ($1000-$2000)

- Possibly Lower Cost For Near “Droplns”

- HFC-134a

- HCFC-22

)) Not A Blend

c3 Consider Retrofit While Servicing *Costs Based On An Average 5 hp Semi-Hermetic Compressor

Page10 .

REFRIGERATION RETROFIT (R m 502)

o R-502 Alternatives - HCFC Blends (Example: R-402A)

8) Low Cost Retrofit ($200-$400) w Zeotropic Blend

n ZeroODP n Zeotropic Blend (R-404A) Or Azeotropic Blend (R-507) w More Expensive Retrofit ($400-$1500)

- HFC Blends (Examples: R-404A & R-507)

o Consider Retrofit While Servicing

Costs Based On An Average 5 hp Semi-Hermetic Compressor

REFRIGERATION RETROFIT (R- 'I 3 OR R-503)

o CFC-13 Or R-503 Alternatives - HFC-23

n Less Capacity Than R-503 B More Capacity Than R-13 n HighGWP )) Higher Compressor Discharge Temperatures

2) Zero ODP n HighGWP 2) Closer Match For R-503 Than HFC-23

- HFCIPFC Blends (Example: SUVA 95)

Page 11

NEW REFRIGERATION EQUIPMENT

Many Refrigerants (All SNAP-Approved ~ 0 . 0 5 ODP Acceptable) - HCFC Blends (Interim Use By Manufacturers - Will Probably Be

- HFC Blends (Just Coming On Market - R404A, R-507, etc.) - HFC-134a

- PFClHFC Blends (SUVA 95)

Replaced With HFC or HFC Blend)

- HCFC-22

Biggest Considerations For Procuring New Equipment - Logistics Of Handling Multiple BlendslChemicals

)) Recovery Cylinders M Recovery/Recycling Equipment

Supply support - Availabilitv Of EauiDment

HALON 1 3 0 1 ALTERNATIVES a Conduct A Fire Risk AssessmenVDesign Analysis

o Alternative Selection (Use MIL-HDBK-lo08 Criteria)

- Remove Halon With No Replacement )) Computer Room Underfloor With Power Cable In Conduit

)) Automatic Water Sprinklers Already Installed (Wet Pipe Or And Plenum Rated Data Cable

Pre-Action Type) - Replace With Automatic Water Sprinklers (Majority Of Systems) - Replace With Carbon Dioxide

- Replace With Gaseous Alternative Agent )) Computer Room Underfloor Where Protection Is Required

n Remote Sites With Insufficient Water Supply Strategic OperationdHigh Value Equipment

- Consult NAVFAC EFDEFNPWC Fire Protection Engineer

Page 12

GASEOUS AGENT ALTERNATIVES o Must Be SNAP, NFPA 2001, And UUFM Approved o Require Greater Volume And Weight Of Agent

o Common Alternatives

- Usually Require New Piping, Additional Cylinders, NewIAdditional Discharge Nozzles

- HFC-227ea (Great Lakes FM-200) 2) Zero ODP, Low GWP )) Cardiotoxicity Levels Close To Design Concentration

Selected For LPD-17, CVN-76 Use

Mixture Of Carbon Dioxide, Nitrogen, And Argon (Environmentally Friendly)

Carbon Dioxide And Can Survive In Reduced Oxygen

Strategic Operations)

- IG541 (Ansul Inergen)

)) Reduces Oxygen Levels - Personnel “Hyperventilate” Due To

)) In Actual Fire, May Cause Personnel Harm (Not Recommended For

)) Good For ArchivesIMuseurdLibrary Application (No HF Formation) )) High Pressure, Very Large Volume (Stored As Gas Not Liquid)

GASEOUS AGENT ALTERNATIVES cs Common Alternatives (Continued) - HFC-23 (DuPont FE-13)

3) Zero ODP, High GWP Above $3 Cardiotoxicity Levels lMeU4ew Design Concentration

Good For Strategic Operations If HFC-227ea Not Suitable )) Good For Industrial Applications With High Space Leakage

Or “Persistent” Fires (“Pump-Up” Design Concentration) - CdFIO (3-M PFC-4lOICEA-410) w Zero ODP, High GWP w Cardiotoxicity Levels WW3okw Design Concentration )) Best Agent From Personnel Safety Standpoint N Can Only Be Used Other Agents Not Technically Feasible

~b*,,&

- Due To PhysicaUChemical Properties (Performance) - Unacceptable Human Health Risks

- Maintain For Record Purposes - Does Not Have To Be Filed With EPA. However Subject To Inspection

w Requires Formal, Documented Evaluation

Page 13

Example 1 "Browse Method"

In this example we want to locate information on alternatives to vapor degreasers using the ozone- depleting solvent methyl chloroform (1,1,1 trichloroethane) for general metal cleaning applications.

1. Start by going to Enviro$en$e using the following URL:

2. Click on the icon for the Solvent Substitution Data Systems. This takes you to URL:

3. Look down the screen and you will see a section on DOD Ozone Depleting ChernicaVSubstance information. Since you are a Navy activity you decide to select "U.S. Navy CFC & Halon Clearinghouse" Clicking on the word link, you are taken to URL:

4. From the Index you select "ODS Alternatives." This takes you down the home page to: "Information On ODS Alternatives"

5. You notice that there is a selection entitled "Aqueous Parts Washers As Vapor Degreaser Alternatives (General Metal Cleahing)." You click on the word link and it takes you to URL:

6. You have found the information you are looking for!

ODS Alternatives - Using The World Wide Web fTwo Examples)

The folIowing are two examples of how to use Enviro$en$e on the World Wide Web to locate information on ODs alternatives:

In the first example we will use the “browse” method to locate information In the second example we will use the “search” method to locate infomation