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Safety First 31-08.Indd SAFETY FIRST: TECHNICAL GUIDE FOR THE SAFE HANDING OF HYDROCARBON PROPELLANTS ROGRAMME P NVIRONMENTAL E ATIONS N NITED U Acknowledgments This document was produced by UNEP Division of Technology, Industry and Economics (UNEP DTIE) OzonAction Programme as part of UNEP’s work programme under the Multilateral Fund for the Implementation of the Montreal Protocol. The project was managed by: Mrs. Monique Barbut, Director Mr. Rajendra M. Shende, Head, OzonAction Branch Mr. James S. Curlin, Information Manager, OzonAction Programme Ms. Mugure Kibe Ursulet, Technical Data/Documentation, OzonAction Programme The document was researched and written by: Dr. Montfort A. Johnsen, President, Montfort A. Johnsen & Associates, Ltd. Mr. Geno Nardini, Instituto Mexicano del Aerosol Quality review comments were provided by: Dr. Harry B. McCain, Vice President of Research & Development, Aeropres Corp and 1st peer - Aerosols for World Bank Ozone Operations Resource Group Mr. Chandra Effendy, General Manager, PT Candi Swadaya Sentosa, Indonesia Mr. Fareed Ismail Bushehri, Programme Officer – Halon, UNEP Regional Office for West Asia Mr. Ansgar Eussner, Senior Monitoring and Evaluation Officer, Multilateral Fund Secretariat UNEP wishes to thank all contributors and their employers for helping to make this document possible. Copyright United Nations Environment Programme, 2005. The views expressed in this publication are those of the authors and do not necessarily reflect the views of the United Nations Environment Programme (UNEP). The designations employed and the presentation of material in this publication do not imply the expression of any opinion whatsoever on the part of UNEP concerning the legal status of any country, territory or city or its authorities, or concerning the delimitation of its frontiers or boundaries. Mention of a commercial company or product in this publication does not imply endorsement by UNEP. This publication may be reproduced in whole or in part and in any form of educational or non- proper services without special permission from the copyright holder, provided acknowledgement of the source is made, i.e. “UNEP DTIE OzonAction Programme under the Multilateral Fund for the Implementation of the Montreal Protocol”. UNEP would appreciate receiving a copy of any publication that uses this publication as a source. Cover photo: © UNEP DTIE OzonAction Programme, 1999. M. Haddad & Sons Co., the largest aerosol manufacturing plant in Jordan that was successfully converted to HAPs with financial support from the Multilateral Fund and assistance from the World Bank (JOR/ARS/07/INV/14). All other photos: © Mr Geno Nardini, Dr Montford Johnsen Copyright © 2005 UNEP UNITED NATIONS PUBLICATION ISBN: 92-807-2603-X AEROSOL CONVERSION SAFETY MANUAL Table of Contents PREFACE ................................................................................................................................................ 3 SUMMARY ............................................................................................................................................. 5 TECHNICAL ASPECTS OF HYDROCARBON GAS FLAMMABILITY ......................................... 7 INTRODUCTION ............................................................................................................................... 7 TECHNICAL ASPECTS ...................................................................................................................... 8 ENGINEERING ASPECTS ................................................................................................................ 11 GENERAL CONSIDERATIONS ........................................................................................................ 11 SAFETY CONSIDERATIONS ........................................................................................................... 14 TRANSFER LINES (PIPES AND HOSES) ............................................................................................ 18 EMERGENCY EQUIPMENT AND SYSTEMS ......................................................................................... 21 CONSTRUCTION ASPECTS ........................................................................................................... 23 SAFE OPERATION OF WARM WATER BATHS ..................................................................................... 25 OTHER SAFETY FACTORS: ........................................................................................................... 27 TRAINING ENHANCES SAFETY ...................................................................................................... 27 TRAINING OF EMPLOYEES ........................................................................................................... 27 SAFETY OF EMPLOYEES ............................................................................................................. 31 TECHNICAL ASPECTS AND OPERATION OF A MOLECULAR SIEVE HYDROCARBON PURIFICATION SYSTEM ...................................................................... 33 INTRODUCTION ........................................................................................................................ 33 DESCRIPTION OF MOLECULAR SIEVE COLUMNS ............................................................................... 33 SIZES - LENGTH AND DIAMETER – AND FLOW CONSIDERATIONS ........................................................... 34 CONSTRUCTION OF MOL-SIV COLUMNS .......................................................................................... 37 TESTING ................................................................................................................................ 38 ECONOMIES AND IMPROVEMENT OF EFFICIENCY .............................................................................. 38 THE IMPORTANCE OF FEEDSTOCK ................................................................................................ 39 LPG STENCHING ....................................................................................................................... 41 DISPOSING OF USED MOLECULAR SIEVE PELLETS ............................................................................. 42 REGENERATION OF MOLECULAR SIEVE PELLETS ............................................................................... 42 IMPORTATION .......................................................................................................................... 43 HYDROGENATION ..................................................................................................................... 44 CONCLUSION ......................................................................................................................... 44 MODERN AEROSOL FORMULATIONS ....................................................................................... 45 INTRODUCTION ............................................................................................................................. 45 GENERAL PRINCIPLES ................................................................................................................. 45 FORMULATION AND PACKAGING DATA ........................................................................................ 46 PESTICIDES ............................................................................................................................ 46 COSMETICS (PERSONAL CARE) .................................................................................................. 50 HOUSEHOLDS PRODUCTS .......................................................................................................... 54 INDUSTRIAL PRODUCTS ............................................................................................................. 59 ANNEX # 1 PROPERTIES OF THE HYDROCARBON PROPELLANTS ................................................... 61 BIBLIOGRAPHY .................................................................................................................................... 63 ABOUT THE UNEP DTIE OZONACTION PROGRAMME ........................................................................ 65 2 AEROSOL CONVERSION SAFETY MANUAL Preface “Sustainability needs safety” The end of chlorofl uorocarbons (CFCs) is not in question, it is only a matter of time. The global phase out of CFCs is in an advanced stage under the Montreal Protocol, including among industries that manufacture aerosol products. The remaining CFC consumption for aerosols in developing countries has been estimated to be around 4,300 tonnes in 2001, which represents a dramatic 71% reduction compared to the sector’s CFC consumption in 1997. CFCs are a small and ever-diminishing share of propellants -- less than 1% of the total – and hydrocarbon aerosol propel- lants (HAPs) have fi lled the gap with astonishing speed to become the principal replacements. Why then this guide when the CFC phase out is so far along? Because the issue of safety related to HAP propellants, particularly for small and medium-scale enterprises (SMEs), is now at the forefront – Safety is indeed First. The Aerosols Technical Options Committee (ATOC) of UNEP Technology & Economic Assessment Panel has stressed that in the process of replacing CFCs in the aerosol industry of developing countries, every effort should be directed to ensure that safety stan- dards at the manufacturing plant and at the consumer level are maintained. To meet this goal, the ATOC recommended among other things that good manufacturing practices, technical information about
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