ANALYSIS OF ALTERNATIVES Analysis of Alternatives for the use of trichloroethylene as an extraction solvent for removal of process oil and formation of the porous structure in polyethylene based separators used in lead-acid batteries Legal name of applicant(s): ENTEK International Limited Mylord Crescent Camperdown Industrial Estate Killingworth, Newcastle upon Tyne NE12 5XG, UK Submitted by: ENTEK International Limited Substance: Trichloroethylene, CAS 79-01-6; EC 201-167-4 Use title: Use of trichloroethylene as an extraction solvent for removal of process oil and formation of the porous structure in polyethylene based separators used in lead-acid batteries Use number: USE 1 1 CONTENTS SUMMARY ................................................................................................................................................................. 7 ACTIONS AND TIMEFRAME FOR IDENTIFICATION AND DEVELOPMENT OF A SUITABLE AND AVAILABLE ALTERNATIVE. ......................................................................................................................... 15 2. ANALYSIS OF SUBSTANCE FUNCTION ....................................................................................................... 17 2.1 OVERVIEW AND BACKGROUND .................................................................................................................. 17 2.2 MANUFACTURE OF POLYETHYLENE-BASED SEPARATORS - PROCESS DESCRIPTION ................. 20 2.3 CONSIDERATION OF OBSTACLES OR DIFFICULTIES IDENTIFIED OR EXPECTED IN RELATION TO FINDING AN ALTERNATIVE FULFILLING OR REPLACING THE EQUIVALENT FUNCTION OF TRI. 24 3 ANNUAL TONNAGE .......................................................................................................................................... 30 4 IDENTIFICATION OF POSSIBLE ALTERNATIVES ................................................................................... 31 4.1 LIST OF POSSIBLE ALTERNATIVES ............................................................................................................. 31 4.2 DESCRIPTION OF EFFORTS MADE TO IDENTIFY POSSIBLE ALTERNATIVES.................................... 41 4.2.1 Research and Development ............................................................................................................................ 42 4.2.1.1 Solvent Alternatives ............................................................................................................................ 42 4.2.2 Manufacturing Alternatives ............................................................................................................................ 55 4.2.3 Consultations .................................................................................................................................................. 65 5. SUITABILITY AND AVAILABILITY OF POSSIBLE ALTERNATIVES ................................................... 67 5.1 INTRODUCTION ................................................................................................................................................ 67 5.2 N- HEXANE ........................................................................................................................................................ 67 5.2.1 Substance ID and properties ........................................................................................................................... 67 5.2.2 Technical feasibility ............................................................................................................................ 69 5.2.3 Reduction of overall risk due to transition to the alternative .......................................................................... 75 5.2.4 Economic feasibility ............................................................................................................................ 78 5.2.5 Availability ..................................................................................................................................................... 83 5.2.6 Conclusion on suitability and availability for n-hexane ................................................................................. 83 5.3 DICHLOROMETHANE ...................................................................................................................................... 85 5.3.1 Substance ID and properties ........................................................................................................................... 85 5.3.2 Technical feasibility ............................................................................................................................ 87 2 5.3.3 Reduction of overall risk due to transition to the alternative .......................................................................... 87 5.3.4 Economic feasibility....................................................................................................................................... 92 5.3.5 Availability ..................................................................................................................................................... 93 5.3.6 Conclusion on suitability and availability for dichloromethane ..................................................................... 93 5.4 TETRACHLOROETHYLENE ............................................................................................................................ 95 5.4.1 Substance ID and properties ........................................................................................................................... 95 5.4.2 Technical feasibility ............................................................................................................................ 97 5.4.3 Reduction of overall risk due to transition to the alternative .......................................................................... 97 5.4.4 Economic feasibility ...................................................................................................................................... 102 5.4.5 Availability ..................................................................................................................................................... 103 5.4.6 Conclusion on suitability and availability for tetrachloroethylene ................................................................. 103 5.5 VERTREL® SDG ................................................................................................................................................ 105 5.5.1 Substance ID and properties ................................................................................................................ 105 5.5.2 Technical feasibility ....................................................................................................................................... 108 5.5.3 Reduction of overall risk due to transition to the alternative .......................................................................... 108 5.5.4 Economic feasibility ............................................................................................................................ 116 5.5.5 Availability ..................................................................................................................................................... 117 5.5.6 Conclusion on suitability and availability for Vertrel® SDG .......................................................................... 117 5.6 HFE-72DE............................................................................................................................................................ 119 5.6.1 Substance ID and properties ........................................................................................................................... 119 5.6.2 Technical feasibility ............................................................................................................................ 120 5.6.3 Reduction of overall risk due to transition to the alternative .......................................................................... 121 5.6.4 Economic feasibility....................................................................................................................................... 124 5.6.5 Availability ..................................................................................................................................................... 125 5.6.6 Conclusion on suitability and availability for HFE-72DE .............................................................................. 125 5.7 N-PROPYL BROMIDE ....................................................................................................................................... 126 5.7.1 Substance ID and properties ........................................................................................................................... 126 5.7.2 Technical feasibility ............................................................................................................................ 127 5.7.3 Reduction of overall risk due to transition to the alternative .......................................................................... 128 5.7.4 Economic feasibility....................................................................................................................................... 131 3 5.7.5 Availability ....................................................................................................................................................