Introduction to Aerosols. SATA Aerosol 101 Daniel Bonner March 18, 2015
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1 Introduction to Aerosols SATA Aerosol 101 Daniel Bonner March 18,
2 CONTENT Definition of an aerosol How do aerosols work Propellant Classifications and Physical Properties Blending propellants Regulatory and Environmental Considerations Safety Regulations 2
3 WHAT IS AN AEROSOL An aerosol is defined as a substance enclosed under pressure that is able to be released as a fine spray, by means of a propellant gas. Propellant is a component of the aerosol package that delivers the product. Typically propellants consist of liquefied or compressed gases. 3
4 AEROSOL PACKAGE The aerosol package contains two components: 1) Product 2) Propellant 4
5 5
6 LIQUEFIED GAS Propane, Isobutane, Butane, DME, D152A, and D134 are all examples of liquefied gas. Dispersed in the product. Constant pressure and spray pattern. Typical can product fill is 85%. 6
7 COMPRESSED GAS CO 2, N 2, Air are examples of compressed gas Gas is in the head space only Pressure drops as product is used causing coarse spray patterns Can product fill is 50-70% 7
8 LIQUEFIED GAS COMPRESSED GAS 8
9 AEROSOL WITH A LIQUEFIED GAS 9
10 AEROSOL WITH A PERMANENT GAS 10
11 PHYSICAL PROPERTIES TO CONSIDER Vapor Pressure influences how the product will be delivered (Spray, foam, stream etc.). Solubility and Miscibility Does the propellant have the capability to mix with other propellant and solvent? Water Solubility >DME>Hydrocarbons>HydroFlourocarbons 11
12 LIQUEFIED GAS PROPELLANT Properties Hydrocarbons Dimethyl Ether HFCs Flammability Flammable Flammable 152A Flammable Solvency Poor Good Poor Density Low Low intermediate Toxicity Low Low Low Environmental Impact VOC VOC Non-VOC 12
13 LIQUEFIED PETROLEUM GAS PROPELLANTS Propane C 3 H 8 Isobutane (2-methylpropane) Butane C 4 H 10 Isopentane (2-methylbutane) Pentane C 5 H 12 13
14 HYDROCARBON PROPELLANTS Liquefied Petroleum Gases (LPGs) are separated from petrochemical mixtures via separation from natural gas or refinement of crude oil. The majority of LPG propellants are obtained from natural gas liquids. 14
15 PROCESSING OF HYDROCARBON PROPELLANTS Fractionation Mixtures of LPGs are separated by differences in boiling points. Desulphurization Molecular Sieves material 13x is used to remove sulfur species and moisture. Material 13x works on the idea of size exclusion. 13x pore size typically 10 Ângströms. 15
16 16
17 PHYSICAL PROPERTIES OF HYDROCARBON Chemical Formula Propane Isobutane N-Butane Isopentane Pentane C 3 H 8 C 4 H 10 C 4 H 10 C 5 H 12 C 5 H 12 Molecular Weight Boiling Point ºF 10.9 ºF 31.1 ºF 82 ºF 97 ºF 70 (psig) 70F (g/cc) KB Value
18 COMMON HYDROCARBON BLENDS A Blends Consist of propane/isobutane Pressure between Named according to the target pressure of the 70F Common A blends A-70, A-46, A-85 18
19 COMMON HYDROCARBON BLENDS AB Blends Consist of propane and Butane Pressure between Common blend AB-31 and AB-46 19
20 COMMON HYDROCARBON BLENDS AP Blends Propane/Isobutane/Butane Pressure between F Common blends AP-52 and AP-46 20
21 CALCULATING BLEND PRESSURES Raoult s Law The partial pressure of each component of an ideal mixture of liquids is equal to the vapor pressure of the pure component multiplied by its mole fraction. Pressure of blend=(mf1 X VP1 + MF2 X VP2 + ) MF= mole fraction VP = Vapor Pressure Components of the mixture must behave like ideal gases. 21
22 HYDROFLUROCARBONS, HYDROFLUROOLEFINS, AND DIMETHYL ETHER PROPELLANTS Difluoroethane (D152A) 1,1,1,2-Tetrafluoroethane (D134A) trans-1,3,3,3 Tetrafluoropropene (1234ze) Dimethyl Ether (DME) 22
23 DME PROPERTIES Vapor 70 F: 63 psig Vapor 130 F: 174 psig Solubility in H 2 0: 35 wt. % Density: F KB Value: 60 (powerful solvent) Flammable Limits: volume % in air VOC 23
24 D152A PROPERTIES Vapor 70 F: 63 psig Vapor 130 F: 177 psig Not soluble in H 2 0 Density: 0.91 F KB: 11 (poor solvent) Flammable Limits: Volume% in air Non-VOC 24
25 HFO-1234ZE PROPERTIES Vapor 70F: 47psig Vapor 130F: 140psig Not soluble in water Density: 70F KB: <10 (poor solvent) Flammable Limits: None Low MIR 25
26 COMPARISON OF LIQUIFIED GAS PROPERTIES 26
27 CONSIDERING DENSITIES OF YOUR PROPELLANT Assume 100grams of formula in which 25% is propellant. 25g of 47.2cc of propellant 25g of = 27.5 cc of propellant 25g of = 20.5cc of propellant From a volume perspective the LPG takes up 1.7 to 2.5 times more container space assuming equal amounts used in the formulation. 27
28 AZEOTROPIC BLENDS Azeotrope is a mixture of two or more liquids whose proportions cannot be altered by distillation. These mixtures deviate from Raoult s and Dalton s law. Mole fraction cannot be used to calculate blend pressure. D152/Isobutane. DME/Propane. D152/n-Butane. 28
29 DETERMINING PRESSURE OF AZEOTROPIC BLENDS Determine the amount of each component of the blend. Use triangle chart provide by chemical supplier. DME/A45 (20/80) blend. Component break down. 11% Propane 69% Isobutane 20% DME 29
30 30
31 COMPRESSED GASES Carbon Dioxide (CO 2 ) At 70⁰ F the pressure of CO 2 IS 830psig. Density g/cc. CO2 requires a large amount of head space. Nitrogen (N 2 ) Density g/cc. Not soluble in liquids. Produces a stream when delivering product. 31
32 32
33 33
34 VOLATILE ORGANIC COMPOUNDS AND THE ENVIROMENT The Environmental Protection Agency (EPA) defines VOCs as photochemical reactive substance that contribute to photochemical smog. Due to the increase of ozone molecules (O 3 ) in the troposphere regulations have been imposed by organizations such as the EPA and California Air Resource Board (CARB). 34
35 MAXIMUM INCREMENTAL REACTIVITY Maximum Incremental Reactivity (MIR) measures the tendency of a chemical to form ozone. MIR scale was adopted by CARB in 2000 and adopted by the EPA shortly after. Typically MIR values higher than ethane are considered VOCs. Compounds with MIR values lower than ethane are considered Non-VOCs. MIR scale is based on the effect of VOCs on O 3 for specific place. 35
36 MIR SCALE FROM CARB S CONSUMER PRODUCTS REGULATION Compounds HFC-134a 0.00 HFC-152a 0.02 MIR VALUE Methane Ethane 0.28 Propane 1.15 Isobutane 1.24 Butane 1.15 Isopentane 1.45 Pentane 1.31 DME
37 FLAMMBILTY OF PROPELLANTS The Department of Transportation defines flammable propellants as gas which has a flammable range in 20⁰ C (68⁰ F). 37
38 FLAMMBILTY OF PROPELLANTS Flammable Gases are categorized based on the following: ASTM E-681 this test method determines the upper and lower concentration limits of flammability. Enclosed Space Ignition Test. Heat of Combustion. Flame Extension. 38
39 FLAMMBILTY OF PROPELLANTS The flame extension test is done by holding an aerosol can 15cm from a flame. A flame extension of 45cm or more indicates a flammable product. 39
40 FLAMMBILTY OF PROPELLANTS Enclosed space ignition test is done by spraying an aerosol can in a drum. The drum contains a lighted candle and has a hinged bottom. The time to ignition is recorded. 40
41 HEAT OF COMBUSTION Level 1 Aerosols have a heat of combustion less than or equal to 8600 Btu/lbs. (20kJ/g). Level 2 aerosols have a total heat of combustion greater than 8600 Btu/lbs. (20kJ/g). Level 3 aerosols have a total heat of combustion greater than 13000Btu/lbs. (30kJ/g). Aerosols are classified according to National Fire Protection Association 30B regulations. 41
42 MEASURING OR CALCULATING THE HEAT OF COMBUSTION Butane (C 4 H 10 ) Heat of Combustion for one mole ΔH= kJ/mol found from literature. 1g of C 4 H 10 x (1mol/58.1g) x (2877.5kJ/mol) = 49.5kJ Measuring the heat of combustion is done via bomb calorimeter. 42
43 BOMB CALORIMETERS Q v =M C ΔT Q is heat change M is mass C is specific heat ΔT is change in temperature 43
44 PROPELLANT TANK FARM SAFETY Propellant tank farms are required to meet NFPA codes. NFPA58: Addresses design, construction, and operation of a LPG facility NFPA 30B: Addresses manufacturing and storage of aerosol products 44
45 PROPELLANT TANK FARM SAFETY Electrical equipment and connections used in the tank farm must be explosion proof. National Electrical code or NFPA 70 Division 1 or 2 Division I: Vapors present during long periods of time Division II: Vapors present under abnormal conditions 45
46 PROPELLANT TANK FARM SAFETY Storage tank safety requirements per NFPA 58 Security fencing with two access points should surround tanks Tanks must be fitted with safety relief valves Tanks must have liquid level, temperature, and pressure gauges 46
47 PROPELLANT TANK FARM SAFETY Adequate fire protection must be provided for tanks A water supply capable of providing cooling water for 10 minutes should be on the premises 47
48 48
49 GAS DETECTION Catalytic Detector Uses the principle that when gas oxidizes it produces heat. Sensor converts temperature change to a signal via Wheaton bridge circuit. 49
50 Open Path Gas Detector Emits infrared light along a path If gas molecules are present they absorb the light and infrared beam does not make it to the receiver. GAS DETECTION 50
51 Thank you! 51
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