A major outlet for perchloroethylene (perc, also called tetrachloroethylene) is as a chemical intermediate, particularly as the basic raw material in the manufacture of hydrofluorocarbon (HFC) 134a, an alternative to chlorofluorocarbon (CFC) refrigerants. It is also used in the synthesis of hydrochlorofluorocarbons (HCFCs) 123 and 124 and HFC 125.
Perchloroethylene is also an important solvent because of its stability and non-flammability. It is the primary solvent used in commercial and industrial dry cleaning because it is safe to use on common textiles, fibres and dyes, and is effective at removing fats, oils and greases. The textile industry also uses it as a spotting agent, wool scourer, dye carrier, and for sizing and finishing of cloth.
Many industries, including aerospace, appliance and automotive manufacturers, use perc for vapour degreasing of metal parts during various production stages. Its high boiling point and long cleaning cycle enable difficult 'soils' such as waxes with high melting points to be removed. It is also favoured in many applications for its low vapour pressure and high vapour density, resulting in lower fugitive emissions compared to other choices such as trichloroethylene.
Other applications include the extraction of fats, dissolving rubber, paint removal, sulphur recovery and as a carrier solvent for silicones. Perchloroethylene is used in aerosol formulations for the automotive aftermarket, particularly for brake cleaning, as well as water repellents for garments, spot removers and silicone lubricants. It can be used as an insulating fluid in some electrical transformers as a substitute for polychlorinated biphenyls (PCBs).
The outlook for perc is mixed. Environmental pressure, legislation and improved recycling will lead to a decline in its use for dry cleaning in the US and Europe. However, this could be offset by growth in other regions of the world and its use as a chemical intermediate.
In Europe, the decline in the sales of perc for solvent uses has continued. The decline faced by the chlorinated solvent sector is mainly due to the implementation of the EU’s Solvents Emissions Directive, which came into force in various countries between 2005 and 2007.
According to the European Chlorinated Solvents Association (ECSA), sales of perc in Europe fell to 52,000 tonnes in 2007 compared to 55,000 tonnes in the previous year, despite Romania and Bulgaria being added to the list of countries reported.
Large quantities of perc are used in the dry-cleaning sector. The introduction of new generation machines has improved the recycling efficiency and reduced emissions. ECSA says that perc remains the solvent of choice for 80% of Europe’s dry cleaning shops and continues to gain market share as a substitute for trichloroethylene in metal degreasing.
However, the use of perc in the manufacture of the refrigerant HFC-134a is under threat in Europe. An EU directive has called for the phase-out of HFC-134a in automobile air conditioning systems by 2017 with consumption of HFC-125 likely to grow as a replacement.
In the US, the largest use for perc is in the manufacture of fluorocarbons, primarily HFC-134a and HFC-125, for use in refrigeration and air conditioning systems. This market application is growing at 2%/year in the US consuming 114,000 tonnes of perc in 2007, according to ICIS Chemical Business (ICB).
As in Europe, the use of perc in dry cleaning has been declining in the US as the industry converts to more efficient equipment to limit emissions. This permitted compliance with stringent government rules covering workplace exposure levels.
Efforts are underway to remove perc from the dry cleaning sector. In 2007, California passed measures to eliminate the use of perc in machines by 2023. Since then, similar proposals have been introduced in New Jersey and New York.
However, nearly 90% of US dry cleaners still use perc, alone or in combination with other solvents. Alternatives to perc have been implemented on a limited commercial scale, but there is no favoured technology that is a threat in the short term. Hence, perc demand in the US is expected to grow at 0.5%/year.
Overall perc demand in the US is expected to grow at 1.5%/year through to 2011 from 168,000 tonnes in 2007 to 178,000 tonnes in 2011, according to ICB. However, in the longer term, increased recycling and gradual substitution of perc in cleaning applications will reduce demand.
(Updated: November 2008). Sources: ICB Chemical Profile, 25 August 2008)
Perchloroethylene
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Perchloroethylene
Process Technologies
Traditionally, perchloroethylene was produced by reacting acetylene with chlorine via trichloroethylene as an intermediate but acetylene has now been replaced by a variety of feedstocks such ethylene dichloride (EDC), C1-C3 hydrocarbons or chlorinated hydrocarbon wastes. The decline in demand for carbon tetrachloride and CFCs has also led to the switch of processes.
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