Halon recycling units are available to help extend the life of Halon 1301 where it is used as a fire-suppression and explosion-protection agent. Halon 1301 is still approved for use only in mission-critical applications. Mission-critical applications include flight-line fire fighting, and ship- and shore-based crash and rescue operations. Each application requires a waiver for procurement of Halon 1301 replacement. Procurement must come from the Defense Logistics Agency’s (DLA) halon reserve (Defense Supply Center, Richmond, Virginia), since production was banned in January 1996. Conservation of halons is necessary to preserve existing supplies until replacement products and systems can be implemented.

Halon 1301 recycling systems remove contaminants by filtration and condensation to meet required product specifications. These recycling units transfer Halon 1301 from aircraft fire bottles into a storage vessel to eliminate venting Halon 1301 to the atmosphere. This equipment is required to safely transfer the halon so that it can be sent in bulk to a reclamation site.

The basic recycling system includes a pumping system that efficiently transfers the halon from the storage tank into the processing equipment, and modules for filtration and condensation. The recycling process first recovers halon at 99% efficiency with the use of the pump and filtration units. The pump operates on 100-120 psi of compressed air at 13 cubic feet per minute, and has an average of 16 pounds per minute of liquid transfer rate and 2 pounds per minute of vapor transfer rate. The filtration unit operates at 120 volts, 4-amp circuit, and removes contaminants accumulated during transfer or fill operation, or when a cylinder or storage vessel rusts and degrades. Molecular sieve filters are used in the unit to remove particulate matter, moisture, oil, water, wax, and sludge. The filtration unit also has a salt crystal indicator that shows the presence of moisture. The condensing unit requires the use of liquid nitrogen and operates at 120 volts and 4 amps. Nitrogen in the halon is separated via condensation, and is then vented to the atmosphere. The recycling rate for this technology is 99%. Consult the American Society for Testing and Materials (ASTM) standard, ASTM D5631-94, to determine proper procedures for handling, transportation, and storage of Halon 1301.

• Extends the useful life of the Halon 1301 supply.
• Reduces activity down time associated with the Halon 1301 replacement procurement process.
• Transfers halon more efficiently (99%) and effectively
• Provides the ability to filter halon independently while continuing to pump out cylinders.
• Provides the fleet with a system capable of future growth to provide an organic reclamation capability.

• Requires operator training.

Halon 1301 can be procured at no cost to mission-critical applications from DLA Defense Supply Center located at Richmond, Virginia. However, Halon 1301 recycling systems can be used to extend the useful life of existing Halon 1301 supply at a minimal cost. Naval Air Station, North Island is currently operating a Halon 1301 recycling system. This system is comprised of pumping, filtration, and nitrogen separation units that remove contaminants and recycle the halon to ASTM and Mil-Spec levels. The cost elements for operating a Halon 1301 recycling system are provided below. According to the Pollution Prevention Equipment Program Book, the capital cost for a Halon 1301 recycling system is approximately $8,333. The following economic analysis is based on information provided by Mike Zitaglio at the Naval Air Warfare Center, Aircraft Division in Lakehurst, NJ.

Assumptions:

• Estimated equipment cost for pump unit: $5,000
• Estimated equipment cost for filtration unit: $5,000
• Labor rate: $30/hr.
• Electricity: negligible
• Utility air cost: negligible
• Multiple types of bottles processed ranging from 2.5 lb. to 25 lb.
• Number of bottles processed: 33/month or 400/year
• Average pumping rate: 10 min/bottle or
  5.5 hr/month or 66 hr./year
• Average filtration rate: 10 min/bottle or
  5.5 hr/month or 66 hr./year
• Total recycling system labor hours: 2 hrs./bottle or 800 hrs./year
• Labor hours required to process and turn in used halon bottles (disposal): 24 hr/month or 288 hr/yr
• Shipping costs to replace halon bottles with new ones: $50/month

Annual Operating Cost Comparison for Halon 1301 Recycler and Disposal of Used Halon Bottles

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