June 19, 2007

Refrigerant + Steel = WTF?! (Updated)

The greatest thing about the internet is that you don't have to just sit there and wonder about stuff anymore. Let's say you're wondering what the chief export of Taiwan is. Unless you're either in a library or have a late vintage World Almanac or encyclopedia on hand, you don't know.

But, sometimes an exhaustive internet search will fail you and you must cry out a virtual call to arms to see if anyone out there can give you a clue. Because, much like the big money answers in Annika's Jeopardy, some questions seem to be deliberately google-proof.

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J'ever wonder how that plastic bottle cap is made? Or those plastic keys on your keyboard? Or that wooden plastic Lincoln Log?

Well, solid plastic pellets are fed, by gravity, from a conical bin called a "hopper" into a heated barrel. The barrel temperature melts the plastic and injects the liquid into the steel mold. The plastic then sits in the mold for a duration of time called a "cure time", during whence is solidifies. In the relatively small molds that we use, this could last anywhere from 10 seconds to nearly a minute. Once the plastic is solid, the mold opens and ejects the plastic part, which then falls onto a chute that guides it into a plastic bin that was made by a machine much bigger than any of ours.

Now, in order to keep the hot molten plastic from over-heating the mold and, thereby, preventing the plastic from solidifying, cold water is continually running through the mold to keep it cool. The water is first run through an air conditioner on steroids called a "chiller". The chiller lowers the incoming city water to somewhere around 55 degrees F, which prevents heat from the plastic from building up and keeps the mold, the plastic, the customer and the business very happy.

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So anyway, on Friday we were sitting in the office and the run of the mill k'chunka'k'chunka'k'chunka noises were sounding smoothly. Then there was a very ugly, loud, churning, constipated metallic gurgling sound that none of us had ever heard before. Then it stopped.

Tex said, "What the hell was that?". Big Red had ju-u-u-u-st stepped out of the office and onto the floor and, thus, was the only one of us who could tell where that brand new sound had come from. He headed straight for the chiller.

The chiller wasn't chillin'. We didn't know what exactly was wrong with it, but Tex knew that we weren't gonna be in business without it so he called HVAC Man and had him come in right away to look at this thing.

By the time the HVAC Man and his team showed up, Tex had gone for the day. So it was Big Red, his employees (three sweet Hispanic ladies of questionable legal status --- but you didn't read that here), and me. And I wasn't even on the clock yet. (Yeah, I "hang out" at work. What's it to ya?)

'Round about 2:00pm I had my head down on the desk, trying to catch some zzz's before beginning my shift, when Big Red tapped me on my shoulder.

"Bob, we gotta go outside," he said. "There's freon filling the shop, we can't stay in here."

He opened the windows in the office and I stepped out onto the floor. **choke** You can't breath this stuff if you tried. Your lungs are smarter than your brain in that area of biological expertise. Outside we went, with all the windows and the loading dock's door open. Big Red sent his girls home early. I trust he paid them for the full day. At about 6:00pm we re-entered the shop and it seemed to have been pretty well aired out. We closed up and shut down for the weekend.

I found out later that HVAC Man had the bright idea of turning on the chiller, to see what it does, and then it burst into flames.

They put the electrical fire out.

Then he had the even brighter idea of turning it on again and freon started spewing out refrigerant like Noam Chomsky spews sophistry.

(That crud was "refrigerant", actually, because "Freon" is a trademarked name that hasn't been installed in cooling units since 1995. Saying "freon" is kinda like saying "scotch tape". I have no info yet on just which refrigerant it was.)

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Monday morning. Big Red discovers that the steel tools that were near the chiller had a thin coat of what looks like rust. What were shiny steel wrenches and pliers and screwdrivers and mallots now have surfaces that have some sort of reddish-brown dust-like corroded texture.
Then he noticed that the labels on the cardboard boxes that were closest to the chiller had turned from white to baby blue. What the huh?

So, what in the world went on here this weekend?

I, of course, hopped onto the internet to find the answer. I searched "freon steel reaction", "refrigerant steel chemical reaction", "freon rust steel contact" and many many other search terms. Nothin'.

The HVAC guy showed up today to retrieve some tools he'd left behind when we evacuated on Friday. Big Red showed him what had happed to the labels and the steel tools. HVAC Man said he'd never seen anything like it before.

Big Red speculated that the cold refrigerant may have hit the warm air and thus induced condensation on the steel that may have resulted in all this oddly curious rustification. But, I mean, if you leave a piece of steel in a dishpan full of water it'd, I'm sure, take longer than a weekend for it to rust. And it wouldn't rust in the same way that these tools rusted. I mean, there'd be frickin' rust, not a thin dusty coating of rust-like grit.

The worst part was when we noticed this afternoon that a brand new mold had the same outer damage as the tools. A brand spanking new mold. Do you know what these things cost to manufacture? We're talking seven figures here. Luckily the mold was closed tight, so it shouldn't effect it's usefullness. But, sheesh, if the customer ever sees the condition of that outer surface he's gonna wanna know what the @#$% happened to his investment and why it isn't in pristine condition before it has ever even been used.

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So, to any longtime experts in heating and air conditioning out there:

What the @#$% happened to that steel over the weekend?!!!!!!!!!!

I thank ye in advance. :)


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UPDATE (6-21-07): As it turns out, that was indeed Freon that spewed from the chiller. Freon 22. Clorodifluoromethane. Apparantly it is no longer used in small air conditioners like those in automobiles, but is still widely used in larger contraptions.

Anyway, according to my new research, Freon doesn't burn but it does decompose at high temperatures. It decomposes into toxic gases like hydrogen fluoride and phosgene.

Phosgene was first used as a chemical weapon in World War I. But it is odorless and acts on the nervous system, so that's not what we smelled on Friday. And certainly not what rusted the steel tools.

Hydrogen fluoride is a gas that is highly corrosive. When diluted in water it becomes hydrofluoric acid. It can dilute glass, and is used to etch and "frost" glass. It's corrosive to metals such as silver, brass, aluminum and, of course, steel.

So what happened, I'm pretty convinced, was that the electrical fire in the chiller heated the cylinder that contained the Freon. And, Freon being very cold, it doesn't take much heat to bring it to boil. The cylinder was punctured by the "boiling" Freon (luckily it didn't explode), and the overheated Freon decomposed until it produced hydrogen fluoride, and the hydrogen flouride gas corroded the steel.

Everything I've read claims that Freon is harmless except in extreme exposures, and the descriptions of the smell and effects of hydrogen fluoride match with what we experienced on Friday.

Luckily, Tex found a polish that can clean the corroded surface of the molds and tools. The stuff wipes away rust like it was nothing but a slight tarnish on dinner utensils. Actually, that's probably what it is very much like, if not exactly like.

What the hell is "tarnish", anyway?

I don't have to just sit here and wonder. Back to google.....

Yep.

Posted by Tuning Spork at June 19, 2007 10:06 PM | TrackBack
Comments

I don't have a clue what happened, but I be fairly concerned if I had inhaled any of what did that.

Posted by: Stephen Macklin at June 20, 2007 09:15 PM

Google

Posted by: dzpjb at March 11, 2008 05:03 PM

I work for an industrial hygiene consulting company and the exact same thing just happened to a client of mine. There was a freon leak in a hockey arena and a kitchen in a senior center adjacent to the arena has a powder-like rust on a lot of the stainless steel appliances. We speculate that the oven in the kitchen is heating the freon gas enough to produce hydrogen fluoride.

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