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APPENDIX C AREA AIR SAMPLING RESULTS
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PLANT OPERATIONS INFORMATION
CYWI 3-000798
I. Building 19
A. Litharge 1. Process Description:
Pig lead is cut into 15-20 pound pieces and fed into a watercooled ball mill where partial Oxidation occurs. The dross is fed through a series of two kilns, one gas-fired and one oil-fired, in which oxidation to lead monoxide is completed. The litharge is milled and packaged or used further in pro
duction.
2. Equipment Used;
Lead cutter Ball mills (2) Kilns (2) Mill Packers (2) Dust collectors
(5)
3. Ventilation System; Two Northern blowers, two Pangborns and one Micro-Pulsaire dust collector.
4. Manning; One man/shift plus help when required.
5. Job Description - Litharge Operator;
Utilizing the lead cutter, proceeds to cut pig lead into approximately five pieces and moves the pig lead to the ball mill charging area using a lift truck. Feeds pig lead to the ball mill at the prescribed rate maintaining proper process controls.
Allows the ball mill discharge (dross) to be charged through screw conveyors to the two kilns maintaining proper process controls by visual observations and chemical tests. Allows the material to be completely oxidized and transfers via screw conveyors and elevators to storage bins.
Mills the product for further processing or packaging.
B. Lead Carbonate
1. Process Description;
Litharge is slurried in water and carbonated with carbon dioxide. The slurry is dried on a steam-heated double drum dryer, milled, and packaged or used in carbonate blends.
cnv? 3'007 9g
2- -
2. Equipment Used:
Carbon.itors (2) CO^ storage tank Drum dryer Mill Packer Dust collector
3. Ventilation System: One Northern blower dust collector.
4. Manning: Two men/shift.
5. Job Descriptions:
a. Process Operator - Lead Carbonates, Sulfates, Phthalates , and Phosphites
Weighs and charges materials to the reactor performing various tests to assure the process is under control and completed.
Transfers the completed reaction slurry to a dryer hold tank and performs the drying operations which are required. Uses a belt dryer, double drum dryer or a tray dryer depending on which process is being run.
Maintains plant housekeeping standards.
b. Blender-Packer
Performs packing of product, as assigned, at any packing station in the plant. Stencils proper I.D.'on paper bag, places same on an auger packer and fills to 50 pounds. Checks and adjusts weight as necessary and stacks bags on a pallet. Moves the filled pallets to the warehouse using a rider lift truck.
Samples the packed product as required.
C. Major Sources of Lead Contamination in Building 19
1. Milling Process
2. Kilns
3. Drumming & bagging stations (litharge)
4. Transfer of material between processing stations.
5. Litharge charging to carbonate units.
3.00080
-3-
6. Carbonate drum dryer: slurry dries on the floor leaving lead residue.
7. Carbonate bag packaging unit.
II. Building 20 and 20A
A. Proctor & Schwartz Unit - Lead Phthalate and Lead Sulfate
1. Process Description:
Lead Phthalate
Litharge is slurried in water in a ribbon blender and reacted with phthalic anhydride which is pre-slurried in water before charged. The product slurry is dried in a continous belt dryer,- milled, conveyed to a blender, and packaged.
Lead Sulfate
Litharge is slurried in water in a ribbon blender and reacted with sulfuricacid to make either the monobasic or the tribasic lead sulfate. Phthalic anhydride is included in the case of the sulfophthalate. The product slurry is dried in a continuous belt dryer, milled and packaged or transferred to the blender.
-
2. Equipment Used:
Ribbon mixers (2) Dryer Mill Packer Dust collectors (3)
3. Ventilation System: Consists of one Northern Blower and two Micro-Pulsaire dust collectors.
4. Manning: Two men/shift.
5. Job Description - Blender-Packer:
Performs packing of product, as assigned, at any packing station in the plant. Stencils proper I.D. on paper bag, places same on an auger packer and fills to 50 pounds. Checks and adjusts weight as necessary and stacks bags on a pallet. Moves the filled pallets to the warehouse using a rider lift truck.
Samples the packed product as required.
CYWl 3-000801
-4-
C, Major Sources of Lead Contamination in Buildings 20 and 20A
1. Charging to the ribbon blender 2. Mixing of phthalate or sulfate
3. Trans fer to dryer
4. Drying 5. Milling
phthalate or sulphate
6. Bagging
7. Tray dumping A
8. Milling 9. Bagging
J
phosphate
III. Building 24
A. Cowles Unit - Lead Phosphite
1. Process Description
Litharge is slurried in water in a Cowles reactor and reacted with phosphorous acid to make dibasic lead phosphite. The slurry is fed directly to dryer pans. These products are dried in a tray dryer, milled and packaged.
2. Equipment Used;
Cowles reactor Dryer Mill Packer Dust collector
3. Ventilation System; Micro-Pulsaire dust collector.
4. Manning: One-two men/shift.
B. Maior Sources of Lead Contamination in Building. 24
1. Materials handling to Cowles
2. Tray filling: material becomes a source of dust after it dries.
CYWI 3-000802
-5-
3. Drying 4. Tray handling 5. Blending 6. Bagging XV. Building 24 - Warehouse A. Description of Operations: Storage and transfer of bagged material. B. Sources of Lead Contamination: 1. Movement of.bags and pallets 2. Fork lift movement
CTD/as 6203W/STORED
CYWI 3-000803
CONTROL RECOMMENDATIONS
Recommendations for reducing lead dust emissions and protecting workers against hazardous airborne lead levels are presented in Appendix A. Recommendations
are listed by building and process in order of source significance on the
basis of a source priority rating. This rating was calculated as follows:
Priority Rating 3 C x P x T
Where C = average lead dust concentration associated with the given source (mg/m^)
P = average number of persons exposed to the source
T = average number of hours (per 24 hours) of dust generation
For several processes mote than one alternative recommendation is submitted. These are listed numerically in order of effectiveness in reducing or elimin ating dust sources.
Supplementary information in the form of process descriptions, equipment lists, existing controls and job descriptions, is included in Appendix D.
GENERAL PLANT RECOMMENDATIONS
General control recommendations applying to the plant as a whole rather than specific processes are listed below:
1. Transfer all lead compounds in sealed containers. Special equipment may be required.
Consider enclosing major dust sources and/or providing clean rooms or
clean areas-for.-enl,9x<ees to occupy when stationary. This is especially
important in
tht the current regulatoTjr-mAaii^*. calls
for use
Mi <11Hi'IIIW -two.
years.
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3. Efforts to keep surfaces free of dust should be expanded to include pipes, window ledges, equipment and other dust laden surfaces.
4. Consider methods to prevent the release of lead products from bags during handling (e.g., shrink wrap, vacuum after filling).
5. Continue air sampling at regular intervals in the lab, warehouse and office to determine which of these areas are adequate for placing employees who may be removed from lead exposure due to high blood-lead levels.
CYWI 3-000804
PERSONAL HYGIENE AND GENERAL EMPLOYEE PROTECTION CONTROLS
Although the major intent of this study was the development of workplace control recommendations aimed at reducing airborne lead levels in the Chicago plant, some observations of personal hygiene and /employee protection practices were made. These practices, of course, have a, major impact on the blood--lead levels and health of exposed, employees- For this reason, efforts to upgrade and maintain controls in this area are of prime importance. The following reCominendations are submitted for consideration:
1. Continue efforts to improve respiratory protection. The MSA forced air respirator shows promise as the manufacturer reports recent improvements. Its evaluation is ongoing and final recommendations will be forthcoming.
2. Provide disposable suits and shoe covers for maintenance activities.
3. Improve showering facilities and practices.
a. Investigation into the use of an air shower exhaust prior to locker room entry is recommended. These units, currently used by the Ford Motor Corporation, may be used in lieu of vacuums and would reduce the airborne lead levels in the lockermoom during change periods (greater than 100 ug/m^). An improved general ventilation system in this area is also recommended.
b. The use of both sides of the existing shower to provide both a clean and dirty locker room is recommended.
c. Provide an adequate supply of warm water for the shower facility to promote compliance with showering requirements.
4. Assure that adequate storage facilities are provided for all types of respirators: half-masks, full masks, and air supplied units.
CTD/as 6202W/STORED
CYWI 3-000805
APPENDIX A
r e c o mme n d a t io n s f o r t h e p r e v e n t io n a n d c o n t r o l o f a ir b o r n e l e a d
CHICAGO PLANT
CYWI 3-000806
RECOMMENDATIONS FOR THE PREVENTION AND CONTROL OF AIRBORNE LEAD
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Employee P ro te c tio n
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Carbonate Bagging
CYWI 3-000809
Location/P rocess
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CYWI 3-000812
P rio rity
R ating
Location/P rocess
appen d ix b
PERSONAL AIR SAMPLING RESULTS SUMMARY
CYWI 3-000813