Document 6bEqRjbJRE09qRkG78xwDdGYm

o o MONSANTO INDUSTRIAL CHEMICALS COMPANY Visit At AEROVOX CORPORATION NEW BEDFORD, MASS. SEPTEMBER 1972 To Review Status of Capacitor Aroclor (PCB) Dielectric Fluid HONS 040231 INDEX SECTION I - The Need For PCB-Type Fire Resistant Dielec tric Fluids (Excerpts from the Jan. 5, 1972 report by the National Industrial Pollution Control Council - U.S. Dept. Commerce, Washington, D.C. . A. Capacitors .. B. Transformers XI U.S. Government Interdepartmental Task Force Report, May 14, 1972 entitled "Polychlorina ted Biphenyls and the.Environment". A. Continued PCB use for capacitors and transformers is considered necessary B. Disposal of scrap capacitors by burial C. Disposal of scrap PCB fluid by incinera tion III Handling and Policing PCB Dielectrics A. ANSI Committee C107 guidelines for capacitors and transformers B. ASTM D-27, Methodology for sampling PCBs and analysis of water and air. IV Purchase of Capacitor and Transformer Askarels A. Pounds Aroclor Purchased by Aerovox B. Prices Table II C. Pricing Characteristics Table III V Summary of Monsanto's Actions to Meet the Elec trical Industry Requirements and To Minimize PCB Environmental Pollution 15 charts PAPE 1 1-3 3-5 6 6 6 6 7 7 7 8 8&9 10 11 12 12 on HONS 040232 SECTION I The Need For PCB-Type Fire-Resistant Dielectric Fluids (Excerpts from the Jan. 5, 1972 report by the National Industrial Pollution Control Council - U.S. Dept. Commerce, Washington, D.C.) HONS 040233 I. The Need.For PCB-Type Fire-Resistant Dielectric Fluids (Excerpts from the Jan. 5, 1972 report by the National industrial Pollution Control Council - U.S. Dept. Commerce, Washington, D.C.) A". The Need For PCB Type Dielectric Fluids In Capacitors 1. Widespread use of PCB capacitors PCBs are used in more than 90# of the electric utility (large power) type and smaller indus trial type capacitors made today. They are needed for safety, reliability and long life, and to achieve sizes compatible with equipment and installation requirements. The principal types of PCB-Impregnated capaci tors and their applications are high voltage power capacitors used primarily for power fac tor correction in the distribution of electric power; low voltage power capacitors Installed in industrial plants at the load (typically large motors); ballast capacitors to Improve the efficiency of lighting systems; and small industrial capacitors for power factor improve ment in such equipment as air conditioning units, pumps, fans, etc. Almost 80 million such capa citors are manufactured annually, most of them for first-time use. Capacitors used in lighting and air condition ing applications contain 0.005 to 0.09 gallons of PCB per unit. The largest pow.er capacitors contain about 6.7 gallons of askarel. The most popular size contains about 3.1 gallons.' The National Electrical Code requires that any in stallation of capacitors in which -any single unit contains more than 3 gallons of combustible liquid shall be in a vault like that required for transformers. During 1968, the last complete "normal" year for the electrical Industry, the total amount of fire resistant PCBs used in capacitors was approximately l^.il thousand tons. 2. Reliability, life and safety of PCB capacitors PCBs are thermally and oxidatively more stable than mineral oils and most other dielectric fluids. Discharges, which can occur in capa citors, are less likely to generate gases from askarels than from mineral oils. The chemical stability of PCBs in the presence of capacitor MONS 040^34 o o o . tissue and plastic films and the favorable stress distributions between solid and liquid have made it possible to design lowcost capacitors with a life expectancy of more than 10 years life in lighting applica tions and more than 20 years in electric utility applications. In each application the first-year failure rates are less than 0.2#. This level of life and reliability had not been achieved prior to the introduction of PCBs. The relative non-flammability of PCBs signi ficantly reduces the fire hazard that might otherwise accompany those failures that re sult in rupture of the case. 3. Consideration of other dielectric fluids for PCB-type capacitors a) Mineral oil The single most important property of a liquid to be used in a capacitor is its dielectric constant (the ratio of its ability to store electrostatic energy relative to air). The dielectric constant of the capacitor-grade PCB (Aroclor 1242) is 5.85 while that of mineral oil is 2.25. Reverting to an oil-paper dielectric system would increase the average capacitor volume (size) by approximately 600#, the weight by 500#, and the cost by approximately 400#. At the present levels of demand for capaci tor KVAR, there would be a shortage of elec trical grade paper and a shortage of capa citor factory facilities further tending to increase the cost to the utility, and ultl- , mately to the consumer. . b) Castor oil The dielectric constant of castor oil is 4.5 and this material is useful as an impregnant in D.C. energy storage capacitors. However, A.C. capacitors filled with this liquid have relatively short lives and are not very stable under A.C. discharges and in the presence of water derivable from the celluloslc paper. -2- HONS 040235 o) Dlbutyl Sebacate This ester Is especially useful in high frequency parallel plate capacitors because of its low, flat loss characteristics over a broad frequency range. In this type of con struction the liquid is the sole dielectric material. When used in conjunction with paper this ester is also unstable. d) Silicone Fluids These materials have a dielectric constant of 2.7 and would generally be subject to the same disadvantages as mineral oil. 4. Monsanto developed Capacitor Aroclor 1016 to achieve a higher degree of environmental compatibility. As the environmental studies indicated that the higher boiling (the higher chlorinated) PCB isomers persist in the general environment, Monsanto sub stantially removed these persistent components from commonly used capacitor Aroclor 1242. This Aroclor 1016 capacitor dielectric has the same fire-resistant rating assigned to Aroclor 1242 by the Underwriter's laboratory. Replacement of Aroclor 1242 with Aroclor 1016 in capacitors Involved no handling, process nor capa citor design changes. This work done by Monsanto in collaboration with the capacitor industry was culminated by universal adoption of Aroclor 1016 for capacitors in mld-1971. The Need For PCB-Type Dielectric Fluid Jn Transformers Because of the nonflammability of transformer askarel fluids, their vapors, and their arc-formed gaseous products, transformers filled with PCBs are free of fire and explosion hazards and may be used in locations where failures of oil-insulated transformers would pre sent a potential danger to life and property. Most of these transformers are located inside public, commercial, or Industrial buildings; on the roof tops of such buildings or in close proximity to such build ings, and require no special enclosures other than what are necessary to prevent accidental hazardous mechani cal or electrical contact of persons with the equipment -3- MONS 040236 o o The amount of Aroclor used in various types of trans formers ranges from 40 to 500 gallons (516 to 6,450 lbs.) with an average of about 235 gallons (3,032 lbs.). During 1968, the last complete "normal" year for the electrical Industry, the total amount of PCBs used In transformers was approximately 1.3 million gallons (8.4 thousand tons). The only present alternatives to Aroclor-insulated transformers are mineral oll-lnsulated transformers or dry-type transformers (either those open to the atmos phere or those that are gas-filled and sealed). Alternatives 1. Mineral oll-lnsulated transformers a) If one disregards safety considerations, there are no technical reasons why mineral oil-lnsulated transformers could not be directly sub stituted for PCB-lnsulated transformers. The size of the unit would be unchanged; the weight and cost would be less. b) But one cannot disregard safety considerations, which are often embodied In legal codes. Obviating the safety hazards Involves serious economic and space constraints, that would occur either by the use of protective vaults, or use of Insulated buses (with the transformer loca' ted outdoors). Either solution. If the space is available, could cost $5>00.0 - $50,000 per transformer. 2. Dry-type transformers ` In most locations, dry-type transformers (either those, open to the atmosphere or those that are gas-filled and sealed) could not be directly sub stituted for PCB-lnsulated transformers. There are several restrictions to such a direct substitution: a) The reliability of dry-type transformers Is less than that of comparably rated liquid-insu lated transformers. An EEI survey of failures In network transformer banks showed a 75$ per year failure rate for dry-type units compared to 0.2J$ for liquid-insulated units. -4- MUNS 040237 Q O b) Furthermore, liquid-insulated transformers have a much greater overload capability. Many liquid-insulated units can sustain a 100% overload for 8 hours and a 200% over load for 2 hours. These transformers are able to maintain continuity of electrical service during periods of temporary mal function of related equipment. c) Some dry-type transformers are larger by 10 to 30% than comparably rated liquid in sulated units, and most are more expensive. d) Dry-type transformers are noiser by 5-10 dB than are liquid-insulated transformers. e) Open dry-type transformers, which are cheaper than sealed dry-type transformers, cannot be used in certain corrosive or hazardous atmos pheres, e.g. on furnaces or on electrostatic precipitators near hot stacks. 3. Other fluids The fire underwriters will not accept the use of oils, silicones and other flammable liquids for indoor transformers. No currently available liquid which will replace askarels in existing transformers is known. MONS 040238 o SECTION II U.S. Government Interdepartmental Task Force Report May 14, 1972 Entitled "Polychlorinated Biphenyls and the Environment" HONS 0<*0Z39  o II. U.S. Government Interdepartmental Task Force Report May lit, 1972 Entitled "Polychlorinated Biphenyls and the Environment This report is available from the National Technical Information Service, U.S. Department of Commerce, Springfield, Va. 22151. The task force included opera ting units of five Executive Branch Departments: Department of Agriculture Department of Commerce ' Department of Health, Education & Welfare Department of Interior Environmental Protection Agency These government agencies are fully appraised of Mon santo's voluntary actions to discontinue sale and supply of PCBs for all non-electrical uses. The Task Force Report states: A. "The use of PCBs should not be banned entirely. Their continued use for transformers and capacl- tors in the near future is considered necessary because of the significantly Increased risk of fire and explosion and the disruption of electri cal service which would result from a ban on PCB use. Also, continued use of PCBs in transformers and capacitors presents a minimal risk of environ mental contamination. The Monsanto Company, the sole .domestic producer, has reported voluntarily eliminating its distribution of PCBs to all ex cept manufacturers of electrical transformers and capacitors." , B. Disposal of Scrap Capacitors ^ "Most capacitors presumably have been disposed of In landfills. PCB-containing material burled in soil is not expected to migrate but should remain in place. In the past, many fluids containing PCBs have been disposed of in sewers. More appro priate means of disposal such as high temperature (at least 970C) incineration must be used instead." C. Disposal of Scrap PCB Fluid Monsanto is one of several to provide proper high temperature incineration and HC1 neutrallzatlng facilities to completely destroy PCB liquids. Monsanto charges 3 cents a pound and shipping charges are to the sender's account. -6- MQNS 040240 3 SECTION III Handling and Policing PCB Dielectrics o o HONS 040241 o III. Handling and Policing PCB Dielectrics A. The American National Standards Institute ANSI Committee C107 composed of a capacitor section and a transformer section, on behalf of all parties interested in PCB dielectrics, is scheduled to publish Guidelines for hand ling and disposal of capacitor-grade askarels and transformer-grade askarels. B. PCB analysis Methodology developed by Monsanto and others is in process of documentation at ASTM D-22 for sampling and analyzing of PCB from water and air. C. Need to Avoid Environmental Contamination While the continuing need for PCBs in closed elec trical applications is conclusive, the electrical industry must well understand that continued use of these materials requires unusual protective measures and exceptionally clean "house keeping". EPA plans to regulate the controllable sources of PCBs to the water environment. Pish and shellfish will be examined to reveal locations with high PCB content. The PDA guideline allows no more than 5 ppm PCB in the edible portion of fish. It is not believed necessary to regulate PCBs in air, at this time. The industry goal is "zero" concentration of PCB in plant water effluent streams. However, it is recognized that existing drain systems in (for example) capacitor manufacturing plants are prob ably contaminated as a result of past practices and PCB traces may continue to 3how up in effluent streams for some time. o MQNS 040242 -7- Section IV Purchase of Capacitor Aroclor HONS 040243 IV, Purchase of Capacitor Aroclor A. Pounds Aroclor Purchased by Aerovox Corporation As Aerovox is one of the early manufacturers of Aroclor capacitors, their initial use of Aroclor 125*1 must date back to the 1930s. Over the past twenty years Aerovox's use has ranged from 6.056 to 8.9 of the total annual amount of capacitor Aroclor used in the USA. The annual pounds used by Aerovox has ranged from 771,000 to 1,441,800 pounds per year during the 1950s, to the 1,898,000 peak used in 1970, when the dollar volume was also a maximum at $294,300. The pounds of capacitor Afoclor purchased by Aerovox over the past five years are shown in Table I. B. Prices The historical sales prices per pound for capacitor Aroclor sold to Aerovox are given in Table II. C. Monsanto Dielectric Fluids Pricing Characteristics 1. Unusual price stability through the years until .1970. 2. Increases 1970-1972 fully accounted by factors related to the PCB environmental problem; see Table III. -8- MQNS 040244 Table II Historical Price of Capacitor Aroclor Sold to Aerovox Year 1953 1957 I960 1964 1966 1970 1971 1972 Price Per Pound (Bulk) 14.0^ Not Delivered 13.88^ Delivered 14.98^ Delivered 14.50^ Delivered 14.95^ Delivered l6.00j< Delivered 18.00^ Delivered 20.50^ Not Delivered - Product Aroclor 1242 Aroclor 1242 Aroclor 1242 Aroclor 1242 Aroclor 1242 Aroclor 1242 Aroclor 1016 , Aroclor 1016 -10- MONS 040245 Table III Monsanto Dielectric Fluids Pricing Characteristics 1. Unusual price stability until 1970 even though -- Cost Increases Labor Costs: 197# Increase (1953-1972) Raw Materials: 20# Increase (1953-1972) Indirect Fixed Costs: itl# Increase (1953-1972) (e.g. Capacitor Fluids increased by only 7# 1953-1969) 2. Increase 1970-1972 due to: A. Successful development of Aroclor 1016 B. Loss of ^5# PCB sales to other markets -- divisor loss C. Costs of environmental control programs -- Incinerator Program Plant'Clean-up -11- MONS 040246 o SECTION V. Summary of Monsanto's Actions to Meet the Electrical Industry Requirements and to Minimize PCB Environmental Pollution o o -12- MQNS 040241 HONS 0 4 0 2 4 8 . O' I' i o ' MONSANTO PRESENTATION TO FEDERAL GOVERNMENT PCB TASK FORCE . MAY 15, 1972 . OBJECTIVES O PROGRESS REPORT ON LABORATORY BIODEGRADATION OF PCB'S O RESIDUE ACCUMULATION STUDIES IN FISH, BIRDS AND HAriHALS O TO SHOW REDUCTION IN LESS BIODEGRADABLE PCB'S AS A RESULT OF MONSANTO ACTIONS ON SALES AND PRODUCTS & MONSANTO PCB ACTIONS O PHASE-OUT OF PCB SALES WORLDWIDE IN ALL APPLICATIONS EXCEPT DIELECTRICS O CONVERSION OF DIELECTRIC FLUIDS TO MORE BIODEGRADABLE PCB'S \3 o co <D MONSANTO PCB SALES IN U.S.A. (million pounds) DIELECTRICS ALL OTHERS TOTAL 1969 37.0 30.0 67.0 1970 * 1972 (est.) 40.5 32.a 33.5 74.0 -- ' 32.0 MONS 0 4 0 2 5 0 MQNS 0 4 0 2 5 1 Q Oo EFFECT OF PHASE-OUT POLICY PCB SALES REDUCED IN U.S.A. BY 30 TO 33 MILLION POUNDS. OR 452 <h MONS 0 4 0 2 5 2 ) O I oo PCB PRODUCT CHANGES IN DIELECTRICS ' CAPACITORS 971 CONVERSION TO AROCLOR 1016 TRANSFORMERS ELIMINATION OF AROCLOR 1260 o On I / DEGREE OF BIODEGRADATION OF PCB'S BASED ON DATA PRESENTED O TRANSITION IN BIODEGRADATION OCCURS AROUND PENTA-/HEXA-CHLOROBIPHENYL O DISAPPEARANCE OF ALL HOMOLOGS BELOW HEXA-CHLOROBIPHENYL OBSERVED O PENTA- AND HIGHER PCB DETERMINED BY SPECIFIC GLC/MS TEST METHOD HONS 0 4 0 2 5 3 (D OO CD PCB'S USED IN CAPACITORS PCB AROCLOR 1254 AROCLOR 1242 AROCLOR 1016 ' * % PCB (PENTA-" MAJOR CHLORO- AND USE PERIOD HIGHER 1930-1952 77.0 1952-SEPT. 1971 9.0 OCT. 1971 1.1 % PCB CHEXACHLORO- AND HIGHER 29.0 1.0 0.1 HONS 0 4 0 2 5 4 11 <> : 05 ^ CAPACITOR FLUIDS WHY CONVERT TO AROCLOR 1016 I O 9-FOLD REDUCTION IN PCB'S OF PENTACHLORO- AND HIGHER O 10-FOLD REDUCTION IN PCB'S OF HEXACHLORO- AND HIGHER O MINIMUM INDUSTRY TESTING REQUIRED HONS 0 4 0 2 5 5 V5. o <D CAPACITOR FLUIDS WHAT IS THE EFFECT OF AROCLOR 1016 ? U.S. CAPACITOR FLUID SALES (1972h~20 M LBS. ' IF AROCLOR WAS %PENTACIIL0R0AND HIGHER PCBs WOULD BE* l HEXA CHL0R0AND HIGHER PCBs WOULD BE* 1254 1292 1016 , 15,900.000 pounds 1,800,000 ' 220,000 5,800,000 pounds 200,000 20,000 THIS DOES' NOT MEAN AMOUNTS OF PCB ENTERING THE ENVIRONMENT 9s? 0 *0 SNOH CD oo 03 WHAT IS CAPACITOR FAILURE RATE ? O INDUSTRY SOURCES CITE : 0.02-0.2Z per year HONS 0 4 0 2 5 7 PCB CHANGES IN .. TRANSFORMER FLUID APPLICATIONS O AROCLOR 1260 BEING PHASED-OUT NOW O INCINERATION OF SCRAP PCB'S - 1971 MONS 0 4 0 2 5 8 , NOTE: ASKAREL (PCB) TRANSFORMERS ARE TIGHTLY SEALED UNITS oo GD WHAT IS FAILURE RAIE IN LIQUID TRANSFORMERS ? INDUSTRY SOURCES CITE: UNDER 0.2% PER YEAR* ALL LIQUID TYPES - -MINERAL OIL M PCB. CD IF ASKAREL (PCB) TRANSFORMERS FAIL AT 0.2%/YEAR HOW MUCH PCB IS AFFECTED *' ? ALL PCB HOMOLOGS 24,000 lbs. (ESTIMATED PCB TRANSFORMER FLUID SALES IN U.S. 12 M LBS./YEAR) `WITH INCINERATION FACILITIES AVAILABLE, NOT ALL THESE AMOUNTS WILL ENTER ENVIRONMENT. HONS 0 4 0 2 6 0 & o CP MONSANTO'S PRESENT PROGRAM TO PREVENT ENVIRONMENTAL POLLUTION BY PCB'S O NO MORE SALES WORLD-WIDE EXCEPT APPROVED DIELECTRIC USERS . * O RESTRICT OVER 97% CAPACITOR FLUID SALES TO S AROCLOR 1016 ONLY O ELIMINATE AROCLOR 1269 FROM TRANSFORMER FLUIDS O CONTINUE INCINERATION FACILITIES FOR SCRAP PCB'S o ENCOURAGE DIELECTRIC INDUSTRY THROUGH ANSI 0107 TO ENFORCE STRICT ENVIRONMENTAL CONTROL OVER PCB'S MQNS 0 4 0 2 6 1 I Monsanto has attempted to act responsibly as concern about the effects of PCBs on our environment developed. Based on cur rent knowledge about PCBs, the approach presently being taken by the U.S. Government and the continued need by our customers In the electrical Industry for PCB-contalnlng dielectric fluids, Monsanto Intends to maintain Its policy of remaining a supplier of these materials for dielectric uses. However, should changes In present conditions occur, Monsanto may find It appropriate to revise Its policy. MQNS 040262