Document K6Q51wKVMvRkyx2Jer0R4vL00

MONSANTO INDUSTRIAL CHEMICALS COMPANY Visit At P. R. MALLORY COMPANY INDIANAPOLIS, INDIANA AUGUST 10, 1972 To Review Status of Capacitor A roclor (PCB) Dielectric Fluid HONS 063203 INDEX ( SECTION PftQE I The Need For PCB-Type Fire Resistant Dielec tric Fluids (Excerpts from the Jan. 5, 1972 report by the National Industrial Pollution Control Counoll - U.S. Dept. Commerce, Washington, D.C. 1 A. Capacitors 1-3 B. Transformers 3_5 II U.S. Government Interdepartmental Task Force Report, May 14, 1972 entitled "Polychlorina ted Biphenyls and theEnvironment" 6 A. Continued PCB use for capacitors and transformers Is considered necessary 6 B. Disposal of scrap capacitors by burial 6 C. Disposal of scrap PCB fluid by Incinera tion 6 III Handling and Policing PCB Dielectrics J A. ANSI Committee C107 guidelines for capacitors and transformers 7 B. ASTM D-27, Methodology for sampling PCBs and analysis of water and air 7 IV Purchase of Capacitor and Transformer Askareis 8 A. Pounds Aroclor Purchased by P. R'. Mallory 8ft9 B. Prices Table II 10 C. Pricing Characteristics Table III 11 V Summary of Monsanto's Actions to Meet the Elec trical Industry Requirements and To Minimize PCB Environmental Pollution 12 15 charts 12 on ( HONS 063204 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.) MCNS 063205 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-lmpregnated 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 8o million such capa citors are manufactured annually, most of them for first-time use. Capacitors used in lighting and air conditionlng applications contain 0.005 to 0.09 gallons of PCB per unit. The largest power capacitors contain about 6.7 gallons of askarel. The most popular size oontalns about 3.1 gallons. The National Electrical Code requires that any in stallation of capacitors in which a'ny 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 14.4 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 HONS 063206 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 tion': and more than ?0 years lr. electric utility applications. In each application the first-year failure rates are less than 0.2)8. 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 accompatiy those failures that re sult in rupture of the case. 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)8, the weight by 500)8, and the cost by approximately 400)8. 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 furthdr tending to Increase the coBt to the utility, and ulti mately to the consumer. b) Castor oil The dielectric constant of castor oil is 4.5 and this material is useful as an lmpregnant 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- MONS 063207 o) D1butyl Sebacate This ester is especially useful in high frequency parallel plate capacitors beoause 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 Plulds 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 Id 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 oll-lnsulated 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 063208 The amount of Aroclor used In various types of trans ( formers ranges from 4o 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-lnsulated 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 oll-lnsu lated transformers could not be directly sub stituted for PCB-lnsulated transformers. The size of the unit would be unchanged; the weight and oost 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 oost $5,000 - $50,000 per transformer. 2. Dry-type transformers _ In most locations, dry-type transformers (either thoBe 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 llquid-lnsulated transformers. An EEI survey of failures In network transformer banks showed a 7% per year failure rate for dry-type units compared to 0.2% for llquld-lnsulated units. ( -4- MONS 063209 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 nolaer 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. -5- MQNS 063210 ( SECTION II U.S. Government Interdepartmental Task Force Report May 14, 1972 Entitled "Polychlorinated Biphenyla and the Environment" ( ( MGNS 063211 II. U.S. Government Interdepartmental Task Force Report May 14, 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 Bupply 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 capacltors In the near future Is considered necessary because of the significantly Increased risk of fire and explosion and the disruption of electri I 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-contalnlng 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 970SC) Incineration must be used Instead." C. Disposal of Scrap PCB Fluid Monsanto Is one of several to provide proper high temperature Incineration and HC1 neutralizeting facilities to completely destroy PCB liquids. Monsanto charges 3 cents a pound and shipping charges are to the sender's account. -6- MONS 063212 SECTION III Handling and Policing PCB Dielectrics MGNS 063213 ( 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 dean "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 show up In effluent streams for some time. ( -7MONS 063<Ut SECTION IV Purchase of Capacitor Aroclor MGNS 063215 IV. Purchase of Capacitor Aroclor A. Pounds Aroclor Purchased by P. R. Mallory As P. R. Mallory Is one of the early manufacturers of Aroclor capacitors, their Initial use of Aro clor 125^ must date back to the 1930s. Over the past twenty years Mallory's use has ranged from 0.5# to 8.3# of the total annual amount of capacitor Aroclor used In the USA. The annual pounds used by Mallory has ranged from 73,000 to 220,000 pounds per year during the 1950s, to the 2,205,000 peak used In 1970, when the dollar volume was also a maximum at $330,000. The pounds of capacitor Aroclor purchased by P. R. Mallory over the past five years are shown in Table I. B. Prices The historical sales prices per pound for capacitor Aroclor sold to P. R. Mallory 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- MONS 063216 Table I P. R. Mallory, Purchaae of Capacitor Aroclor bounds 1968 1262 1,006,000 1,152,000 1970 2,205,740 1971 799,538 6 mo. 1972 730,900 -9- MONS 063217 Table II Historical Price of Capacitor Aroclor ----------Sold To'P.R. Mallory------------- 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 16.00* 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 063218 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: 4ljJ Increase (1953-1972) (e.g. Capacitor Fluids Increased by only Tjt, 1953-1969) 2. Increase 1970-1972 due to: - A. Successful development of Aroclor 1016- B. Loss of 45)8 PCB sales to other markets -- divisor loss C. Costs of environmental control programs -- Incinerator Program Plant Clean-up -11- MCNS 063219 SECTION V. Summary of Monsanto's Actions to Meet the Electrical Industry Requirements and to Minimize PCB Environmental Pollution -12- HONS 063220 / o MONSANTO PRESENTATION TO FEDERAL GOVERNMENT PCB TASK FORCE HAY 15, 1972 <* OBJECTIVES O PROGRESS REPORT ON LABORATORY BIODEGRADATION OF PCB'S O RESIDUE ACCUMULATION STUDIES IN FISH, BIRDS AMD MAMMALS O TO SHOW REDUCTION If) LESS BIODEGRADABLE PCB'S AS A RESULT OF MONSANTO ACTIONS ON SALES AND PRODUCTS MGNS 0 6 3 2 2 1 -O ? ? 7 E 9 0 SNOM 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 oQa MONSANTO PCB SALES IN U.S.A. (million pounds) DIELECTRICS ALL OTHERS TOTAL <o 1969 37.0 30.0 67.0 1970 40.5 33.5 74.0 1972 (est.) 32.a - 32.0 E 7 ? E 9 0 SNOW HONS C 6 3 ii4 (3 o Q~ EFFECT OF PHASE-OUT POLICY PCB SALES REDUCED IN U.S.A. BY 30 TO 33 MILLION POUNDS. OR HSl a PCB PRODUCT CHANGES IN DIELECTRICS CAPACITORS 97% CONVERSION TO AROCLOR 1016 TRANSFORMERS ELIMINATION OF AROCLOR 1260 9 ? 7 f9 0 SNOW o I o / DEGREE OF BIODEGRADATION OF PCB'S BASED ON DATA PRESENTED 0 TRANSITION IN BIODEGRADATION OCCURS AROUND PENTA-/HEXA-CHLOROBIPHENYL O DISAPPEARANCE OF ALL HOMOLOGS BELOW HEXA-CHLOROBIPHENYL OBSERVED 0 PENTA- AND HIGHER PCB DETERMINED BY SPECIFIC GLC/MS TEST METHOD CL LiiT < o~ a PCB'S USED IN CAPACITORS PCB AROCLOR 1254 AROCLOR 1242 AROCLOR 1016 MAJOR USE PERIOD 1930-1952 1952-SEPT. 1971 OCT. 1971 X PCB (PENTACHLORO- AND HIGHER 77.0 9.0 1.1 X PCB (HEXACHLORO- AND HIGHER 29.0 1.0 0.1 ? ? 9 0 SNOW o O- CAPACITOR FLUIDS WHY CONVERT TO AROCLOR 1016 ? O 9-FOLD REDUCTION IN PCB'S OF PENTACHLORO- AND HIGHER 10-FOLD REDUCTION IN PCB'S OF HEXACHLORO- AND HIGHER O MINIMUM INDUSTRY TESJING REQUIRED HOMS 0 6 3 2 2 8 TT7 5 a ' CAPACITOR FLUIDS WHAT IS THE EFFECT OF AROCLOR 1016 ? U.S. CAPACITOR FLUID SALES (1972):~20 M LBS. IF % -PENTACHLORO- Z HEXA CHLORO- ^ AROCLOR AND HIGHER PCBs AND HIGHER PCBs ~ WAS WOULD BE* WOULD BE* , 1254 15/400/000 pounds 5,800,000 pounds 1242 1016 1/800,000 220,000 200,000 20/000 THIS DOES NOT MEAN AMOUNTS OF PCB ENTERING THE ENVIROMENT 6 7 7 C 9 0 SNOW o_ OL WHAT IS CAPACITOR FAILURE RATE ? N. INDUSTRY SOURCES CITE : 0.02-0.2Z per year O E 7E 90 ENOW TX IF CAPACITOR FAILURE RATE IS 0.2% PER YEAR (WORST CASE) TT PCB ESCAPE TO THE ENVIRONMENT* IS -- ALL PCB HOMOLOGS PENTA CHLORO-AND HIGHER HEXA CHLORO- AND HIGHER AROCLOR 12*12 40.000 pounds 3,600 400 AROCLOR 1016 40.0Q0 pounds 440 ; zio ASSUMES U.S. FLUID SALES OF 20 M LB./YEAR MGNS 0 6 3 2 3 o ex o PCB CHANGES IN , TRANSFORMER FLUID APPLICATIONS % O AROCLOR 1260 BEING PHASED-OUT NOW O INCINERATION OF SCRAP PCB'S - 1971 NOTE; ASKAREL (PCB) TRANSFORMERS ARE ' TIGHTLY SEALED UNITS ? C ? f9 0 SNOW cx I CL WHAT IS FAILURE RATE IN LIQUID TRANSFORMERS ? INDUSTRY SOURCES CITE; UNDER 0.22 PER YEAR* *ALL LIQUID TYPES - -MINERAL OIL MD PCB. HONS 0 6 3 2 3 3 IF ASKAREL (PCB) IRANSFORMERS 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) #. 'A WITH INCINERATION FACILITIES AVAILABLE, NOT ALL THESE AMOUNTS KILL ENTER ENVIRONMENT. MUMS 0 6 3 2 3 4 4, o/ a MONSANTO'S PRESENT PROGRAM TO PREVENT ENVIRONMENTAL POLLUTION BY PCB'S O NO MORE SALES WORLD-WIDE EXCEPT APPROVED DIELECTRIC USERS ------------- '* O RESTRICT OVER 97Z CAPACITOR FLUID SALES TO AROCLOR 1016 ONLY O ELIMINATE AROCLOR 1260 FROM TRANSFORMER FLUIDS ` O CONTINUE INCINERATION FACILITIES FOR SCRAP PCB'S i O ENCOURAGE DIELECTRIC INDUSTRY THROUGH ANSI C-107 TO ENFORCE STRICT ENVIRONMENTAL CONTROL OVER PCB'S I MGNS 0 6 3 2 3 5