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INDUSTRIAL HYGIENE SURVEY OF THE
Polychlorinated Biphenyl Production Operation Monsanto Industrial Chemicals Company Sauget, Illinois
SURVEY DATE July 21-22, 1976
SURVEY CONDUCTED BY
Mark Jones Janson Becker
REPORT WRITTEN BY Mark Jones
DATE OF REPORT
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Industrial Hygiene Section
Industrywide Studies Branch
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Division of Surveillance, Hazard Evaluations and Field Studies
National Institute for Occupational Safety and Health
Cincinnati, Ohio
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PLACE VISITED: DATE OF VISIT:
Monsanto Company W.G. KrnmmricTi Sauget, Illinois
July 21-22, 1976
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PEOPLE CONTACTED:
Mr. Art Leisy Manufacturing Superintendent
Mr. Paul Heisler Supervisor--'-Air--Pollution f- . r { ,
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Mr. Bruce Eley Corporate Industrial Hygienist
Mr. Virgil Brawley Supervisor - PCB Production
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Mr. John Peduzzi Supervisor - Incineration
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' " ' ' ^ Mr. Julio MunSoz - Air Pollution Group
<;... Mr. Neil Sullivan - Air Pollution Group
Mr. Frank Basile - Air Pollution Group
, Mr. Ed Newman - Air Pollution Group
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Mr. Dale Rachel - Foreman, Mr. Tom Carrico - Foreman,
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PCBs PCBs
Production Production
PERSONS MAKING VISIT:
Mark Jones ' Janson Becker
PURPOSE:
To conduct an industrial hygiene survey to determine the'workers' level of exposure to chemicals present in the polychlorinated biphenyls production area at the Sauget, Illinois facility.
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. INTRODUCTION
Recent-literature has .
. carcinogenic effects.
linked polychlorinated biphenyls with possible _.
Because this literature is incomplete, the
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Division of Surveillance, Hazard Evaluations and Field Studies of the
National Institute for Occupational Safety and Health has underway an
"industrywide" study of industries using polychlorinated biphenyls.
Since Monsanto is the sole producer of polychlorinated biphenyls in the
United States, an industrial hygiene survey was conducted at their
PCBs production area in Sauget, Illinois, on July 21-22, 1976. This
survey was conducted by Janson Becker and Mark Jones.
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During the visit, 18 air samples were collected for evaluation of
polychlorinated biphenyls exposure. In addition, samples were collected
for exposure to iron silica and chlorine.
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DESCRIPTION OF THE FACILITY
The polychlorinated biphenyls production operation is one_of many operations
present at the Monsanto facility in Sauget, Illinois. Sulfuric acid,
-V -boasrsns', and benzene derivatives, rubber chemicals (antioxidants, etc.),
activated chlorine and phosphorous products are other products produced
at the facility.
The facility began production of polychlorinated biphenyls around 1929.
Production continued to grow until 1970 when Monsanto began restricting
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the sale of PCBs let use in closed systems. .
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The entire work force at the facility is approximately 1300 persons,
with approximately 835 of these persons being hourly employees.
Approximately 25 employees are involved with the production of PCEs.
The union representing this group is the International Chemical
Workers, Local $12.
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MEDICAL., INDUSTRIAL HYGIENE AND SAFETY PROGRAMS
A dispensary is located at the plant. Nurses are present at the
dispensary 24 hours a day and a physician is present during the
day. All employees are required to take a pre-employment physical
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examination Certain--employees-are -then--required~to--take -periodic
iica-1 examinations. physical
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Industrial hygiene matters at the facility are handled by the Air
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Pollution Group. The six people,who are assigned to this group*work
in conjunction with the safety department. The only sampling that has
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UAbeen done for polychlorinated biphenyls is the discharge1 from the area / v.^u-
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<0 ^ i-SnJnoai'fcQiad twice a week and the collection of. a few air samples (Appendix B),
Four people work in the safety department. Safety meetings are . held every month and safety information is provided to the different work areas through safety committees. Personal protection programs used at the plant include safety shoes, safety glasses, hard hats, protective clothing and respirators (where needed).-
Corporate industrial hygienists also give support to the industrial hygiene and safety programs.
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DESCRIPTION OF PROCESS
Three products are made in the PCBs production area: Aroclor 101b,
Aroclor 1242, and Aroclor 1254. Aroclor 1016 is used in capacitors
and Aroclor 1242 and 1254 are used in transformers. The operation is
outdoor and consists mainly of pipeline, reaction vessels, distillation
columns and storage tanks. Even though the system is theoretically
a closed system, samples are drawn off and leaks occur which give
a potential for employee exposure.
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Biphenyl is brought to the facility by tank car and pumped to storage tanks. The chlorine used for the operation comes by pipeline from another part of the plant. The chlorine and biphenyl are piped into a ' ' O- -~. chlorinator in the presence of an--Armi catalyst and allowed to react. ' There are two separate groups of chlorinators, one group for producing Aroclor 1254 and the other for Aroclor 1242. The product from the Aroclor 1254 chlorinators goes through a purifying operation which includes a still, receiving tank and filtering system. From this operation the polychlorinated biphenyls go to the appropriate storage tank. The product from the Aroclor 1242 chlorinators goes to an inter mediate storage tank and then either through a similar operation as the Aroclor 1254 or to a distillation column which soparatoc the--difforcnt pelyehlerina-ted--hiphenytrisemers- for producing Aroclor 1016. From here it goes to the storage tanks. :
The mixing tanks are used to formulate the final product by the intro duction of the appropriate additives needed to give the polychlorinated
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biphenyls the properties desired by the customer. To give-the--pely-
. (Mu. Otiutl /tr. Uiatomaceous earth is added--to the blend-
^iltered-eut.
. INSPECTION OF PLANT.
Potential Health Hazards
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Potential health hazards observed during this survey were as follows:
1. Polychlorinated biphenyls exposure
2. Chlorine exposure
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3. Free silica exposure .
Ventilation
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Since the operation is outdoors there is very-littie-ventilation. Local
exhuast ventilation is used in two operations. The drumming operation
is equipped with a hose which is placed near the opening of the 55 gallon
drum while it is filled. Near the chlorinators is a work station where
employees perform specific tests on samples drawn from the chlorinators.
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This work station has a hood over the area where the tests are performed.
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Housekeeping
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Housekeeping in the polychlorinated biphenyls production area was taken
care of fairly well. The aisleways were kept clean and clear.
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SURVEY PROCEDURES
. General `
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Air samples were collected in the polychlorinated biphenyls production
area for evaluating exposure to polychlorinated biphenyls, iron chloride,
and chlorine. A bulk sample of the diatomaceous earth used was analyzed
for free silica content. The following paragraphs describe the methods
used to collect and analyze the air samples.
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Polychlorinated Biphenyls
Both personal and area air samples were collected in the polychlorinated
biphenyls production area. Sipin SP1 pumps were used to collect the air
samples on florosil tubes. The tubes contain a magnesium silicate,
absorbent called florosil and have a 100 mg primary section and a 50 mg
backup section. Samples were collected for six to eight hours at a flow
rate of approximately 200 cc/min. The polychlorinated biphenyls were
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desorbed from the florosil with hexane and analyzed by using a gas chromato
graph with an electron capture detector.
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Iron Chloride
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Area air samples were collected, for iron chloride while the employees
poured the iron chloride (powder)
in t-n
cfwr.i. MSA Model G
pumps were used to collect the air samples on a 0.8 micrometer pore
size mixed cellulose ester filter (37 mm in diameter). Samples were
collected for the duration of the task which was approximately three
minutes at a flow rate of 1.7 liters per minute. The samples were
analyzed for iron by atomic absorption and are reported as such.
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Free Silica
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One bulk, sample of the diatomaceous earth used was collected for analysis of
free silica content- The per cent free silica was determined by x-ray
diffraction.
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Chlorine '
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Detector tubes were used to evaluate concentrations of chlorine in the
PCBs production area. Chlorine measurements were made using "Bendix
Gastec Analyzer Tubes - Low Range (1-8 ppm)."
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RESULTS AND DISCUSSION
Polychlorinated Biphenyls
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The results of the area and personal air samples are given in Table 1
and the job descriptions corresponding to the job titles are in Appendix A.
Eleven personal and seven area air samples were collected for analysis
for polychlorinated biphenyls. The polychlorinated biphenyls being
produced at the time of the survey were for Aroclor 1016 (42% chlorine).
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The personal air samples ranged from a concentration of 20 pg/m to
86 pg/m while the area air samples ranged from 16 pg/m to 55 pg/m .
These are all well below the current standard for chlorodiphenyl (42%
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of chlorine) of 1 mg/m . However, this--standard--is~based-upon~&kin
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`irritation
Recen.t. lite-r-a---t_u--r--e- Lhas^Tihlced ^ca-r-c-in-o-g--enic e^ffects to
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polychlorinated biphenyls. Therefore, this standard may not adequately
' protect the workers health.
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Iron Chloride
The results of the air samples are given in Table II. Two samples were
collected for deCerrrLiiing worker exposure to iron chloride. No iron
. could be detected on one of the samples, but the other sample ffad an
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iron concentration of 8.1 mg/m . Since this procedure of adding the iron pv>> '>
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catalyst~t.o_the_reactor only takes^ 3 minutes a-nd-is nitjne--oneeffcrshif t
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the workers time weighted average is well below the current standard for iron salts of 1 mg/m^ based upon soluble iron. The big difference in
sample results was probably due to the differences in operating procedures
observed each time the task was performed.
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Free Silica
The bulk sample of diatomnceous earth was analyzed and determined to
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have a free silica content of 9.8%. Since the pr-oeedure-rtf--adding
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<jiatomac.eious~earth- to~&he~blend-~-tank'-is done usually only once a week,
the survey team was unable to observe this procedure.
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Chlorine
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No concentrations of chlorine were detected.
CONCLUSIONS AND RECOMMENDATIONS
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Based on the observations made during this survey and the results of the
air samples, the following conclusions are drawn and recommendations for
improvements made:
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1) Even though the concentration of iron chloride found during--the
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addition-nf--tne~-catalyst'to-the "reactor is below the Federal
Standard, it would be good industrial hygiene practice to continue
wearing an approved respirator when this task is performed.
2) Since the diatomaqeous earth contains 9.8% free silica., an. ' approved dust respirator should be worn when the worker performs this task if this practice is not presently employed.
3) Because of the recent concern of the possible carcinogenic effects of polychlorinated biphenyls, engineering methods should be used to prevent employee exposure to polychlorinated biphenyls.
4) Emergency equipment (self-contained breathing apparatus) should
be readily available in case of a chlorine leak. .
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. Table I
CONCENTRATIONS OF POLYCHLORINATED BIPHENYL (detected as Aroclor 1016) IN A FACILITY MANUFACTURING POLYCHLORINATED BIPHENYLS.
Personal Air Samples
Job Title ,
Premium Operator , ' . II
Second Operator l
Column Operator VI
Still Operator . II
Standard Operator
Distribution Operator .11 .
Date
7/21 7/22
7/21 7/22
7/21 7/22
7/21 7/22
7/22
7/21
7/22
Total Time (min.)
Volume (liters)
436 451
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91.0 97.8
432 448
80.0 95.3
446
74.9 85.7
432
444
445
94.6 67.6
96.1
413
88.3
419
91.3
Concentration ^ (yg/m3)
(y^/m3)
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33
46 44
43
64 57* 51
40 86 63
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54 45
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Location
Area Air Samples
1------------------ Total Time .
Date
(min.)
Volume (liters)
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Concentratian Average
(l_g/m3)
(u>:/m ) |
Drumming If
7/21 7/22
Temperature Testing
7/21 7/22
418 418
417 455
89.1 . 87.6
201.6 : 105.4
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25 52
It48 ' K |
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Chlorinators ' . ' vi.
Incinerator Burner
7/21
419
. ' 7/22 . , 459
7/21
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89.0 70.3
81.6
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Arithmetic Average
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Table II
CONCENTRATIONS OF IRON CHLORTOK FOUND WHILE OPERATOR ADDED IT AS A CATALYST
' Location
Date
Near Reactor Lid
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7/21 7/22
Total Time (min.)
Volume (liters)
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5.1 5.1
Concentration of Iron (mg/m3)
N.D. 8*.1
Concentration of Iron Chloride (mg/m3)
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Appendix A
''V': ; ; . JOB DESCRIPTIONS
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Premium Operator - Operates both the continuous and batch chlorinators.
This includes keeping the chlorinators running, adding
iron chloride
cafcalyst^nce-'e^shift and drawing samples offr-twlce'd' bhilL. . =.
Second Operator - Loads the tank cars for shipment and takes care of the
tank farm and blend tanks.
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Standard Operator - In charge of making sure area is clean and does all
the filling of the 55 gallon drums.
Column Operator - Operates the distillation column used to produce
Aroclor 1016;
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Still Operator -Operates both stills used in producing Arolcor 1254 and
1242. :
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Distribution Operator - Works in a different area of the plant and is
in charge of operating the incinerator.
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