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ETHYL CORPORATION
INTER-OFFICE
To : T. R. Robinson, M.D,
Address : BRP
From : J. D. Watts
Subject : Vinyl Chloride Monomer Survey Hydrocarbon Area
Address ; BRT/BRP Date : Nov. 14, 1975
As part of the comprehensive survey, an industrial hygiene evaluation was made of the airborne contaminants associated with the production of vinyl chloride monomer.
Summary and Recommendations
The environmental sampling scheme indicates that the levels of vinyl chloride monomer (VCM) are usually below the OSHA standard of 1.0 ppm on a time weighted basis. Furthermore, only five of 21 samples collected (24%) exceeded the action level of 0.5 ppm. Also, the levels of many other hydrocarbon contaminants (the spectrum from methyl chloride to perchloroethylene) were well below their re spective standards.
The highest VCM concentrations were localized on the ground floor of the #2 EDC plant (compressor P23A) and in the rundown tank area. From an environmental standpoint and under restrictive operating conditions (production rates less than 50% of maximum), there appears to be no hygienic problem and thus, no additional control measures are recommended.
Description of Process - Recognition
Vinyl chloride monomer is used predominantly in the manufacture of polyvinyl chloride but is also utilized as an intermediate in the production of 1,1,1 trichloroethane. It is manufactured by the cracking of 1,2 dichloroethane (EDC) as shown in the following reaction
Cl, CH2C1CH2C1 + heat -------- --------- ^ CHC1 = CH2 + HC1
EDC VCM
The gas mixture from the furnace is quenched, partially condensed, and fractionated into VCM product, by-product HCl, and recovered EDC for recycle to the process.
Seven employees are potentially exposed to this cancer-suspect agent including the following operator job codes: control room (2), compressor house, tower, furnace cracking, tank car loader, and process attendant. The compressor house man and loading operator are potentially exposed to the higher VCM concentrations due to the collection of quality control samples and disconnecting tank car lines.
EC 4327
Nov. 14, 1975 Page 2
Evaluation
Samples were collected at fixed station points (#2 EDO plant, control room, VCM/HCl column, and rundown tank area) at a sample rate of approximately 1.5 liters/minute. The hydrocarbon contaminants were adsorbed on activated charcoal with subsequent analysis by gas chromatography. The survey results are shown in the following appendix.
JDW:sp cc: H. M. Taylor Enclo.
u. D. Watts Industrial Hygienist
APPENDIX VCM Plant Survey Results AREA: #2 EDC Plant (North)
Component
TLV (ppm)
Benzene Butane Carbon Tet Chloroform 1,1 DCE EDC Ethyl Cl Methyl Cl Methylene Cl Per Propane Toluene 1,1,1 TCE Tri
10
10 25 100 50 1000 100 200 100
100 350 100
VCM
Vinylidene Cl Unk^ Unk2 Unk3
1 10
Weather Conditions
Sampling Dates and Concentrations (ppm)
8/29
10/7
10/8
10/21
0.02 0.11
< 0.04
0.07
0.12
0.16 0.53 0.03
0.15 0.21 0.01 0.24 0.24 0.09 0.07
5.4 0.24 0.09
0.06 0.06
0.13 4.45* 0.18
PC, 850 ESE-E
Cloudy, 70o, NW
1.06 0.24 0.16
0.06 0.34 0.02
0.035
< 0.03 1.26 0.05 0.27
< 0.02 < 0.01
1.8 0.01 < 0.005 0.01
0.13
0.49
0.05
X X X
Cloudy-PC, 75,variable
Clear, 76, S
EC 4329
II
APPENDIX VCM Plant Survey Results
AREA: #2 EDO Plant (Ground Floor)
Date
Location
10/7
South Compressor P28A
10/8
Middle Compressor P28-C-P28D
Component
Benzene EDC Ethyl Cl Methyl Cl Per Propane Tri VCM
Vinylidene Cl
Concentration
< 0.04 6.8 0.27 0.08 0.06 0.085 0.095 0.78
0.06
Butane EDC Ethyl Cl Methyl Cl Per Propane Toluene Tri
VCM
0.07 1.83 0.25 0.16 0.04 0.45 0.01 0.04
0.175
F.C 4330
Ill
AREA: #2 EDC Plant
Component
10/7
Benzene Butane EDC Ethyl Cl Methyl Cl Methylene Cl Per Propane Toluene Tri Unk
VCM Vinylidene Cl
< 0.04
6.64 0.31 0.085
0.06 0.37
0.08
0.42 0.02
10/8 0.075
3.7 0.33 0.19
0.04 0.97 0.02 0.03
0.24 0.02
10/17
0.13 1.06 0.26 0.32 0.07
5.08 0.01
X
0.12
Location
Between Compressor House & Production Unit
EC 4331
IV
AREA: Control Room
Component
10/9
Benzene Butane Carbon Tet Chloroform 1,1 DCE EDC Ethyl Cl Methyl Cl Methylene Cl Per Propane Toluene 1,1,1 TCE Tri VCM Vinylidene Cl Unk
0.08
0.8 1.8 1.85
0.06 0.03
< 0.025 0.05 0.15
Weather Conditions
10/14
10/17
10/21
0.21
0.14
0.4
0.63 0.22 0.02 0.15
0.09 2.26 0.02 0.51 0.11 0.03
X
Clear-PC, 80, E-SE
0.04 0.56 0.4 3.06 0.14
36.2 0.05
0.135 0.04
X
Cloudy, 70 WNW-MW
0.23 0.185 0.06 2.37 < 0.06 0.11 35.2 0.04 0.26 0.05 0.19 < 0.01
X
Clear, 76, S
433?
V
AREA: VCM/HC1 Column
Component
10/9
Butane 1,1 DCE EDC Ethyl Cl Methyl Cl Methylene Cl Per Propane Toluene 1,1,1 TCE Tri
VCM Vinylidene Cl Unk
0.05
0.31 0.34 0.20
0.03 1.06
0.03 0.05 0.57
10/14 0.03
0.02 0.06
0.29 0.25 0.01 0.24 0.07 0.24
X
10/17
0.25 0.03 0.30 0.295 0.06 0.28
0.59 0.06
0.22 0.04
X
10/21
0.15 0.23 0.07 0.03 0.24 0.07
0.09 0.03 0.01 0.07 0.12
X
PC a4333
VI
AREA: VCM Rundown Tanks
Component
Butane Carbon Tet 1,1 DCE EDC Ethyl Cl Methyl Cl Methylene Cl Per Propane Toluene 1,1,1 TCE Tri VCM Vinylidene Cl Unk
10/9 0.05
0.66 0.31 0.10
0.02 0.03
< 0.02 0.07 1.98*
10/14
0.06 0.22
0.05 0.01 0.06
0.55 0.11 0.01 0.06 0.08 0.08
X
10/17 0.31
10/21 0.16
< 0.01 0.06 0.29 0.03 0.17
{ 0.03 0.12 0.01 0.25 0.07
0.02 0.05
0.05 < 0.01
X
0.075 0.01 0.01 0.02 2.75*
X
EC 4334