Document qqrpLV65K6GKYjjbybwEoJrq

INDUSTRIAL HYGIENE SURVEY OF THE Polychlorinated Biphenyl Production Operation Monsanto Industrial Chenlcals coapany Sauget, Illinois SURVEY DATE July 21-22, 1976 SURVEY CONDUCTED BY Mark Jones Janson Becker REPORT WRITTEN BY Mark Jones DATE OF REPORT Industrial Hygiene Section Industrywide Studies Branch Division of Surveillance, Hazard Evaluations and Field Studies National Institute for Occupational Safety and Health Cincinnati, Ohio HONS 001091 PLACE VISITED: DATE OF VISIT: PEOPLE CONTACTED: PERSONS MAKING VISIT: PORPOSE: Monsanto Company W.G. Krummrich Suuget, Illinois July 21-22, 1976 ` Mr. Art Leisy Manufacturing Superintendent Mr. Paul Helsler Supervisor - Air Pollution Mr. Bruce Eley Corporate Industrial Hygienist Mr. Virgil Brawley Supervisor ~ PCB Production Mr. John Peduzzi Supervisor - Incineration Mr. Julio Mundoz - Air Pollution Group Mr. Neil Sullivan - Air Pollution Group Mr. Frank Basile - Air Pollution Group Mr. Ed Newman - Air Pollution Group Mr. Dale Rachel - Foreman, PCBa Production Mr. Tom Carraco - Foreman, PCBe Production Mark Jones Janson Becker 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. MONS 001092 INTRODUCTION Recent-literature has linked polychlorinated biphenyls with possible carcinogenic effects. Because this literature is incomplete, the 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 Che 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. During the visit, 18 air samples were collected for evaluation of polychlorinaced biphenyls exposure. In addition, samples were collected for exposure to iron silica and chlorine. DESCRIPTION OF THE FACILITY The polychlorinated biphenyls production operation is one of many operations present at the Honaaoto facility in Sauget, Illinois. Sulfuric acid, benzene, and benzene derivatives, rubber chemicals (ancioxidants, 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 the sale of PCBs for use in closed systems. MONS 001093 The entire work force at the facility is approximately 1300 persons, with approximately 835 of these persons being liourLy employees. Approximately 25 employees are involved with the production of PCHs. The union representing this group is the International Chemical Workers, Local #12. MEDICAL, INDUSTRIAL HYGIENE AND SAFETY PROGRAMS A dispensary is located at the plant. Nurses are present at the Ulapansary 24 hours a day and a physician is present during the day. All employees are required to take a pre-employment physical examination. Certain employees are then required to take periodic physical examinations. Industrial hygiene matters at the facility are handled by the Air Pollution Group. The six people,who are assigned to this group*work in conjunction with the safety department. The only sampling that has been done for polychlorinated biphenyls is the discharge from the area is monitored twice a week and the collection of a few air samples (Appendix t). 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. -2- MDNS 001094 DESCRIPTION OF PROCESS Three products are made la Che PCBs production area: Aroelor 101b, Aroclor 1242, and Aroelor 1254. Aroelor 1016 Is used In capacitors and Aroclor 1242 and 1234 are used in transformers. The operation is outdoor end 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. Biphenyl la 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 chlorinator in the presence of an Iron catalyst and allowed to react. There are two separate groups of chlorlnators, one group for producing Aroclor 1254 end the other for Aroclor 1242. The product from the Aroclor 1254 chlorlnators 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 chlorlnators goes to an inter mediate storage tank and then either through a similar operation as the Aroclor 1254 or to a distillation column which separates the different polychlorinated biphenyl isomers 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 -3- MGNS 001095 biphenyls chs properties desired by the customer. To give the poly chlorinated biphenyls better eLectrical properties a small amount of dlatomaceous earth Is added to the blend tanks once a week and then filtered out. INSPECTION OF PLANT Potential Health Hazards Potential health hazards observed during this survey vere as follows: 1. Polychlorinated biphenyls exposure 2. Chlorine exposure 3. Free silica exposure Ventilation Since the operation is outdoors there is very little ventilation. Local exhuast ventilation is used in two operations. The drunsning operation is equipped with a hosa which is pieced near the opening of the 55 gallon drum while it is filled. Near the chlorlnators is a work station where employees perform specific tests on samples drawn from tbe chlorlnators. This work station ham a hood over tha area vhare the tests are performed. Housekeeping Housekeeping in the polychlorinated biphenyls production area was taken care of fairly well. The aisleways were kept clean and clear. HONS 00X09b SURVEY PROCEDURES Central Air samples were collected in the polychlorinated biphenyls production area for evaluating exposure Co 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. Polychlorinated Biphenyls Both personal and area air samples were collected in the polychlorinated biphenyls production area. Sipln SP1 pumps were used to collecc the air samples on florosll cubes. The tubes contain a magnesium silicate absorbenc called florosll 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 desorbed from the florosll with hexane and analyzed by using a gas chromato graph with an electron capture detector. Iron Chloride Area air samples were collected, for iron chloride while the employees poured the iron chloride (powder) catalyst into the reactors. MSA Model G pumps were usad to collect the air samples on a 0.8 micrometer pore sizo 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. 001097 -5- MONS Fret Silica One bulk sample ox Che diatomaceous earth used was collected for aualysi S O t free silica content. The per cent free silica was determined by x-ray diffraction. Chlorine Detector tubes were u9ed to evaluate concentrations of chlorine in Che PCBs production area. Chlorine measurements were made using "Bendlx Gastec Analyzer Tubes - Low Range (1-B ppm)." P*. MONS 001098 P-6- l RESULTS AND DISCUSSION Polychlorinated Biphenyls The results of the area and personal air samples are given in Table l and the job descriptions corresponding to the job titles are in Append!* 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). 3 The personal air samples ranged from a concentration of 20 pg/iu to 86 |ig/m3 while the area air samples ranged from 16 ug/m3 to 55 ug/m3 . These ate all well below the current standard for chlorodiphenyl (42% of chlorlno) of 1 mg/m . However, this standard is based upon skin irritation and recent literature has linked carcinogenic effects to polychlorinated biphenyls. Therefore, this standard may not adequately protect the workers health. Iron Chloride The results of the- air samples are given in Table II. Two samples were collected for determining worker exposure to iron chloride. No iron could be detected on one of the samples, but the other sample had an 3 iron concentration of 8.1 mg/m . Since this procedure of adding the iron catalyst to the reactor only takes 3 minutes and is done once a shift 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. -7- oov" Frw Silica TUo bulk, sample of diatomnoeous earth was analyzed and determined to have a free silica content of 9.82. Since the procedure of adding diatomaceous earth to the blend tank is done usually only once a week, the survey team was unable to observe this procedure. Chlorine No concentrations of chlorine were detected. CONCLUSIONS AND RECOMMENDATIONS 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: 1) Even though the concentration of iron chloride found during the addition of the 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 diaramaceoue 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 4 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. -fi- HONS oonoo . Table I CONCENTRATIONS OF POLYCHLORINATED BIPHENYL (detected as Aroelor 1016) IN A FACILITY MANUFACTURING POLYCHLORINATED DIPHENYLS Personal Air Samples Job Title Premium Operator ii Second Oii perator IIColumn Operator ItStill Operator Standard Operator Distribution OpIIerator Data 7/21 7/22 7/21 7/2Z 7/21 7/22 7/21 7/22 7/22 7/21 7/22 Total Time (min.) 436 451 432 448 446 432 444 445 413 419 Volume (liters) 91.0 97.8 80.0 95.3 74.9 85.7 94.6 67.6 96.1 88.3 91.3 Concentration (ug/m3) 4/ 20 46 43 64 51 40 86 61 54 36 Cul^3> 33 44 57* 63 61 45 Area Air Samples Location Date Drumming II 7/21 7/22 Temperature Testing M 7/21 7/22 Chlorlnators M 7/21 7/22 Incinerator Burner ^---------------------------------------- 7/21 ^Arithmetic Average Total Time (min.) 418 418 417 455 419 459 409 Volume (liters) 89.1 87.6 ' 201.6 105.4 89.0 70.3 81.6 Concentration ACv-ej-r.a'ag*e) |i Ug/m3) 45 51 48 25 52 39 55 36 46 16 16 ] HONS 001101 Table IX CONCliNTKATTONS Or TRON CHIOKIDK FOUND WHILE OPERATOR ADDED XT AS A CATALYST ' Location Date Total Time (min) Naar Reactor Lid It 7/21 7/22 3 3 Volume (liters) 5.1 5.1 Concencretion of Iron (mg/m3) N.D. 8.1 Concentration oC Iron Chloride (mg/m3) _ 18.4 HONS 001102 Appendix A JOB DESCRIPTIONS Premium Operator - Operacee both the continuous and batch chiorinators. This Includes keeping the chlorinatora cunning, adding the iron chloride catalyst once a shift and drawing samples off twice a shift. Second Operator ~ Loads the tank cars for shipment and takes care of the tank farm and blend tanks. 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. Still Operator - Operates both stills used in producing Arolcor 1254 and 1242. Distribution Operator - Works in a different erea of the plant and is in charge of operating the incinerator. HONS 001103 Appendix B CONCENTRATION IN THE ATMOSPHERE U. THE MANUFACTURING DEPARTMENT BATTERY LIMITS AS MEASURED IN OCTOBER, 1975 Date 10/ 9/75 10/ 9/75 10/13/75 10/13/75 10/14/75 10/16/75 Location 12 ft. operating level at batch chlorlnator 12 ft. operating level at contlnuoua chlorlnator 12 ft. operating level at batch chlorlnator 12 ft. operating level at contlnuoua chlorlnator Ground floor operating level Ground floor, acrubber dlacharge area rng/m 0.022 0.012 0.057 0.058 0.006 0.338 SOURCE: Monaanto HONS 001104