United States
Environmental Protection
Agency
Industrial Environmental
Research Laboratory
Cincinnati OH 45268
•/ V \'
Research and Development
EPA-600/S2-84-120 Aug. 1984
&ERA Project Summary
Paper Production and
Processing—Occupational
Exposure and Environmental
Release Study
Robert Soklow
This report presents an analysis of
chemicals and processes used during
the production and processing of paper
and paper goods with emphasis on the
workplace exposure and environmental
release of chemicals from these
operations. Reviews of chemical sub-
stances in the report are intended for
use in developing realistic exposure and
release scenarios associated with the
review of new chemical substances
used in the industry.
In this report, a description of the
industry is presented along with profiles
of the various process subcategories
occurring in the industry. A literature
search and discussions with know-
ledgeable persons in the industry during
the development of the report have
been aimed at developing process
descriptions that address occupational
exposures to workers, as well as
information on the concentration of the
release of chemicals to the environment.
Process characteristics for each study
area, including raw materials and
chemicals used, are presented along
with the description of chemicals in
wastestreams and other effluent
characteristics. Discussion of waste
control and treatment technologies
used throughout the industry are also
presented. The sources, effects and
control of worker exposure to
chemicals are described on an industry-
wide basis. Specific case studies have
also been reviewed to address detail
information on occupational exposures
to workers (including the number of
workers involved, duration of exposure,
and workplace concentrations).
This Project Summary was developed
by EPA's Industrial Environmental Re-
search Laboratory. Cincinnati. OH, to
announce key findings of the research
project that is fully documented in a
separate report of the same title (see
Project Report ordering information at
back).
Introduction
The full report presents the results of a
study to characterize the chemicals and
processes used during the production of
paper and paper goods, with emphasis on
work place exposure and environmental
release from these operations. This
information will assist in the U.S. Environ-
mental Protection Agency's (EPA's)
review of Premanufacture Notices (PMN)
under the Toxic Substances Control Act
(PL94-469). PMN review includes a
review of exposure to humans and to the
environment during the manufacturing
and processing of chemicals.
For this study, the pulp and paper
industry has been described in terms of
this industry's major processing
technologies. This division of
technologies is based on the definition of
the paper industry as presented in recent
EPA studies to develop effluent limitation
guidelines and new source performance
standards, and to analyze related
economic impacts. For this study,
subcategories established by EPA have
been further grouped into study areas
best suited to the organization of the
investigation of process and waste
chemicals.
General crewing and exposure
patterns in each study area were
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developed during this study from a
National Institute for Occupational Safety
and Health (NIOSH) project conducted to
survey, evaluate and document worker
exposure to toxic chemicals and harmful
physical stresses and related controls to
exposure used in the pulp and paper
industry. Detailed exposure scenarios
were also developed during this study
from case studies which review the most
documented occurrences of worker
exposures to specific chemicals and
associated processes. These exposure
scenarios provide detailed information on
the process characteristics, number of
workers and their activities associated
with the process and associated
chemicals and the concentrations of
these chemicals that are likely to occur in
the work place during operator activities.
Since the case studies presented may
serve to supplement the approach taken
to establish general crewing and
exposure patterns, the reader is often
referred to appropriate case studies
during discussions on the development of
general crewing and exposure patterns.
Additional information was obtained
from NIOSH and the Occupational Safety
and Health Administration (OSHA) for a
broad review of the sources and extent to
which workers are exposed to specific
chemicals. The review includes a listing of
•known carcinogens to which workers
may be exposed and information on
accidents and fatalities due to chemical
hazards and acute exposures as well as a
description of human factors contributing
to such chemical hazards.
Of the various sources of data used to
identify process and waste chemicals, the
most comprehensive is the NIOSH
National Occupational Hazard Survey
(NOHS) database for pulp and paper mills.
To establish this database, NIOSH made
visits to many facilities throughout the
industry where over 800 chemical
agents were identified and related to the
various production and manufacturing
operations and associated worker
occupations.
Each chemical identified during this
project is presented in the Chemical
Profiles (Appendix A of the full report)
along with pertinent information
summarizing discussions in the text as
well as other information which
characterizes the chemical. This
information includes its occurrence in the
industry as a use or waste chemical, its
description and physical properties, per-
missable air and water concentrations,
synonyms and health effects and safety
data for those chemicals known to be
hazardous to workers. For many of these
chemicals, additional discussion on their
occurrence throughout the industry
and/or health effects is presented in the
main body of the text.
To acquaint the reader with general
aspects of the pulp and paper industry,
the full report presents a brief overview of
this industry's technology, production,
economics and projected growth, and
presents a definition of product sector
divisions which are based on grade
descriptions defined by the American
Paper Institute.
Discussion
In the full report, an industry descrip-
tion is presented in Section 3 which
consists of a brief overview of the pulp
and paper industry's technology, produc-
tion, economics and projected growth. An
operations analysis is presented in
Sections 4 and 5 for pulping and
papermaking, respectively. These
analyses include a description of process
equipment, raw materials, and process
chemicals, including water consumption
and other operating characteristics. The
analyses include a description of the
environmental release of chemical
pollutants including an identification of
chemical by-products and effluent
characteristics. Occupational exposure is
discussed in Section 6 for the sources,
effects and control of exposure on an
industry-wide basis. In addition, a review
of previous case studies and general
crewing and exposure patterns investi-
gates specific occupational exposure
problems. In Appendix A, chemical
profiles are presented for process and
waste chemical species identified in Sec-
tions 4, 5, and 6. In Appendix 6, process
control measures used to reduce waste
'loads and improve process efficiencies
are discussed. In Appendix C, specific
waste treatment technologies used to*
treat 'end of the pipe' effluents are
discussed. A copy of OSHA regulations •
governing pulp and paper mills (29 CFR
1910.261) is presented in Appendix D.
The full report also includes a glossary of
terms commonly used throughout the
text.
For many papermaking process and
waste chemicals, a qualitative and quan-
titative description of their occurrence
throughout the industry is presented in
the main body of the text and is based on
the nature and limitations of information
made available in the literature. Each
chemical identified during this research is
again presented in the Chemical Profiles
(Appendix A of the full report) along with
pertinent information summarizing ^
discussions in the text as well as other
information which characterizes the
chemical. In Appendix A of the full report
and throughout the text, environmental
and toxicity data are not emphasized;
rather, scientific criteria from which
impacts can be determined are
emphasized. For each chemical in
Appendix A of the full report, available
data have been used to profile a
chemical's occurrence in the industry as
a use or waste chemical, its description
and physical properties, permissable air
and water concentrations, and synonyms.
For those chemical species known to be
hazardous to workers, additional items of
information profiled include symptoms,
target organs, routes of entry, protective
equipment, respirator requirements, first
aid and medical surveillance, as well as
any appropriate information on leaks,
spills and waste disposal.
For many chemicals identified as
significant in terms of occupational
exposure, additional discussion of their
health effects to workers is presented in
Section 6 of the full report. The selection
of chemicals for which this additional
discussion is presented is based on
several criteria. Many of these chemicals ^
may be considered potential hazards fl
because of their known toxic effects and
the existence of Federal standards
limiting work place exposure, including
recommended NIOSH and American
Conference of Governmental Industrial
Hygienists (ACGIH) exposure levels. The
health effects of other chemicals are
discussed because of their wide-spread
occurrence throughout industry in
general, and because of the resulting
actual or anticipated chronic worker
exposure. Some of these chemicals may
not produce specific toxic effects but may
be considered potentially hazardous due
to their ability to produce allergic
reactions or due to their possible
presence in the workplace as respirable
dusts. In the full report. Section 6
discussions are, therefore, intended to
expound the identification of health
effects of selected chemical agents
presented in Appendix A.
To supplement the development of
general crewing and exposure patterns,
detailed exposure scenarios were
developed during this study from case
studies which review the most documen-
ted occurrences of worker exposures to
specific chemicals and associated
processes. The case studies are based on
Health Hazard Evaluation (HHE) reports ^
developed by NIOSH which were ^
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performed following written requests by
employers or employee representatives
to NIOSH to investigate specific
occupational exposure problems. The
HHE investigations are aimed at
components of processes suspected of
localized impacts to workers. One such
HHE, for example, addresses worker
exposure hazards at the paper coating
preparation station of a printing paper
production process. The general crewing
and exposure patterns and case studies
provide detailed information on the
process characteristics, number of
workers and their activities associated
with the process and associated chemi-
cals and the concentrations of these
chemicals that are likely to occur in the
workplace during operator activities.
Environmental monitoring data is often
used to quantify the findings. In addition,
the use or misuse of protective
equipment, engineering controls and
procedures typically used to limit
exposure are described. Most of the case
studies include medical histories of
worker health problems associated with
each process.
Since the detailed exposure scenarios
developed in this study account for only
segments of the paper industry,
additional information has been obtained
from NfOSH and OSHAfora broad review
of the sources and extent to which
workers are exposed to specific
chemicals and other significant material
agents. This broad review includes a list-
ing of known carcinogens to which
workers may be exposed and the identifi-
cation of specific occupations involving
exposure to these chemicals. A broad
review of accidents and fatalities due to
chemical hazards and acute exposures is
also derived from NIOSH and OSHA liter-
ature and includes a description of
human factors contributing to such
chemical hazards.
In the full report, specific aspects of the
environmental release of chemicals are
addressed in discussions on occupational
exposure (Section 6). A general
description of the environmental release
of chemicals is presented in Sections 4
and 5 in terms of the paper industry's
major processing technologies. This
division of technologies is based on the
definition of the paper industry as
presented in recent EPA studies to
develop effluent limitation guidelines and
new source performance standards, and
to analyze related economic impacts.
These studies are based on the process
subcategories of the pulp, paper and
paperboard industry as established in 40
CFR, Part 430, by grouping mills which
employ similar production and process
techniques. Such a grouping has been
established so that EPA can develop
uniform national effluent limitations and
standards which would affect similar
mills in a similar fashion in terms of
modifications required and costs incurred.
For this study, subcategories established
by EPA have been further grouped into
study areas best suited to the
organization of this study's investigation
of process and waste chemicals. To make
such a grouping, attention has been given
to similarities and dissimilarities in pro-
cess components (stages) occurring
throughout the various subcategories. In
this regard, consideration has been given
to significant variations in materials
used, wastes created and other process
characteristics.
For each study area, a generic process
flow diagram has been developed to
illustrate overall process characteristics.
With each flow diagram, a set of tables
has been developed to characterize
process and waste chemicals and
materials, effluent conditions and
process control technologies used
throughout the process. All process
components listed within the prescribed
formats of these tables are shown on the
flow diagram in the full report. The
generic flow diagram and corresponding
table sets serve to develop a context in
which detailed profiles of the product
processes are illustrated.
For each study area, internal process
control technologies are itemized and
illustrated on the process flow diagram.
These technologies which are also
discussed in Appendix B of the full report,
are commonly employed within the
industry to control pulping, bleaching,
washing, liquor recovery and papermak:
ing operations. Their occurrences and'
general effectiveness as described in this
report have been identified in various
effluent limitations development
documents.
For each study area, the investigation
of effluent BOD, TSS, and other
conventional, nonconventional, toxic,
and priority pollutants occurring as
multimedia emissions, includes efforts to
quantify these materials in process waste
streams. A discussion of effluent
characteristics is presented to illustrate
the relative and qualitative relationship
between BOD and TSS and the
occurrences of associated waste
chemicals. Chemicals are listed which
are generated (pollutants, by-products) by
the process, as well as those which are
used by the process. The effectiveness of
external waste treatment to reduce the
final concentrations of chemicals in
effluent streams is addressed in the full
report (Sections 4 and 5 and Appendix C).
Appendix C discusses effluent treatment
technologies and describes the many
types of wastewater treatment systems
used throughout the industry and
presents examples of existing
commercial applications as well as pilot-
scale case studies.
Conclusions and
Recommendations
Of the many chemicals used and
released during pulp and paper process-
ing, some are important in terms of both
occupational exposure (as process and
waste chemicals) and environmental
release (emission, effluent and solid
waste chemicals). However, many chem-
icals are known to be significant in only
one of these areas.
Among the chemicals released to the
environment, many toxic, nonconven-
tional and priority pollutants have been
identified in pulp and paper industry
discharge waters. Their occurrences
throughout the industry have been
reviewed in the full report. This review
includes discussions illustrating the
relationship between these pollutants
and conventional pollutants (Biological
Oxygen Demand, Total Suspended Solids
and pH) and water usage. These discus-
sions are centered on data obtained from
previous effluent guidelines development
studies designed to verify and quantify
the presence of conventional, noncon-
ventional, toxic, and priority chemical
pollutants in industry discharges. Data
(when available) are expressed in ranges
to account for variations in process
conditions.
Information obtained from the industry
broad review of chemicals and associated
processes indicates that the most
significant occupational exposure
problems associated with papermaking
chemicals include fatal exposures to high
concentrations of hydrogen sulfide and
other sulfur compound emissions, as well
as carbon monoxide and chlorine
exposures. OSHA sampling tests have
revealed that these chemicals frequently
exceed OSHA standards, thus
contributing to problems of short-term,
accidental and acute exposure.
Regarding long-term illness in pulp and
paper mill workers, more information is
needed due to a lack of relevant epidemi-
ologic studies. In addition, plant visits are
essential to assess quantitatively the
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uses and hazards of the numerous chem-
ical additives used throughout the in-
dustry.
Although the literature discusses
general categories of additives, the
problem is to determine which are in
wide-spread use and, of those in wide-
spread use, which are toxic under the
conditions of use. In short, there is a
surprising lack of quantitative informa-
tion on the use and exposure effects of
additives throughout the industry.
Moreover, trie distinction is seldom
made between the quantity of such
materials applied and the quantity
present in the final product. Most
additives are furnished to the mills by
chemical suppliers who have technical
service representatives to advise on the
proper methods for handling and applica-
tion. Since each pulp furnish and each
paper machine has individual character-
istics that must be understood for best
results, the quantity of additives used
may be quite variable. Extensive, addi-
tional study is therefore required to
quantify the ranges of usage and
describe the process variations contribu-
ting to such ranges for the many additives
used throughout the industry.
For the vast majority of chemicals,
information on work place emission
sources, worker exposure and other char-
acteristics is scarce. Needs to gather such
data have been tempered by the fact that
many chemicals occur in such small
quantities that worker exposure prob-
lems have not been seriously considered.
Regarding the development of general-
ized job descriptions and crewing
patterns, it should be noted that wide
variations in these categories create job
descriptions that are generally not
comparable, since mills combine work
tasks depending on equipment layout,
automation and complexity. Hence, the
number of required workers and the tasks
they perform vary considerably through-
out the industry. Occupational exposure
characteristics for each machine type
might therefore be most accurately
determined on a plant by plant basis for
each paper type. The study area analyses
presented in Sections 4 and 5 of the full
report include discussions and illustra-
tions of equipment, machinery and
process operations that can serve as a
guide to assess the need for further work
to characterize occupational exposure in
operations not addressed fully by the
development of general crewing and
exposure patterns, or in the case studies
of specific occupational problems pre-
sented in Section 6 of the full report.
Studies similar to that described in
Section 6 {Gas Concentrations in Kraft
Mill Work Areas) of the full report, can be
applied throughout the industry to
quantify worker exposures to the wide
range of organic and inorganic process
chemicals and by-products, escaping to
the work area. This type of investigation
can also be used to assist the
development of training programs and
safety procedures designed to control or
limit worker exposure. Such activities
would serve to bolster the benefits
obtained from the existing training
programs and safety procedures
discussed in this report.
For many of the chemicals presented in
Appendix A of the full report, certain
items of data are not available in the
literature and are therefore missing from
the Chemical Profiles. Moreover, the
exact nature of the industrial occurrence
of many chemicals (many of which are
identified by the NOHS walk through) is
not characterized. For these chemicals,
additional research is required to
establish completely the items of
information presented by the Chemical
Profiles.
Robert Soklow is with S-CUBED, La Jolla, CA 92038-1620.
M. J. Stutsman is the EPA Project Officer (see below).
The complete report, entitled "Paper Production and Processing—Occupational
Exposure and Environmental Release Study, "(Order No. PB 84-215 730; Cost:
$46.00, subject to change J will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA22J61
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Industrial Environmental Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
U S GOVERNMENT PRINTING OFFICE. 1984 — 759-015/7782
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Official Business
Penalty for Private Use $300
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