United States Environmental Protection Agency Water Engineering Research Laboratory Cincinnati OH 45268 Research and Development EPA/600/S2-85/088 Sept. 1985 &EPA Project Summary Industrial Process Profiles for Environmental Use: The Plastics and Resins Industry Three research reports, each concern- ing an aspect of the plastics and resins industry, are summarized here. Chapter 10 of the Industrial Process Profiles for Environmental Use (IPPEU) describes the plastics and resins production in- dustry, which converts industrial or- ganic chemicals into solid or liquid polymers. IPPEU Chapter 10a describes the plastics processing industry, which converts polymers and resins into con- sumer products. IPPEU Chapter lOb dis- cusses plastics additives used in the processing and production of plastics. This IPPEU (Chapters 10, 10a, and lOb) series is an update and expansion of material published in the 1977 report, "IPPEU Chapter 10, The Plastics and Resins Industry," EPA/600/2-77/ 023j. This Project Summary was devel- oped by EPA's. Water Engineering Re- search Laboratory, Cincinnati, OH, to announce key findings of the research project that is fully documented in sep- arate reports of the same title (see Proj- ect Report ordering information at back). Introduction The IPPEU Series Chapters 10, 10a, and 10b describe the plastics industry, the recipes and formulations used to manufacture plastics products, the manufacturing process, environmental and occupational impacts, and addi- tives used in the industry. IPPEU Chapter 10: The Plastics and Resins Production Industry IPPEU Chapter 10 contains a detailed analysis of the plastics and resins pro- duction industry, which includes opera- tions that convert industrial organic chemicals into solid or liquid polymers. tions and descriptions of the industry, raw materials, products and manufac- turers, environmental impacts, and oc- cupational health concerns. The following polymers are dis- cussed: acrylic resins, acrylonitrile bu- tadiene styrene (ABS), alkyd molding resins, amino resins, modified polyph- enylene oxide and polyphenylene sul- fide, epoxies, fluoropolymers, phenolic resins, polyacetal, polyamides, poly- olefins (polybutylene, polyethylenes, polypropylene), polycarbonate, poly (ester-imide) and poly (ether-imide) resins, polyesters, polystyrenes, polyurethane, polyvinyl acetate and al- cohol, polyvinyl chloride, polyvinyli- dene chloride and styrene acrylonitrile (SAN). Raw materials for plastics and resins are industrial organic chemicals used as monomers or platicizers and specialty chemicals used as additives to modify resin properties. Polyethylenes, polyvinyl chloride, polypropylene, and polystyrene ac- counted for almost 80 percent (by weight) of the plastics produced in the United States in 1980. The types of com- panies involved in plastics production vary, but the principal producers are major oil and chemical, paint, tire and rubber, steel, and electrical manufactur- ing companies. Plastic and resin production pro- cesses generate air emissions, waste- water, and solid waste. Volatile emis- sions are generally highest in processing steps upstream of the reac- tor and in mass and solution polymer- ization monomer and solvent recovery steps. Suspension and emulsion poly- merization processes typically generate more paniculate emissions. The most significant source of wastewater in plastics production is the ------- water used for emulsion and suspen- sion polymerization. Wastewater may contain monomer, comonomer, addi- tives, and fillers. Solid waste is generated from plastics production in one of two ways: polymer lost from the process (i.e., spills, routine cleaning, or particulate collection) and byproduct formation (i.e., low- molecular-weight polymers). Spent cat- alyst or additives also may constitute solid waste from some processes. Some of the chemicals used as raw materials in plastics production are highly toxic and may produce serious adverse health effects in overexposed employees. However, effective engi- neering controls and personal protec- tive equipment and clothing exist that greatly reduce worker exposure poten- tial. Successful application of these con- trols depends on plant-specific factors such as plant design, materials handled, process configuration, and manage- ment and employee dedication to main- taining a good occupational health pro- gram. IPPEU Chapter 10a: The Plastics and Resins Processing Industry IPPEU Chapter 10a contains a detailed analysis of the plastics and resins pro- cessing industry, which includes opera- tions that convert polymers and resins into consumer products. Analytical ele- ments include industry definition, raw materials, products, manufacturers, en- vironmental impacts, and occupational health impacts. For the purpose of this analysis, the Plastics and Resins Processing Industry has been divided into 11 segments, some of which are made up of a number of different processes: calendering, casting, coating, compounding, extru- sion, finishing, foam (expandable bead, extruded thermoplastic, multi- component thermoset, and structural), laminating, molding (blow, compres- sion injection, reaction injection, rota- tional, and transfer), reinforced plastics, and thermoforming. The plastics and resins processing in- dustry is made up of nearly 10,000 pro- cessors who produced an inventory of products valued at $37 billion in 1982. The industry is made up of many plants, most of which are small and located in or near urban centers. A compounded annual growth rate of 6 percent is pro- jected through 1990. Raw materials for the industry are the basic resins and additives described in IPPEU Chapter 10 (The Plastics and Resins Production Industry) and IPPEU Chapter 10b (Plastics Additives). Products of plastics processing oper- ations are used as substitutes for wood, metal, glass, leather, or natural fibers. Primary uses of plastics are packaging, construction, housewares, transporta- tion, electric and electronic products, paints, furniture, appliances, and toys. Plastics processing operations pro- duce air emissions, wastewater, and solid waste resulting from both polymer and additive raw materials. Many pro- cessing operations do not produce all three waste streams. Particulate emis- sions made up of polymer and additive fines are possible during feeding, load- ing, and blending of dry materials, part trimming, and grinding of thermoplas- tic scrap for recycle. Volatile emissions are possible from operations in which polymers and additives are heated. Most process-related wastewater pro- duced during polymer processing oper- ations is generated from direct-contact cooling of newly formed plastic prod- ucts. Contamination of wastewater re- sults from material washed or leached from the polymer. Solid waste is produced by the collec- tion of particulates from feeding, han- dling, and grinding operations and by trimming of parts. Thermoplastic scrap may be recycled, but thermoset scrap must be disposed of. Worker exposure to harmful chemical substances and physical agents de- pends on the materials being handled, plant design, and effectiveness of engi- neering controls and personal protec- tive equipment and clothing. These fac- tors are essentially plant-specific and are highly variable throughout the in- dustry. IPPEU Chapter 10b: Plastics Additives IPPEU Chapter 10b analyzes the chemicals used as additives in the pro- duction and processing of plastics, envi- ronmental releases of these chemicals, and possible occupational exposures to them. The report describes in detail more than 2000 chemical additives used in the plastics industry. The following additive classes are dis- cussed in Chapter 10b: Antioxidants, antistatic agents, blowing agents and other additives for foamed plastics, cat- alysts for thermoplastic polymerization, colorants, coupling agents, curing agents and catalysts for thermosettin resins, fillers and reinforcers for plas- tics, flame retardants, free radical initia- tors and related compounds, heat stabi- lizers, lubricants and other processing aids, plasticizers, preservatives, solu- tion modifiers and other polymerization aids, and ultraviolet stabilizers. The plastics additives are presented as major functional groups of chemicals and are further subdivided into chemi- cally, functionally, or physically similar chemicals. An overview of each major functional group includes the properties and application of the subclasses, their environmental impacts, and possible occupational exposures. A notation is made for specific chemicals on the Ap- pendix VIII, Michigan Hazardous Waste List and/or the priority pollutant list. Common worker exposure practices for each functional group of additives are also presented. The overview refers to a series of three appendices that detail (1) the physical and chemical properties of polymer application of each chemical within the functional groups, (2) the industrial, commercial, and consumer uses and consumption volumes for each chemical. The full reports were submitted ir fulfillment of Contract No. 68-02-3994 under the sponsorship of the U.S. Environmental Protection Agency. ------- This Project Summary was prepared by staff of Radian Corporation, McLean, VA 22102-9990. Mark J. Stutsman is the EPA Project Officer (see below). This Project Summary covers the following reports: "Industrial Process Profiles for Environmental Use: Chapter 10, The Plastics and Resins Production Industry," (Order No. PB 85-245 280/AS; Cost: $52.95, subject to change). "Industrial Process Profiles for Environmental Use: Chapter 10a. The Plastics and Resins Processing Industry," (Order No. PB 85-245 298/AS; Cost: $34.95, subject to change). "Industrial Process Profiles for Environmental Use: Chapter 10b, Plastics Additives," (Order No. PB 85-245 306/AS; Cost: $58.95, subject to change). The above reports will be available only from: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: Water Engineering Research Laboratory U.S. Environmental Protection Agency Cincinnati, OH 45268 United States Environmental Protection Agency Center for Environmental Research Information Cincinnati OH 45268 BULK RATE POSTAGE & FEES P> EPA PERMIT No G-35 Official Business Penalty for Private Use $300 EPA/600/S2-85/088 0169064 W5RL US EPA REGION \ LIBRARY 230 S OE5R80RN CHICAGO ST. IL 60604 ------- |