GCA-TR-75-32-G (7) ASSESSMENT OF CYCLOHEXANONE AS A POTENTIAL AIR POLLUTION PROBLEM VOLUME VII FINAL REPORT Contract No. 68-02-1337 Task Order No. 8 Prepared For U.S. ENVIRONMENTAL PROTECTION AGENCY Research Triangle Park North Carolina 27711 January 1976 GCA TECHNOLOGY DIVISION «®A BEDFORD, MASSACHUSETTS 01730 ------- CCA-TR-75-32-G(7) ASSESSMENT OF CYCL011EXANONE AS A POTENTIAL AIR POLLUTION PROBLEM Volume VII by Robert M. Patterson Mark I. Bornstein Eric Garshick GCA CORPORATION GCA/TECHNOLOGY DIVISION Bedford, Massachusetts January 1976 Contract No. 68-02-1337 Task Order No. 8 EPA Project Officer Michael Jones EPA Task Officer Justice Manning U.S. ENVIRONMENTAL PROTECTION AGENCY Research Triangle Park North Carolina 27711 ------- This report was furnished to the U.S. Environmental Protection Agency by the GCA Corporation, GCA/Technology Division, Bedford, Massachusetts 01730, in fulfillment of Contract No. 68-02-1337, Task Order No. 8. The opinions, findings, and conclusions expressed are those of the authors and not neces- sarily those of the U.S. Environmental Protection Agency or of the cooperating agencies. Mention of company or product names is not to be considered as an endorsement by the U.S. Environmental Protection Agency. ------- ABSTRACT This report is one of a series which assesses the potential air pollution impacts of 14 industrial chemicals outside the work environment. Topics covered in each assessment include physical and chemical properties, health and welfare effects, ambient concentrations and measurement meth- ods, emission sources, and emission controls. The chemicals investigated in this report series are: Acetylene Methyl Alcohol Ethylene Bichloride Benzene Acetone Acrylonitrile Cyclohexanone Formaldehyde Methyl Methacrylate Ortho-Xylene Maleic Anhydride Dimethyl Terephthalate Adipic Acid Phthalic Anhydride. Volume I Volume II Volume III Volume IV Volume V Volume VI Volume VII Volume VIII Volume IX Volume X Volume XI Volume XII Volume XIII Volume XIV ill ------- CONTENTS Page Abstract m List of Figures v List of Tables v Sections I Summary and Conclusions 1 II Air Pollution Assessment Report 3 Physical and Chemical Properties 3 Health and Welfare Effects 3 Ambient Concentrations and Measurements 7 Sources of Cyclohexanone Emissions 9 Cyclohexanone Emission Control Methods 11 III References 16 Appendix A Cyclohexanone Manufacturers 18 Iv ------- FIGURE Ko«> Page 1 Estimated Installed Cost of Cyclohexanone Storage Tanks (Equipment Costs Assumed to be the Same as Gasoline Storage Tanks) 15 TABLES No» Page 1 Significant Properties of Cyclohexanone 4 2 Acute Effect of Cyclohexanone on Animals 6 3 Cyclohexanone Consumption - 1974 10 4 Sources and Emission Estimates of Cyclohexanone 1974 10 5 Estimated Installed Costs of Adsorption Systems 12 6 Estimated Annual Operating Costs of Adsorption Systems 12 7 Estimated Installed Costs of Thermal and Catalytic Incinerators 14 8 Estimated Annual Operating Costs of Thermal and Catalytic Incinerators 14 ------- SECTION I SUMMARY AND CONCLUSIONS Cyclohexanone is a colorless, slightly volatile liquid with an odor similar to acetone and peppermint. It is chemically stable and is manufactured mainly by catalytic dehydration of cyclohexanol. It is used extensively in the production of nylon and adipic acid, and it is also used as a solvent and degreaser. Cyclohexanone is a strong irritant and a narcotic agent at high concentrations, although concentrations producing such effects are unlikely to occur due to the low volatility of Cyclohexanone. The occupational standard for an 8-hour time weighted exposure is 50 ppm. Simple diffusion modeling estimates place the likely maximum 1-hour average ambient concentration at 1.3 ppm. The maximum 24-hour average ambient concentration might be expected to be about 1 ppm. Approximately 850 million pounds of Cyclohexanone were produced at 10 plants in 1974, with about 43 percent of this being used to make capro- lactum for nylon 6, and 52 percent to make adipic acid. The remaining 5 percent was used as a solvent and as a degreasing agent. Total production is expected to increase at 10 percent per year for the next several years. Emissions result mainly from solvent usage, production losses, and bulk storage. About 6 percent of total production is eventually lost to the atmosphere. Although emission controls specifically for Cyclohexanone are not reported, two types of controls are used extensively by the chemical ------- industry to control hydrocarbon emissions. These are vapor recovery and incineration. Control by adsorption on activated charcoal is used when recovery is economically desirable. The primary advantage of in- cineration is that low concentrations may be oxidized with only small supplemental fuel requirements. Fixed roof storage tanks can be con- trolled by venting to an adsorber or to an incinerator, or they can be converted to floating roof design. Based on the results of the health effects research presented in this reportj and the ambient concentration estimates, it appears that cyclohexanone as an air pollutant does not pose a threat to the health of the general population. In addition, cyclohexanone does not appear to pose other environmental insults which would warrant further inves- tigation or restriction of its use at the present time. ------- SECTION II AIR POLLUTION ASSESSMENT REPORT PHYSICAL AND CHEMICAL PROPERTIES Cyclohexanone is a colorless to pale yellow, slightly volatile liquid with a ketone-type odor similar to acetone and peppermint. It is chem- ically stable and not very flammable except at high temperatures. The main method of manufacture is by the catalytic dehydration of cyclohexanol. Its most important use is as an intermediate in the manufacture of nylon 6, and it is also used as a metal degreaser, a solvent and a thinner for lacquers and synthetic resins. It is found in paint removers, and it is an excellent solvent for DDT, some organic phosphorous insecticides, and 1 2 other similar materials. ' Significant characteristics of cyclohexanone are listed in Table 1. HEALTH AND WELFARE EFFECTS Effects on Man Acute Poisoning - Cyclohexanone is a strong irritant and a narcotic agent. Humans exposed for 3 to 5 minutes found 50 ppm irritating to the 3 eyes, nose, and throat. Exposure to higher levels and human response have not been documented in the literature, but animal studies indicate that human exposure to elevated levels would cause narcosis, dizziness, unconsciousness, and death due to respiratory failure. Concentrations producing such effects are unlikely to be encountered due to cyclo- hexanone's low volatility, except when handled at high temperatures. ------- Table 1. SIGNIFICANT PROPERTIES OF CYCLOHEXANONE Synonyms: anone, hexanon, hytrol o, ketohexamethylene, nadone, pimellc ketone, sextone Chemical formula Molecular weight Boiling point Melting point Specific gravity Vapor density Vapor pressure Solubility Lower explosive limit Ignition .temperature Flash point At 25°C and 760 mm Hg H2C CHr CH, C H, 98.14 155.6°C -45°C 0.9478 at 20°/4°C 1.01 (air = 1) 5.2 mm Hg at 25°C 2.4 g/100 ml water at 31 C, soluble in alcohols, ketones, esters, halogenated hydrocarbons. Partially soluble in benzene. ' 1.1% by volume 420°C 43.6 C (closed cup) 2 1 ppm =4.01 mg/ra =0.25 ppm ------- Its vapors have such strong warning properties at low concentrations that the acute exposure necessary to cause severe poisoning will not be tolerated voluntarily by humans. Irritation of the eyes, nose, and throat due to exposure at low concentrations is only temporary, with recovery after removal of the vapor. 2 Cyclohexanone has a low acute oral toxicity, and absorption through the skin will not be a problem unless there is excessive exposure.. It is capable of defatting the skin, and exposure to high concentrations may cause skin irritation. Chronic Poisoning Prolonged or repeated exposure will cause dermatitis. It has been reported that no ill effects, except drowsiness, were observed 2 in workers in daily contact with cyclohexanone. No fatality or serious poisoning has been reported in the literature. Chronic exposure to con- centrations able to produce delayed narcotic symptoms and death as shown in animal studies are not likely to be encountered in humans due to human sensory warning response at low levels. A concentration of 25 ppm has been estimated to be the highest concentration tolerable for an 8-hour 3 exposure with no ill effects, but the United States occupational standard for an 8-hour time weighted exposure average is 50 ppm. Effects on Animals Acute Poisoning - Studies done on animals illustrate the acute narcotic action of cyclohexanone. Table 2 summarizes available dose-response data from various inhalation studies. ' ' Symptoms in guinea pigs prior to death i were narcosis; lachrymation; excess salivation; depression of body tem- perature, respiratory rate, and heart rate; and opacity of the cornea. Recovery was slow, with some guinea pigs dying within 4 days. A concen- tration of 2,000 ppm inhaled over 4 hours is the lowest recorded concen- tration able to cause death in susceptible rats. ------- Table 2. ACUTE EFFECT OF CYCLOIIEXANONE ON ANIMALS Animal Rat Guinea pig Rat Rat Dose , ppm 8,000 4,000 4,000 2,000 Time, hr 4 6 4 4 Response Anesthesia and death Narcosis; death to some within 4 days Narcosis; all survived Narcosis; some deaths Reference 6 1 6 7 Rabbits were killed by the absorption of 10.2 to 23.0 g/kg body weight Q through clipped uncovered skin. Symptoms prior to death were marked hypothermia, convulsions, and narcosis. Pure cyclohexanone dropped 9 into the eyes of rabbits caused irritation and corneal injury. Oral Q administration of 1600 mg/kg body weight to rabbits resulted in narcosis and death within a day. An LD,.n value of 1620 mg/kg body weight has 7 been given for rats. Chronic Poisoning - Monkeys and rabbits were exposed for 6 hours per day, 5 days per week, for 10 weeks to various concentrations of cyclohexanone. At 190 ppm there were no detectable effects or abnormal behavior except very slight liver and kidney injury. At 309 ppm, there was slight eye irritation. At 773 ppm, salivation increased as did eye irritation. Death occurred among animals exposed to 3082 ppm after 3 weeks of the exposure periods. Prior to death the animals became lethargic, showed loss of coordination, secreted mucus, and entered a narcotic state. No hematological disorders could be linked to cyclohexanone exposure. 10 Effects on Vegetation The effects of cyclohexanone on plants have not been documented in the literature. However, due to its properties as a solvent and as a ------- defatting agent, it would act as an acute contact poison on plant parts, especially the leaves. Other Effects Cyclohexanone can be used as a sole carbon source for growth by a species of bacteria. Due to its properties as a solvent, it could attack and dissolve some rubbers and plastics. AMBIENT CONCENTRATIONS AND MEASUREMENT Ambient Concentration Estimates Although cyclohexanone emissions are greatest from the solvent usage source category, these sources tend to be small and geographically scattered. Production of cyclohexanone, however, occurs at a few loca- tions for which the emissions characteristics can be fairly well defined, and which as single point or area sources have a large emission density. The largest installation for cyclohexanone production is located in a town of about 1,800 population, and it has a capacity of about 240 mil- lion Ib/yr. Assuming a 1 percent loss, this converts to an emission rate of: (0.01 emission factor) (240 x 1Q6 Ib/yr) (453.6 g/lb) 3.1536 x 107 sec/yr = 34.5 g/sec of cyclohexanone. Some assumptions must be made regarding this release to the atmosphere. First of all, the emissions do not all come from one source location, but rather from a number of locations within the plant where vapor leaks to the atmosphere. Thus, the emissions can be characterized as coming ------- from an area source which will be taken to be 100 meters on a side. Secondly, the emissions occur at different heights, and an average emission height of 10 meters is assumed. Ground level concentrations can then be estimated at locations downwind 12 of the facility. To do this a virtual point source of emission is assumed upwind of the facility at a distance where the initial horizontal dispersion coefficient equals the length of a side of the area divided by 4.3. In this case: a = 100m/4.3 = 23.3m . yo Assuming neutral stability conditions (Pasquill-Gifford Stability Class D) with overcast skies and light winds, the upwind distance of the virtual point source is approximately 310 meters. With consideration of the plant boundary, it is reasonable to assume that the nearest receptor location is thus about 500 meters from the virtual point source. Finally, taking 2 m/sec as an average wind speed, the ground level concentration may be calculated from: X = V7TC7 CT y z %.5 -U-LU-'2 or X = (2) TT (36) (18.5) = 7.124 x 10"3 g/m3 for a 10-minute average concentration. Over a period of an hour this becomes (7.124 x io"3 g/m3) (0.72) = 5.129 x IO"3 g/m3 or 1.3 ppm 1-hour average concentration. Over a 24-hour period, the average concentration might roughly be expected to be about 1.0 ppm. ------- Measurement Techniques Measuring cyclohexanone in air involves its adsorption on charcoal with 13 subsequent desorption and analysis by a gas chrotnatograph. In this method a known volume of air is drawn through a charcoal tube on which the organic vapors are adsorbed. The tube is then transferred to a small stoppered container where it is desorbed with carbon disulfide. An aliquot of the desorbed sample is injected into a gas chromatograph. The area of the resulting peak is determined and compared with areas obtained from the injection of standards. Concentrations in the range of 2.5 to 125 ppm can be readily detected by this method. Interferences will result if the amount of water in the air is so great that condensa- tion in the tube will affect the collection efficiency, and other inter- ferences will result from compounds having similar retention times. This technique is especially well suited for air pollution work, since there is no requirement for special chemicals in the field. SOURCES OF CYCLOHEXANONE EMISSIONS Cyclohexanone Production and Consumption The production of cyclohexanone in 1974 was approximately 850 million pounds, and it is expected to increase at 10 percent per year for the next several years. Presently, about 43 percent of all cyclohexanone is used to make caprolactam for nylon 6 and 52 percent is oxidized as mixed oil (cyclohexanone and cyclohexanol) to make adipic acid. The remaining 5 percent is used as a solvent. Nine companies at ten lo- cations are producing both cyclohexanone and cyclohexanol. The names and locations of production facilities are given in Appendix A. The consumption of cyclohexanone for final products is shown in Table 3. ------- Table 3. CYCLOHEXANONE CONSUMPTION 197414'15 Product Adipic acid Caprolactam Solvent Million pounds 442 365.5 42.5 "1, Annual growth 5.5 17.0 5.0 Cyclohexanone Sources and Emission Estimates Primary sources of emissions of cyclohexanone result from solvent usage, production losses, and bulk storage. Total emissions from all categories in 1974 are estimated to have been 51.3 million pounds as shown"in Table 4, representing 6 percent of total production. Table 4. SOURCES AND EMISSION ESTIMATES OF CYCLOHEXANONE - 1974 Source Solvent usage Production losses Storage Total Million pounds 42.5 8.5 0.3 51.3 The major source of cyclohexanone emissions results from its use as a solvent. It is used in the manufacture of lacquers and crude rubber, as a spot remover, and as a degreaser for leather. Since 1967, sales have increased due to its use as a solvent for coatings, especially as a replacement for isophorone in vinyl solution coatings. This replacement is due mainly to avoid new solvent regulations, since cyclohexanone is 10 ------- considered a nonreactive solvent. However, a recent EPA report has classified it as highly reactive. Assuming that all cyclohexanone used as a solvent will evaporate to the atmosphere, 42.5 million pounds of cyclohexanone are emitted due to solvent usage. The second major source of emissions occurs from the production of cyclohexanone. Most cyclohexanone and cyclohexanol is prepared as a mixture by the catalytic oxidation of cyclohexane. If only cyclo- hexanone is desired, the cyclohexanone/cyclohexanol mixture can be dehydrogenated with a zinc oxide catalyst to give an essentially pure product. Cyclohexanone may also be produced by the hydrogenation of phenol using a palladium on carbon catalyst. Palladium emissions may result from the process operation and from the disposal of spent bed material. Since data are not available concerning emissions from these processes, 17 18 based on other similar chemical processes, ' it is estimated that 1 percent of production is emitted as cyclohexanone resulting in 8.5 million pounds of emissions. The last major source of emissions results from bulk storage of cyclo- hexanone. Using emission factors in AP-42 and assuming all storage tanks are fixed roof, emissions are 0.3 million pounds. CYCLOHEXANONE EMISSION CONTROL METHODS The literature does not report specific control equipment for cyclohexanone, but it does report on control devices for other similar hydrocarbons. Two types of control devices are presently used by the industry to con- trol hydrocarbon emissions: vapor recovery and incineration. Both systems have reported efficiencies of at least 95 percent. Control of hydrocarbon emissions by adsorption on activated charcoal is generally applied when recovery of adsorbed material is economically 11 ------- desirable. Because of the heat generated in adsorbing ketones, the tem- perature of the bed must be cooled by adding moisture to the gas stream. Adsorption is generally used when concentrations of hydrocarbons are 19 greater than 2500 ppm. Other applications are for the control of very low concentration hydrocarbons that are poisonous to catalytic incinerators, and for collection and concentration of low concentration emissions for subsequent disposal by incineration. Cost data for the cases utilizing adsorption are presented in Tables 5 and 6» The three cases presented are adsorption with solvent recovery, adsorption with incineration, and ad- sorption with incineration plus heat recovery. Table 5. ESTIMATED INSTALLED COSTS8 OF ADSORPTION SYSTEMS 20 Adsorber capacity, SCFM based on 25 percent lower explosive limit With solvent recovery, $ With thermal incineration/ no heat recovery, $ With thermal incineration/ primary heat recovery, $ 1,000 74,000 89,500 101,500 10,000 162,300 202,000 255,000 20,000 280,000 344,000 431,000 Costs updated to first quarter 1975. a 20 Table 6. ESTIMATED ANNUAL OPERATING COSTS OF ADSORPTION SYSTEMS •Adsorber capacity, SCFM - based on 25 percent lower explosive limit With solvent recovery, $/yr With thermal incineration/ no heat recovery, $/yr With thermal incineration/ primary heat recovery, $/yr 1,000 13,200 23,400 25,600 10,000 10,479b 64,300 82,000 20,000 37,200b 123,200 141,600 ••J Costs updated to first quarter 1975. b. Indicates a savings. 12 ------- Control of cyclohexanone emissions by incineration or catalytic oxidation involves direct oxidation of the combustible portion of the effluent, the desired ultimate products being water and carbon dioxide. The primary advantage of catalytic incineration is that extremely small concentrations of organics can be oxidized with only small amounts of supplemental fuel required. The main disadvantages are the higher capital cost and the fact that certain hydrocarbons may poison the catalyst. Cost data for thermal and catalytic incinerators with and 20 without heat recovery are presented in Tables 7 and 8. Control of emissions from storage tanks will require the use of floating roof tanks or venting the emissions to the previously mentioned "adsorber or incinerator. Emissions from fixed roof tanks can be vented to either system without any major increase in cost. If these systems are not available, the fixed roof tanks should be switched to floating roof tanks resulting in a 90 percent reduction of emissions. Figure 1 provides esti- 20 mated costs of various gasoline storage tanks. These equipment cost estimates can also be applied to cyclohexanone. As can be seen, conversion of fixed roof to floating roof tanks by installation of internal floating covers is more economical than the installation of new pontoon floating tanks. 13 ------- Table 7. ESTIMATED INSTALLED COSTS OF THERMAL AND CATALYTIC INCINERATORS20 Incinerator capacity, SCFM - based on 25 percent lower explosive limit Installed costs, $ Catalytic without heat recovery Catalytic with primary heat recovery Catalytic with primary and secondary heat recovery Thermal without heat recovery Thermal with primary heat recovery Thermal with primary and secondary heat recovery 1,000 43,500 54,100 68,300 27,200 40,300 54,400 10,000 272,000 306,000 361,800 92,500 144,200 200,000 20,000 504,600 573,900 666,400 137,400 232,600 322,300 Costs updated to first quarter 1975, Table 8. ESTIMATED ANNUAL OPERATING COSTS OF THERMAL AND CATALYTIC INCINERATORS20 Incinerator capacity, SCFM - based on 25 percent lower explosive limit Operating costs, $/yr Catalytic without heat recovery Catalytic with primary heat recovery Catalytic with primary and secondary heat recovery Thermal without heat recovery Thermal with primary heat recovery Thermal with primary and secondary heat recovery 1,000 16,200 16,400 19,300 12,000 11,500 14,400 10,000 102,800 78,500 108,700 54,300 36,300 50,800 20,000 195,000 177,900 203,700 96,700 59,200 84,500 Costs updated to first quarter 1975. 14 ------- 500 - 400 300 8 "J 200 _» < 100 T~l I' I 1 1—i I i—1 1 i Told Coil Cono Roof Tank Converted with Internal Floating Roof i 1 1 1 I / Pontoon Floating Roof Tank Cona Roof Tank Internal FIool Cover en Existing Cone Roof Tank (Incremental Cost - Conversion) I I t I 1 I » 50 100 CAPACITY, barrels 150 200 Figure 1. Estimated installed cost of cyclohexanone storage tanks (equipment costs assumed to be the same as gasoline storage tanks)20 15 ------- SECTION III REFERENCES 1. American Industrial Hygiene Association. Hygienic Guide Series: Cyclohexanone. Amer Ind Hyg Assoc J. 26:630-34, 1965. 2. Rowe, V.K., M.A. Wolf. Ketones. In: Industrial Hygiene and Toxicology, Patty, F.A. (ed.). New York,"Interscience Publishers, Vol. II, 2nd edition,. 1963. p. 176-68. 3. Nelson, K.W., J.F. Ege, Jr., M. Ross, L.E. Woodman, and L. Silverman. Sensory Response to Certain Industrial Solvent Vapors. J Ind Hyg Toxicol. 25:282-85, 1943. 4. The Toxic Substances List 1974 Edition. HEW Publication No. (NIOSH) 74-134, p. 235. 5. NIOSH/OSHA Draft Technical Standards: Cyclohexanone. 3 January 1975. 6. Smyth, 'J.F. Improved Communication. Hygienic Standards for Daily Inhalation. Am Ind Hyg Assoc Quart. 17:129-185, 1956. 7. Smith, H.F., C.P. Carpenter, C.S. Weil, U.C. Pozzanij J.A. Striegel, and J.S. Nycum. Range Finding Toxicity Data. List VII. Am Ind Hyg Assoc J. 30:470-76, 1969. 8. Treori, J.F., W.E. Crutchfield, Jr., and K.V. Kitzmiller. The Physiological Response of Rabbits to Cyclohexane, Methylcyclohexane, and Certain Derivatives of Those Compounds. J Ind Hyg Toxicol. 25:199-213, 1943. 9. Carpenter, C.P., H.F. Smyth, Jr. Chemical Burns of the Rabbit Cornia. Amer J Opthalmol. 25:1363, 1946. 10. Treon, J.F., W.E. Crutchfield, Jr., and K.V. Kitzmiller. The Physio- logical Response to Animals to Cyclohexane, Methylcyclohexane, and Certain Derivatives of These Compounds. J Ind Hyg Toxicol. 25: 323-47, 1943. 16 ------- 11. Murray, J.P., T.A. Scheikowski, and I.e. MacRae. Utilization of Cyclohexanone and Related Substances by a Nocardia Sp. Ant. van Leeuwenhoek. 40:17-24, 1974. 12. Turner, D.B. Workbook of Atmospheric Dispersion Estimates. U.S. Environmental Protection Agency. Report Number AP-26. January 1973. 13. U.S. Department of Health, Education and Welfare (NIOSH), Div. of Laboratories and Criteria Development. May 1975. 14. Chemical Economics Handbook. Stanford Research Institute, June 1973, 15. Chemical Profiles. Schnell Publishing Co. 1966. 16. U.S. EPA, Guideline on Use of Reactivity Criteria in Control of Organic Emissions for Reduction of Atmospheric Oxidants. Internal Draft. August 13, 1975. 17. Compilation of Air Pollutant Emission Factors. U.S. Environmental Protection Agency. Report Number AP-42. April 1973. 18. Survey Reports on Atmospheric Emissions from the Petrochemical Industry. Volume 1. Report Number EPA-450/3-73-005a. January 1974. 19. Laufer, J. The Control of Solvent Vapor Emissions. N.Y. State Department of Health. January 1969. 20. Hydrocarbon Pollutant Systems Study. MSA Research Corp. NTIS Publication No. PB-219-073. October 1972. 17 ------- APPENDIX A CYCLOHEXANONE MANUFACTURERS Allied Chemical Corp. Celanese Corp. Dow Badische Co. DuPont El Paso Natural Gas Co. Monsanto Co. Monsanto Co. Nipro Rohm and Haas Co. Union Carbide Corp. Hopewell, Virginia Bay City, Texas Freeport, Texas Belle, West Virginia Odessa, Texas Luling, Louisiana I Pensacola, Florida J Augusta, Georgia Louisville, Kentucky Taft, Louisiana Total Estimated capacity, million Ib/yr 173 50 125 240 32 250 75 20 35 1000 18 ------- |