Abstract

Mass balance models have proved to be effective tools for exposure prediction in occupational settings. However, they are still not extensively tested in real-world scenarios, or for particle number concentrations. An industrial scenario characterized by high emissions of unintentionally-generated nanoparticles (NP) was selected to assess the performance of a one-box model. Worker exposure to NPs due to thermal spraying was monitored, and two methods were used to calculate emission rates: the convolution theorem, and the cyclic steady state equation. Monitored concentrations ranged between 4.2 × 104–2.5 × 105 cm−3. Estimated emission rates were comparable with both methods: 1.4 × 1011–1.2 × 1013 min−1 (convolution) and 1.3 × 1012–1.4 × 1013 min−1 (cyclic steady state). Modeled concentrations were 1.4-6 × 104 cm−3 (convolution) and 1.7–7.1 × 104 cm−3 (cyclic steady state). Results indicated a clear underestimation of measured particle concentrations, with ratios modeled/measured between 0.2–0.7. While both model parametrizations provided similar results on average, using convolution emission rates improved performance on a case-by-case basis. Thus, using cyclic steady state emission rates would be advisable for preliminary risk assessment, while for more precise results, the convolution theorem would be a better option. Results show that one-box models may be useful tools for preliminary risk assessment in occupational settings when room air is well mixed.

Highlights

  • Thermal spraying is applied at an industrial scale to produce thermally- and mechanically-resistant coatings

  • Particle number concentrations (Table 1) were monitored during thermal spraying in booth #1 (APS, days 1 and 2) and #3 (HVOF, days 3 and 4)

  • Respirable particle mass concentrations varied from 130 to 709 μg m3 inside the booths, and 93 to 172 μg m3 in the worker area by NanoScan (WA) (Table S2, Supplementary material), which is below the occupational exposure limits (OELs) given in the material safety data sheet (MSDS)

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Summary

Introduction

Thermal spraying is applied at an industrial scale to produce thermally- and mechanically-resistant coatings. A feedstock material (metal, alloy or ceramic) is projected at high temperature and velocity onto the surface to be coated. Protective coatings are widely used in the ceramic, automotive, naval, aeronautic and metallurgy industries to prevent corrosion and wear, as well as to restore different types of damaged surfaces [1,2,3,4,5]. From a risk assessment perspective, thermal spraying is known to generate unintentional nanoparticle (NP) emissions (with diameters < 100 nm; 106 cm−3 ) at pilot-plant and industrial scales [6,7]. Similar NP emission and formation mechanisms have been identified in a large variety of industrial processes [10,11,12,13,14,15,16,17]

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