MERCURY USE: INDUSTRY - Pollution Preventioninfohouse.p2ric.org/ref/04/03851/industry.pdf · DRAFT WISCONSIN MERCURY SOURCEBOOK: INDUSTRY 407 MERCURY USE: INDUSTRY Mercury has a number

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MERCURY USE:INDUSTRYMercury has a number of unique properties that make it a valuable metal

in industry. The metal is very dense (13.5 g per cc) and does not readily

react with non oxidizing acids. It is the only heavy metal that is a liquid at

room temperature. However, mercury vaporizes easily; simply exposing

the metal to air or blowing air through it will release it in a gaseous state.

Fluorescent lights and mercury-vapor lamps rely on mercury’s high vapor

pressure (it vaporizes quickly when current is applied), high electrical

conductivity, and its ability to emit UV light when it is excited (phosphors

in the lamps convert this invisible light to visible light). Mercury alloys easily

with almost any metal (except iron, which is sometimes used for mercury

containers) and forms amalgams.

Sources: M2P2, DOD letter/report Nov 13, hunt for quicksilver

Mercury can potentially be used or released in an industrial processthrough five different routes:

1 A component in equipment (e.g., switches, gauges, thermometers)

2 An ingredient in chemicals or laboratory chemicals (e.g.,

phenylmercuric acetate)

3 A contaminant in raw materials (eg., caustic soda)

4 An intentional introduction of mercury in manufactured products

(e.g., manometer production plant)

5 An incidental release due to a production process (eg., coal

combustion)

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Table of ContentsAbout this Handout ............................... 408

Why Should I Be Concerned AboutMercury? ............................................... 409

What Kind of Industries are Covered inThis Chapter? ....................................... 411

Keeping Mercury Out of Wastewater .... 411

1 A Component in Equipment .............. 412

Mercury Product Focus: Batteries ...... 412

Mercury Product Focus: Detergents andCleaners ................................................ 414

Mercury Product Focus: Gauges -Manometers, Barometers, and VacuumGauges .................................................. 415

Mercury Product Focus: Lamps ......... 415

Mercury Product Focus: Switches andRelays .................................................... 417

Mercury Switches in ElectricalApplications .......................................... 418

Mercury Product Focus: ..Thermo-electricDevices .................................................. 419

Mercury Product Focus:Thermometers ....................................... 419

Mercury Product Focus: ThermostatProbes ................................................... 419

2 Mercury as an Ingredient in Chemicalsor Laboratory Chemicals ..................... 420

Mercury-Containing Chemicals andAlternatives ........................................... 420

Work by The Massachusetts WaterResources Authority .............................. 421

3 A Contaminant in Raw Materials ..... 423

Caustic Soda ......................................... 423

Case study: Potlatch Corporation ....... 424

4 Mercury as a By-product of aManufacturing Process ........................ 426

5 Intentional Introduction into theManufacturing Process ........................ 427

Case study: Ciba-Geigy ....................... 428

Mercury Spills ....................................... 429

Action Steps for Industries ................... 430

Sample Proclamation ........................... 432

Bibliography ......................................... 435

Current Mercury Work Table .............. 437

SHWEC: Conducting an Internal MercuryAudit for Manufacturing Facilities ....... 438

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ABOUT THIS HANDOUTThis is one chapter of the “Wisconsin Mercury SourceBook.” TheSourcebook was written as a guide for communities to help identifyand reduce the purposeful use of mercury. The SourceBook containsbackground information on mercury contamination and provides aseven-step outline for drafting a mercury reduction plan.

This handout is one of the nineteen sectors that were highlighted inthe SourceBook as a potential contributor of mercury in any givencommunity.

What you will find in this handout:

« Information on mercury-containing products and that are uniqueto industrial facilities

« Information on mercury-containing products that are found bothin industrial facilities and in a wide variety of other sectors (e.g.,fluorescent lamps, switches)

« Case studies that describe the source substitution experiences ofother industries

« Action ideas that describe pollution prevention, recycling, andmanagement practices for a mercury reduction plan for anindustry. This provides a good overview of the types of mercury-containing products and alternatives that may exist in theindustrial sector.

« A sample proclamation that explains the mercury issue andpossible mercury minimization options for industries

« Current mercury projects in this sector

For more information, please contact:


WHY SHOULD I BE CONCERNEDABOUT MERCURY?

The good news is that the majorityof products that use mercurypurposefully have acceptablealternatives. For example, electricvacuum gages, expansion oraneroid monitors are goodalternatives to mercury bloodpressure monitors. Mechanicalswitches, magnetic dry reedswitches, and optic sensors canreplace mercury tilt switches.

Replacing mercury-laden productswith less toxic alternatives is

referred to as source reduction.Source reduction allows us toeliminate the use of mercury incertain waste streams. This isespecially beneficial considering thevolatile nature of mercury, becausemercury can so easily transfer fromair to soil to water.

Practicing source reduction incombination with recycling themercury already in the waste streamcan have a significant impact onreducing mercury levels in theenvironment.

Some of you may remember playing with mercury when you were achild. Its silvery white shimmer was entrancing, and the ability of itsglistening mass to split and come back together again was magical.But scientists are now beginning to realize that there is another sideto mercury’s wily nature. In fact, it is some of mercury’s mostelemental qualities that make it a difficult substance to handle.

Mercury is a common element that is found naturally in a free stateor mixed in ores. It also may be present in rocks or released duringvolcanic activity. However, most of the mercury that enters theenvironment in Wisconsin comes from human uses.

Because mercury is very dense, expands and contracts evenly withtemperature changes, and has high electrical conductivity, it has beenused in thousands of industrial, agricultural, medical, and householdapplications.

It is estimated that half of the anthropogenic mercury releases inWisconsin are the result of the purposeful use of mercury. The otherhalf of mercury emissions originate from energy production.

Major uses of mercury include dental amalgams, tilt switches,thermometers, lamps, pigments, batteries, reagents, and barometers.When these products are thrown in the trash or flushed down a drain,the mercury doesn’t go away.

Mercury is a bioaccumulative,persistent, toxic substance thatthreatens the health of humansand wildlife throughout NorthAmerica. The USEPA,Environment Canada, theInternational JointCommission, the Commissionfor EnvironmentalCooperation and many stateand provincial governmentshave identified mercury as oneof the most critical pollutantsfor significant elimination and/or reduction.

SO WHAT’S THE BIG DEAL?

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HEALTH EFFECTS OFELEMENTAL MERCURYThe toxicity of mercury has longbeen known to humans. Hatmakers during the 19th centurydeveloped symptoms of shakingand slurring of speech fromexposure to large amounts ofinorganic mercury, which wasused to give a metallic sheen tofelt hats. This gave rise to theterm “mad as a hatter.”

The hat makers were sufferingfrom neurological damage fromthe inhalation of mercury fumes.Exposure to elemental mercuryvapors can cause acuterespiratory problems, which arefollowed by neurologicdisturbances and general systemiceffects. Acute exposure toinorganic mercury by ingestionmay also cause gastrointestinaldisturbances and may effect thekidneys.


Mercury can enter the environment from a number of paths. For example, ifa mercury-containing item is thrown into the garbage, the mercury may bereleased into the atmosphere from landfill vapors or leachate, or the mercurymay vaporize if the trash is incinerated. If mercury is flushed through awastewater system, the mercury will likely adhere to the wastewater sludge,where it has the potential to volatilize and be deposited elsewhere. Mercurycan enter the atmosphere through these various means because it evaporateseasily. It then travels through the atmosphere in a vaporized state.

Once mercury is deposited into lakes and streams, bacteria convert some ofthe mercury into an organic form called methylmercury. This is the form ofmercury that humans and other animals ingest when they eat some types offish. Methylmercury is particularly dangerous because it bioaccumulates inthe environment. Bioaccumulation occurs when the methylmercury in fishtissue concentrates as larger fish eat smaller fish. A 22-inch Northern Pikeweighing two pounds can have a mercury concentration as much as 225,000times as high as the surrounding water.

These concentrations are significant when one considers the potential toxiceffects of methylmercury. Methylmercury interferes with the nervous systemof the human body and can result in a decreased ability to walk, talk, see, andhear. In extreme examples, high levels of methylmercury consumption hasresulted in coma or death.

Many animals that eat fish also accumulate methylmercury. Mink, otters,and loons in Wisconsin have been found to have high levels of mercury intheir tissue. Mercury can interfere with an animal’s ability to reproduce, andlead to weight loss, or early death.

Mercury Transport and Bioaccumulation

Direct Air Emissions

Solid Waste Disposal

Wastewater Disposal

Incineration

Sludge Land Disposal

M ethyl M ercury

M ercury

Fish ConsumptionAdvisoriesThere are currently 260 lakesand more than 350 miles ofrivers in Wisconsin that havefish consumption advisoriesbecause of mercury.Approximately 1 out every 3sites that is tested is listedon the advisory; no siteshave ever been removed.Forty-eight states now issuefish consumption advisoriesto protect human health.Most of these warnings arerelated to mercurycontamination.


What Kind ofIndustries AreCovered in thisChapter?

We will look both at the customersusing mercury-containing items(#1-3) and the facilities thatproduce or recycle these items (#4).Because mercury is present in lowlevels in rocks and ores, it may alsobe released as a by-product duringa manufacturing process or throughpower generation (#5).

Industries that use or manufacturemercury-containing products mayinclude:

✔ Industries that use ormanufacture measuring orcontrolling equipment (e.g,thermometers, pressure sensingdevices, navigational orelectrical equipment, seals,valves)

✔ Facilities that do extensivelaboratory testing on-site

✔ Industries that use caustic sodaor sulfuric acid

✔ Recyclers of mercurycontaining products (e.g.,instrument and electricalmanufacturing, industrial wasteand scrap, sludges fromresearch laboratories)

✔ Facilities that have on-siteboilers

✔ Industries that producemercury as a by-product oftheir production process (e.g,lime production, petroleumrefining)

Please note that there are specialchapters for the followingindustries:* Automotive Industry

* Chemical Manufacturer/UserIndustry

* Food Processing Industry

* Laboratories

* Paper Mills

Keeping MercuryOut of WastewaterThere are a number of waysmercury can enter the wastewaterstream of an industry. When amercury-containing product such asa thermometer is broken over asink or improperly cleaned up aftera spill, the mercury could getflushed down the drain. Mercurymay also be present in an industry’ssewer pipes and traps fromhistorical use of mercury.

Once mercury enters a wastewatertreatment plant, most of itconcentrates in wastewaterbiosolids during treatment. Sincemost treatment plants dispose ofgenerated solids by land spreading,mercury enters the terrestrialenvironment by this process. Someof this mercury spread on landmay, over time, be volatilized to theatmosphere. This mercury may thenbe deposited into lakes andstreams, methylated, and ingestedby fish, eventually reaching wildlifeand humans.

To prevent such occurrences, it isimportant to have effective spillresponse measures. Instruments

containing mercury should belabeled and proper proceduresshould be followed when cleaningor refilling instruments that containmercury. Instrument cleaning orrefilling should take place in a wellventilated area, and, if possible,over a tray to contain any spills.

Sewer PipesMercury was used extensively inindustrial settings in the past. Oftentimes the mercury may have foundits way into the pipes of an industrywhen items were broken, disposedof, or spilled. This mercury cansettle at a low point such as a sumpor trap and remain in the pipes ofa industry for many years. Often theslow dissolution of the mercury ina sump, trap, or pipe is enough tocause violations of wastewaterdischarge standards even after poormanagement practices have beeneliminated. Hot spots in a industry’spiping may appear whereequipment maintenance areas werelocated. Whenever traps or sumpsare moved or cleaned, the solidcontents should be treated as ahazardous waste unless provenotherwise. For more information,please see the excerpts from theMWRA/MASCO InfrastructureSubcommittee MaintenanceGuidebook that appear in the“Resources” section of thissourcebook.


1 A COMPONENT IN EQUIPMENT✔ Batteries

✔ Cleaning Solutions

✔ Gauges and manometers

✔ Fluorescent lamps

✔ Specialty lamps

✔ Switches, relays, and sensors

✔ Thermometers

✔ Thermoelectric devices

✔ Thermostat Probes

Mercury ProductFocus: Batteries

✔ Mercuric Oxide Batteries

Prior to the 1980s, most primarybatteries and some storage batteriescontained mercury in the form ofmercuric oxide (HgO), zincamalgam (Zn-Hg), mercuricchloride (HgCl2), or mercurouschloride (Hg2Cl2). Although theamount of mercury used in eachof these batteries was very small,the number of batteries sold in theUS was enough to make alkalinebatteries the largest component ofmercury in the solid waste stream in1989.

Great pollution preventionprogress has been made in thisfield. In the last decade, the USbattery industry has achieved a 99percent reduction in their use ofmercury! The use of alternative

materials and differentmanufacturing techniques haveeliminated the use of mercury inalmost all battery applications.

Mercury does exist in mercury zinc,carbon zinc, silver oxide, and zincair batteries. The amount ofmercury discarded in mercury zincbatteries is expected to decline inthe future as the use of silver oxideand zinc air batteries increases. Theuse of mercury in zinc air and silveroxide batteries is expected to bediscontinued.

Today, mercuric oxide batteries arethe only batteries that use mercuryto any measurable degree. Thereare two basic types of mercuricoxide batteries: button cell andlarger sizes. The button cell batteriesare the types that are most oftensold for personal use; they are usedin hearing aids, watches, and otheritems requiring a small battery.

Mercuric oxide batteries offer areliable and constant rate ofdischarge. Therefore, the largermercuric oxide batteries (whichlook like 9-volt or fat AA batteries)are often used in military, hospital,or industrial uses. The mercurycontent in these mercury oxidebatteries total 33 to 50 percentmercury by weight of the battery.

1993 Wisconsin Act 74

The 1993 Wisconsin Act 74prohibits the sale in Wisconsinof any alkaline manganesebattery manufactured afterJanuary 1, 1996, unless themanufacturer can prove thatthe alkaline manganese batterycontains no intentionallyintroduced mercury. Alkalinemanganese button cells canonly be sold if they contain nomore that 25 mg of mercury.

Zinc Carbon batteriesmanufactured after July 1,1994 for sale in Wisconsinmust contain no intentionallyintroduced mercury. BeginningJuly 1, 1994 mercuric oxidebatteries, except button cells,may not be sold in Wisconsinunless the manufactureridentifies a collection site thatmeets prescribed standards,informs each purchaser of thecollection site and a telephonenumber to call for informationon recycling batteries, andinforms the Department ofAgriculture, Trade, andConsumer Protection andDNR of this collection site.The law also states that only acertified collection site maytreat, store, or dispose ofmercuric oxide batteries, andthey must be recycled ifpossible.


Batteries and Mercury ContentFrom “Household Batteries Waste Management Study,” by Gershman, Brickner, and Bratton, Inc., 1992; “Managing Used Dry-Cell

Batteries: A Household Hazardous Waste Fact Sheet,” MPCA

Type of Battery Example of Use Mercury Content

Alkaline

Cylindrical or rectangular cells;the most commonly recognizedbattery. Labeled “alkaline.”

Flashlight, radios, toys,calculators, remote controls,electronic games, portableradios and televisions, garagedoor openers.

Previously contained an average of 0.5percent mercury to control the zincreaction. 1993 Wisconsin Act 74mandates that all alkaline manganesebatteries sold in Wisconsin afterJanuary 1, 1996 be mercury free.Alkaline manganese button cellbatteries to contain no more than 25milligrams of mercury .

Zinc Carbon

Cylindrical or rectangular cells;labeled as “General Purpose”,“Heavy Duty” , or “Classic”

Best used in slow drainapplications like clocks,garage door openers, pagers,and smoke detectors. Havemuch shorter life span thanAlkaline batteries.

Use of mercury in these batteries isbeing phased out. 1993 Wisconsin Act74 mandates that all zinc carbonbatteries for sale after July 1, 1994 bemercury free.

Silver Oxide

Button shaped with nodistinguishing marks

Watches, calculators, toys,greeting cards, musical books

Contain about one percent mercuryby weight. Mercury use in thesebatteries is expected to bediscontinued.

Zinc Air

Usually button shaped. Identifyby pin hole on one side

Hearing aids Contain about one percent mercuryby weight. Mercury use in thesebatteries is expected to bediscontinued.

Mercury Zinc(Mercuric Oxide)

Button shaped, marked with + ;larger mercuric oxide batterieslook like 9-volt or fat AAbatteries

Hearing aids, watches, andother items requiring a smallbattery. In consumerapplications, mercuric oxidebatteries are being replacedby zinc-air button cells.

The larger mercuric oxidebatteries are often used inmilitary, hospital, orindustrial uses.

Contain significant amounts ofmercury ; total 33 to 50 percent byweight of the battery.

Wisconsin Act 74, requires acollection system for those sellingmercuric oxide batteries, and requiresthe recycling of mercuric oxidebatteries unless no reasonablealternative exists.


Mercury Product Focus: Detergents and Cleaners

“Other Sources of Mercury”Information from the Massachusetts Water Resources Authority/MASCO

Product Mercury Content(ppb)

Ajax Powder 0.17

Comet Cleaner 0.15

Lysol Direct <0.011

Soft Scrub <0.013

Kodak Fixer 6.9; 3.7

Kodak Developer 2.65; 6.0

Alconox Soap 0.004 mg/kg0.005 mg/kg<0.0025 mg/kg

Derma Scrub <5.0<2.5

Dove Soap 0.0027

Ivory DishwashingLiquid

0.061

Joy DishwashingLiquid

<0.01

Murphy’s Oil Soap <0.012

Soft Cide Soap (Baxter) 8.1

Sparkleen Detergent 0.0086

Sunlight DishwashingDetergent

<0.011

The Massachusetts Water ResourcesAuthority (MWRA), in conjunctionwith MASCO (a consortium ofLongwood Medical and AcademicArea Institutions), has been workingwith their area hospitals andacademic institutions to identify andaddress the problem of mercurycontamination in hospital andmedical waste streams. As part ofthis process, the MWRA group alsoworked to identify “other sources”of mercury contaminants. These arecommon products, such as bleach,alcohol, laboratory lids, nototherwise thought to be ofsignificant importance or concern,that might contain low levels ofmercury. Thus far, a total of 118products has been identified by thisteam. This information isapplicable in a variety of settings.


Mercury ProductFocus: Gauges -Manometers,Barometers, andVacuum Gauges(From blue waste connection pamphlet)

✔ Air flow measurement devicesusing a Pitot Tube andmanometer (may also be calledan airway controller)

✔ Commercial-industrialmanometers

✔ Permeter (used to measurepermeability of sand mass toflow of air)

Many industries may encounterliquid mercury in the gauges foundin manometers or vacuum gauges.The mercury in these gaugesresponds to air pressure in a preciseway that can be calibrated on ascale. Mercury-free alternatives tothese gauges operate on the sameprinciple as these gauges but usemercury-free liquids in the tube.

Needle or bourdon gauges operateunder a vacuum with a needleindicator. Electronic gauges can beused to measure pressure, but theymust be calibrated with a mercurymanometer. Equipmentmanufacturers recommend thatservice technicians use a needle ordigital gauge to test the systems theyare servicing, but that they calibratethe gauges they use in the field witha mercury manometer kept at theirshop.

Mercury manometers occasionallyneed servicing to maintain theiraccuracy, and elemental mercuryoften remains as a waste. If themanometer is hard to read becauseof dirt and moisture in the tube,the mercury needs to be removedand replaced.

Mercury ProductFocus: Lamps

✔ Cold Cathode Lamps -illumination

✔ Spectral Lamps -monochromatic light source

✔ Fluorescent Lamps

- bilirubin blue

- blacklight

- general purpose straight, u-bent, circline, compact

- high output

✔ Germicidal Lamps

- cold cathode

- hot cathode

- slimline

✔ High Intensity Discharge

✔ “CS - compact source”mercury lamps

✔ “special mercury lamps” (UVproperties)

✔ high pressure sodium lamps

✔ mercury vapor lamps

✔ metal halide lamps

There are a number of electriclamps that use mercury as anintrinsic part of their functioning.These lamps include fluorescent,mercury vapor, metal halide, andhigh pressure sodium lamps. Theselamps may be used indoors oroutdoors in heat lamps, filmprojection, photography, dentalexams, photochemistry, waterpurification, or street lighting.

Fluorescent lamps contain mercuryin a vapor form. The electriccurrent of the lamp “excites” themercury atoms, which then giveoff invisible ultraviolet light. Theultraviolet light then “excites” apowdery phosphorus coating insidethe tube that emits visible light. Themercury that is contained in theselamps is emitted into theatmosphere when the lamps arebroken, disposed of in landfills, orincinerated.

Fluorescent lamps are still a goodoption. They last longer and costless to run than incandescent lightsbecause they use up to 50 percentless electricity. This energy savingshelps reduce mercury emissionsbecause small amounts of mercuryare present in coal that is burned inpower plants. The less energy weuse, the less mercury will bereleased into the environment whencoal is burned.


Recycling YourFluorescent Lamps

Several Wisconsin companies are inthe business of recycling fluorescentlamps and incandescent bulbs. Thecopper coils, and aluminum orbrass end pieces are smelted andreused as raw materials for non-food products. The glass can bepurified and used to makefiberglass. The mercury is distilledfrom the phosphor powder andreused in new lamps andthermometers.

State hazardous waste regulationsprohibit businesses from disposingof waste lamps and light bulbs insanitary landfills if those lamps andbulbs contain levels of heavy metalsthat exceed hazardous waste limits.For information on the storage,collection, and transport offluorescent lamps, please see theinformational handout, “RecyclingYour Fluorescent Lamps,” in the“Resources” section of thissourcebook.

New Low Mercury Fluorescent Bulb

Phillips Electronics has developed a long-life fluorescent that

contains so little mercury it is no longer considered a hazardous

waste. “Typically fluorescent lamps have an overabundance of

mercury, because mercury loses its effectiveness due to physical

and chemical reactions. So manufacturers put in an overdose of

mercury to compensate for these reactions,” said George

Preston, a scientist at Philips Lighting Co. Currently, a four-foot

lamp contains about 22.8 milligrams of mercury, down from

38.4 milligrams in 1990. Philips’s new lamp contains less than 10

milligrams of mercury. The new lamp, named ALTO™, relies

on a “buffering mechanism” that blocks the physical and

chemical reactions that cause the mercury to lose its effectiveness

over time. The lamp also uses a new form of phosphors

patented by Philips.

From “Philips Unveils a Fluorescent Lamp With Less Mercury and a LongLife,” Wall Street Journal, June 9, 1995

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Types of Bulbs and Lamps that Contain Mercury

◆ Fluorescent Lamps - the tube-style were first used as overhead lighting in offices, now they also come incompact globe shapes for a variety of home and office uses

◆ Mercury Vapor Lamps - the first high intensity discharge (HID) lamps with blue-white light, originally usedas farmyard lights

◆ Metal Halide Lamps - newer, more efficient HID lights found in homes and offices

◆ High-Pressure Sodium Vapor Lamps - white-yellow HID lights used for street lamps and outdoorsecurity lighting

◆ Neon Lamps - brightly colored lamps typically used in advertising; most colors contain mercury except red,orange, and pink

- From the Wisconsin Recycling Markets Directory


Mercury ProductFocus: Switchesand Relays

✔ G-sensors (security systemapplications)

✔ Oscillators

✔ Phanatrons

✔ Proximity sensors, magneticallyactivated

✔ Rectifiers

✔ Wetted reed relay/wetted reedswitch: test, calibration,measurement equipment

(used where stable contact resistanceover the live of the product isnecessary. For specialized equipment -mass produced applications do notneed)

Displacement/PlungerRelays:Mercury to Steel or Tungsten Contact;Mercury to Mercury Contact

✔ Industrial process controllers

✔ High current/voltage lighting

✔ Power supply switching

✔ Resistance heating

✔ Tungsten lighting

✔ Welding

Tilt Switches:Including SPST, SPDT, NO, NC, wideangle, omnidirectional, circuit boardmount✔ “man down” alarms

✔ “silent” wall switches, singlepole and three way (believed tobe totally discontinued in 1991)

✔ Airflow/fan limit controls

✔ Building security systems (tiltand trembler devices)

✔ Cameras (still, video, film:overridable position sensor toprotect CCD from sunlightdamage)

✔ Fluid level control (mountedon float, on lever arm, ondiaphragm or on plunger)

✔ Laptop computer (screen shut-off when closed)

✔ Level sensors and controls(likely in vehicle and aircraftapplications)

✔ Marine auto-pilot

✔ Pneumatic tube communicationsystems

✔ Portable phone (mute/privacyswitch when phone is inhorizonal position)

✔ Pressure control

✔ Safety shut off- limit switchesfor industrial machinery

✔ Safety shut-off - outboardmotors

✔ Temperature control

Another source of mercury thatindustries may encounter is mercuryswitches. A small electrical switchmay contain 3,500 milligrams ofmercury; industrial switches maycontain as much as eight pounds ofmercury. Mercury is used intemperature-sensitive switches andin mechanical switches. Themechanical (tilt) switches areactivated by a change from avertical to a horizontal position.These are used in products likethermostats and silent switches.Mercury-containing tilt-switchesmay also be present in or under thelids of clothes washers and chestfreezers - they stop the spin cycle orturn on a light. Mercury tilt switchesare also found in motion-sensitiveand position sensitive safetyswitches in clothes irons or spaceheaters. If a mechanical switch isnot visible in these items, a mercuryswitch is probably being used.

Mercury tilt switches have beenused in thermostats for more than40 years. According to Honeywell,Inc., a major manufacturer ofthermostats, more than 50 millionmercury-containing thermostatshave been sold since the 1950s foruse in homes and offices. Mercuryin these thermostats provideaccurate and reliable temperaturecontrol, require little maintenance,and do not need a power source.However, each mercury switch in athermostat contains about 3 gramsof mercury. (There may be one ormore of these switches in a singlethermostat, each switch in a sealedglass bulb.) Alternatives to these


products include electronicthermostats, which can beprogrammed to set roomtemperatures at predeterminedtimes. (blue brochure: the wasteconnection)

Float control switches may be usedin septic tank and sump pumps toturn the equipment on and offwhen water is at a certain level.Often, these switches are visible.Temperature-sensitive switches maybe used in thermostats. Yet anothertype of mercury switch, the plungeror displacement relay, is used inhigh current, high voltageapplications that could includelighting, resistance heating, orpower supply switching (M2P2).

Reduction Works!

Honeywell Corporation has been running a free take-back program inMinnesota to collect any brand of used mercury-containing thermostatthrough either a reverse distribution system or a recycle by-mail system.

Honeywell works with heating, ventilating, and air-conditioning (HVAC)wholesalers who sell their products. Honeywell has one license (called anetwork license) for all the wholesalers who are participating as aconsolidation point for the thermostats. HVAC wholesalers contact theirHoneywell customer service representatives to order containers for usedthermostats, and Honeywell sends the wholesaler a plastic container with anattached lid that holds 100 thermostats.

Homeowners who replace their own thermostats without contractorassistance or with contractors who are not currently participating in theHoneywell program may recycle their thermostats through the free recycle-by-mail system. These individuals can call a toll-free number to receive a freepostage paid thermostat mailer.

Switch Quantity ofMercury

Available Alternatives

Tilt SwitchTilt Switch

· Thermostats 3,000 - 6,000 mg Electronic type and snap switches

· Float Control(septic tank and sump pumps)

? Magnetic dry reed switch, optic sensor, ormechanical switch

· Freezer Light 2,000 mg Mechanical switch

· Washing Machine(power shut off)

2,000 mg Mechanical switch

· Silent Switches(light switches prior to 1991)

2,600 mg Mechanical switch

Thermo-Electrical ApplicationsThermo-Electrical Applications

· Accustat(“mercury in glass thermostat,” acalibrated device resembling athermometer is used to provideprecise temperature control forspecialized applications)

~ 1,000 mg ?

· Flame Sensor(used in residential and commercialgas ranges, mercury is in capillarytube when heated mercuryvaporizes and opens gas valve oroperates switch. Used for bothelectrical or mechanical output.)

2,500 mg Hot surface ignition system for devices orproducts that have electrical connections.

Mercury Switches in Electrical Applications(source: Michigan Mercury Pollution Prevention Task Force, 1996)


Mercury ProductFocus:Thermo-electricDevices

✔ Mercury in glassthermostat tubes anddevices

Tube is thermometer-likedevice; mercury column opensand closes circuit via metalcontacts. 1, 2, or 4 tubes usedin conjunction with relaycontrol device. Mercury-thallium models fortemperatures to -60 C.

✔ Thermoregulator

An adjustable mercury in glassdevice with an electrical outputdependent on the position ofthe mercury column

Mercury ProductFocus:Thermometers✔ ASTM and laboratory

✔ cup case

✔ incubator/water bath

✔ Mason’s Hygrometer

✔ maximum registering

✔ minimum/maximum

✔ sling psychrometer

✔ tapered bulb

✔ weather

Digital or aneroid thermometersare good alternatives for mostapplications of mercurythermometers.

Mercury ProductFocus:ThermostatProbes (also knownas mercurythermocouples)( from blue waste connection pamphlet +draft text)

✔ Mercury Flame Sensor/Mercury Safety Valve

✔ “Cycle pilot” devices

✔ Some infrared heaters(Robertshaw and Harper-Wyman)

✔ Some furnaces (White Rodgers)

Stainless steel bulb, capillarytube, bellows/control device:Used for “unsupervisedburners” in certain gas fireddevices with standing pilot orelectronic ignition pilot.

Mercury-containing thermostatprobes may be found in severaltypes of gas-fired appliances thathave pilot lights such as ranges,ovens, clothes dryers, water heaters,furnaces, or space heaters. Themetal probe consists of a metalbulb and thin tube attached to agas-control valve. The mercury isinside the tube and expands orcontracts to open and shut thevalve. A high percentage of gasstoves, ovens, and space heaters

contain a mercury thermostatprobe. Electric stoves and hotwater heaters (gas, electric, and oil)may contain mercury thermostatprobes. Although non-mercurythermostat probes have been usedin these appliances, you should treatall probes as though they containmercury, unless you know that theydo not.

Mercury thermostat probes, alsoknown as flame sensors or gassafety valves, are most commonlypresent as part of the safety valvethat prevents gas flow if the pilotlight is not lit. In this application thebulb of the thermostat probeprojects into or near the pilot light.These are commonly present in gasovens and may be present in anyother appliance with a pilot light.

A mercury-thermostat probe mayalso be present as part of the maintemperature controlling gas valve.In this application, the probe is inthe air or water that is being heatedand is not directly in contact withany flame. These are typically foundin older ovens, clothes dryers, waterheaters, or space heaters.


2 MERCURY AS AN INGREDIENT IN CHEMICALS OR LABORATORY CHEMICALS

Chemical reagents, used with regularity in a widerange of laboratory testing, are likely sources ofmercury contamination.The difficulty of identifying which chemicals andreagents contain mercury is compounded by the factthat Material Safety Data Sheets (MSDS) are notrequired to list the hazardous components of aproduct unless that component is present at a level of>1% (0.1% for carcinogens). This means that aparticular product could contain up to 10,000 parts permillion of mercury before the manufacturer wouldhave to alert users of that fact.(MWRA operations subcommittee final report)

Work by the MPCAJohn Gilkeson of the Minnesota Pollution ControlAgency has compiled an extensive list of all mercury-containing compounds that are currently available forresearch and scientific purposes. He has alsodeveloped a list of all mercury-containingcompounds with a CAS number. These charts areattached at the end of the “chemical” chapter.

A number of facilities have discovered that mercuryis present in very low levels in some of their products.However, because the mercury was added as apreservative, not as an active ingredient, its low levelmay be below the reporting threshold and thus notincluded in the Material Safety Data Sheets (MSDS)sheets.(gilkeson, butterworth, Metpath)

Chemical Alternative

Mercury (II) Oxide Copper catalyst

Mercury Chloride None Identified

Mercury (II) Chloride Magnesium Chloride/Sulfuric Acid or ZincFormalin, Freeze drying

Mercury (II) Sulfate Silver Nitrate/Potassium/Chromium-(III)Sulfate

Mercury Nitrate (for corrosion ofcopper alloys) for antifungal use(mercurochrome)

Ammonia/Copper SulfateNeosporin, Mycin

Mercury Iodide Phenate method

Sulfuric Acid(commercial grade; mercury asimpurity)

Sulfuric acid from a cleaner source

Zenker’s Solution Zinc Formalin

Mercury-Containing Chemicals and Alternativescompiled from City of Detroit, MPCA, Terrane, Michigan M2P2


Work by TheMassachusetts WaterResources AuthorityReagents: The MercuryProducts DatabaseThe Massachusetts Water ResourcesAuthority (MWRA), in conjunctionwith MASCO (a consortium ofLongwood Medical and AcademicArea Institutions), has been workingwith their area hospitals andacademic institutions to identify andaddress the problem of mercurycontamination in hospital andmedical waste streams. TheOperations Subcommittee of thisgroup set out to identify mercury inreagents. As part of this process, adatabase worksheet was developedto capture the wide range ofinformation known to containmercury. Next, a letter was sent to153 major reagent vendors to elicitsupplier support in identifying thetrace levels of mercury contained intheir products. The letters alsorequested that suppliers provideverification of product mercurycontent via the submission of astate certified laboratory report.

Using all available inputs, a total of5,504 products were identified andinventoried into the masterdatabase using both vendor andmember responses to requests forinformation. The statistics for theirfindings are as follows:

Total number of products inventoried: ................................................. 5504

Number of records that contain mercury data: ..................................... 781

Number of records that contain mercury concentrations belowdetection: ........................................................................................................ 166

Number of records with mercury concentrations BD - 1 ppb: ........... 43

Number of records with mercury concentrations 1 -5 ppb: ................. 53

Number of records with mercury concentrations 5 - 10 ppb: ............. 19

Number of records with mercury concentrations > 10 ppb: ............. 469

Number of records under review of concentration data: ..................... 31

Due to the size of the overall Mercury Products Database, only thatportion of it which contains chemicals and products that have beenverified, as of 8/21/95, to contain mercury at some level, have beenincluded in the report to the right.

75 Priority SamplesIn an attempt to maximize the value of the database, MWRA selectedseventy-five (75) of the most commonly used products by memberhospitals and institutions and tested these for mercury content.

The analysis results for these 75 priority samples are shown on thefollowing page.


Product Sampled MercuryContent (ppm)

Seven Deionized Water Samples <0.0010

Periodic Acid <0.0010

Acetone <0.0010

Sodium Iodate <0.0010

Acetonitrile <0.0020

Aluminum Potassium Sulfate <0.0010

Boric Acid <0.0010

Butter Solution pH -7 <0.0010

Fixer 0.0049

Formaldehyde 0.012

Glutaraldehyde <0.0010

Herpes Buffer <0.0010

Phosphate Buffered Saline <0.0010

Potassium Carbonate <0.0010

Sodium Carbonate <0.0010

Sodium Sulfate 0.010

Sodium Bisulfate <0.0010

TDX <0.0020

TRIS <0.0010

Triton X-100 <0.0010

Oxalic Acid <0.0010

Sodium Phosphate Dibasic <0.0010

3%, 30% Hydrogen Peroxide 0.0012

Isopropyl Alcohol <0.0010

Nitric Acid <0.0019

Potassium Chloride <0.0010

Silver Nitrate <0.0010

Sodium Bicarbonate <0.0010

Sodium Chloride <0.0010

Trizma Buffer <0.0010

Sodium Phosphate Monabasic <0.0010

Results from 75 Priority SamplesInformation from The Massachusetts Water Resources Authority (MWRA), in conjunction with MASCO (a consortium of Longwood

Medical and Academic Area Institutions)


3A CONTAMINANT IN RAW MATERIALS

Caustic SodaChlorine Production and the Mercury Cell Process(taken directly from November 21, 1994 C&EN)

The mercury process is one of three electrolytic systems that convertsodium chloride in brine into chlorine and sodium hydroxide, which isreferred to as caustic soda. In the US, about 75% of chlorine is made indiaphragm cells, 13% in mercury cells, and 11% in ion-exchangemembrane cells. The remainder is formed as a by-product of otherchemical reactions.

In mercury cells, liquid mercury forms the cathode, gathering sodium ionsfrom brine to form a mercury-sodium amalgam. Chlorine gas is releasedat the anode. The amalgam, when transferred to a “decomposer” andreacted with water, produces sodium hydroxide solution, hydrogen gas,and mercury, which is returned to the electrolytic cell.

As US chlorine production is consolidated, small mercury-based plants arethe most likely to close. In Europe, most chlorine production is based onmercury cells, but the European Union plans to phase out their use by2010. And Japan already has replaced most mercury cells, says Roger E.Shamel, president of consulting Resources Corp., Lexington, Mass.,because of incidents of mercury poisoning.

Diaphragm cells produce chlorine, hydrogen gas, and sodium hydroxidesolution in one cell, with no mercury involved. Brine flows into an anodecompartment, which is separated from the cathode by a diaphragm.Chlorine forms at the anode, and the sodium ions and dilute brinetraverse the diaphragm. Hydrogen is released at the cathode, and thesodium hydroxide-salt solution is removed. The effluent is concentratedby evaporation, and salt precipitates.

Ion-exchange membrane cells, the newest method, allow nearly one-stepchlor-alkali production. As in the diaphragm cells, brine flows into theanode compartment, where chlorine is formed. But the membranesselectively allow only the sodium ions to pass into a water-filled cathodecompartment. The cathode solution is removed from the cell andconcentrated.

Manufacturing plants may usechlorine, caustic soda, or muriaticacid to treat water or to assist in theproduction of paper products,cosmetics, pharmaceuticals, orfood products. Manufacturingplants may dilute sodium hydroxideor potassium hydroxide and use itto regenerate ion exchange resin,adjust the pH of water or processfeedstocks, or in their intermediateor final processes. Additionally,caustic soda may be used to treat“cooling” water used in powerplants and boilers.

The Chlorine Institute, the tradeassociation of chlor-alkalimanufacturers, has recentlysupported an initiative set forth bythe Virtual Elimination Project toreduce mercury emissions frommercury-cell chlor-alkalimanufacturing by 50% by the year2005. The Institute has alsosupported a 50% reduction in thedeliberate use of mercury(purchases or consumption) inchlor-alkali manufacturing by 2005.

These significant commitments arean important step in reducingmercury emissions in the US. Weapplaud the efforts set forth by theInstitute and support theirvoluntary actions ofenvironmental leadership.

from a memo addressed to Ms.Elizabeth LaPlante of the USEPAfrom Robert Smerko, president of theChlorine Institute, dated September19, 1996.


The table below shows the estimated mercury concentration (ppb) in wastewater given the usage ofcaustic (in tons per day) and the average wastewater discharge (in gpm).

REDUCTION WORKS!

Case Study: Potlatch Corporation - Tracking Down Mercury inFeedstock ChemicalsPotlatch Corporation is a pulp andpaper manufacturing facility inCloquet, Minnesota. The plantchanged its bleaching process toElemental Chlorine Free (ECF) inMarch, 1994, which required theintroduction of new feedstockchemicals.

The facility discharges into theWestern Lake Superior SanitaryDistrict, which recently imposed alocal limit for mercury. Prior to thedevelopment of this limit, thecompany and the District wereaware that Potlatch effluent wastypically low in mercury, butoccasional peaks were of concern

to both parties. The two facilitiesbegan an examination of possiblemercury sources in feedstockchemicals.

Caustic soda feedstock was testedand eliminated because thecompany was no longer usingmercury grade caustic soda.However, the testing of sulfuricacid revealed that some shipmentshad low mercury levels, while othershipments were higher. The use ofhigh mercury sulfuric acidcorrelated with the mercury peaksin Potlatch effluent. Furtherinvestigation revealed that the lowand high mercury sulfuric acids

were from different manufacturingprocesses. the company then tookthe step of informing suppliers thatthe company had to be assured oflow mercury content on all itsfeedstock chemicals.

“Worst Month” vs. “Best Month”reductions were about 7.5 poundsof mercury for this facility!

(From “Mercury Reduction ThroughTreatment Chemical Selection,” a handoutfor the Lake Superior basin EnergyEfficiency Workgroup Meeting, 2/27/96)

Mercury in Wastewater (ppb)Wastewater Flow (gpm)

Caustic Used(tons per day)

100 500 1,000 5,000

1 0.017 0.003 0.0016 0.0003

2 0.033 0.007 0.0033 0.0007

10 0.17 0.033 0.016 0.0033

20 0.33 0.066 0.033 0.0066

Table from Vulcan Chemicals


Carri Lohse-Hanson at the Minnesota Pollution Control agency has undertaken a project of “MercuryReduction Through Treatment Chemical Selection.” She has researched mercury levels in caustic soda(see chart below) and has also found that other feedstock chemicals may have high levels of mercury. forexample, sulfuric acid produced at a lead smelter was found to have significantly higher levels of mercurythan sulfuric acid made from a copper smelter.

The Mercury Reduction Through Treatment Chemical Selection project will collect information onsources and characteristics of feedstock chemicals, including the prices of various grades, and will identifylikely users of these materials. The second phase of the project will distribute information and requestswitching to low mercury feedstocks.

The following table from the Minnesota Pollution Control Agency provides preliminary information oncharacteristics of different grades of caustic soda:

Characteristics of Different Grades of Caustic Soda

Properties* Mercury Cell MembraneCell

Rayon Grade DiaphragmGrade

Purified

sodiumhydroxide

50% 50% 50% 50% 50%

sodiumchloride

400 ppm 100 ppm 100 ppm 11000 ppm 300 ppm

sodiumchlorate


sodiumcarbonate


sodium sulfate 100 ppm 250 ppm 250 ppm 500 ppm 500 ppm

iron 3 ppm 3 ppm 3 ppm 10 ppm 5 ppm

nickel -- 0.3 ppm 0.3 ppm 3 ppm 4 ppm

copper -- 0.3 ppm 0.3 ppm 0.2 ppm 0.2 ppm

mercury 0.25 ppm 0.001 ppm 0.2 ppm 0.001 ppm --

heavy metals 1.5 ppm 5 ppm 15 ppm 10 ppm 10 ppm

silica 17 ppm 10 ppm 15 ppm 50 ppm 80 ppm

* Maximum valuesInformation from The Minnesota Pollution Control Agency


4 MERCURY AS A BY-PRODUCT OF A MANUFACTURING PROCESS

Because mercury is present in manyrocks and ores, several industrialprocesses release mercury:

◆ Carbon Black ProductionMercury is present in oilfeedstock

No facilities in Wisconsin

◆ Chlor-Alkali ProductionThe mercury cell processconverts sodium chloride inbrine to into chlorine andsodium hydroxide, which isreferred to as caustic soda. Inmercury cells, liquid mercuryforms the cathode, gatheringsodium ions from brine toform a mercury-sodiumamalgam. Chlorine gas isreleased at the anode. Theamalgam, when transferred toa “decomposer” and reactedwith water, produces sodiumhydroxide solution, hydrogengas, and mercury, which isreturned to the electrolytic cell.

There is one chlor-alkali facilityin Wisconsin; estimated yearlyemissions: 1,141 lbs/year.

◆ Coke ProductionMercury is a by-productpresent in coal used asfeedstock for coke ovenbatteries (primary feedstock foriron and coal industry)

No facilities in Wisconsin

◆ Petroleum RefiningMercury present in petroleumcrude

One petroleum refinery inWisconsin; emissions probablybelow 18 pounds/year.

◆ Lime ManufacturingMercury is present as impurityin processed stone and fromfuel used to heat kilns.

Estimated Wisconsin emissionsfrom lime production: 118pounds per year (high degreeof uncertainty with thisestimate).

◆ Portland CementManufacturing

Mercury present in ore andminerals used as raw materials;mercury in fossil fuels used incement kilns

◆ Phosphate-basedFertilizer FactoriesMercury is a trace element inrock phosphate

◆ Primary Smelting andRefining of CopperCopper recovered from sulfideore contains mercury

◆ Primary Smelting anRefining of NonferrousMetals, except Copperand AluminumMercury is present in almost allminerals; lead recovered fromsulfide ore contains mercury;therefore smelting processgenerates mercury emissions

◆ Industrial BoilersMercury present in coal, oil,natural gas, or wood used inelectric steam generating units.Mercury is emitted as tracecontaminant when volatilized athigh temperatures.

Another potential source ofmercury related to boilers is“cooling water “ used to treatwater used in power plants orboilers. This water is oftentreated with pH-alteringchemicals, such as caustic sodaand sulfuric acid. If the causticsoda was made with a mercurycell process, there may be highlevels of mercury in theirwastewater.

Wisconsin Commercial/Industrial EmissionEstimates:

Coal Combustion: 382 lbs/yr

Wood Combustion: 11 lbs/yr

Oil Combustion: 200 lbs/yr


5INTENTIONAL INTRODUCTION INTO THEMANUFACTURING PROCESS

◆ Battery Production orRecyclingUsed as an anode, as acomponent of the cathode, orto inhibit side reactions orcorrosion.

◆ Copper Foil Productionor Recycling

The high quality copper foilthat is used as a laminate inprinted circuit boards isproduced using elementalmercury, which functions inelectrical contact.

◆ Dental EquipmentProduction or RecyclingMercury used in dentalamalgams

◆ Electrical ApparatusManufacturing orRecyclingElectrical switches, thermalsensing instruments, etc.

◆ Florescent LampProduction or RecyclingElemental mercury used as avapor inside the glass tube.

◆ InstrumentManufacturing orRecyclingThermometers, gauges, etc.

◆ Paints, Coatings,Pigments Production

from Gilkeson:

Historically, mercury was usedin the manufacture of red andorange pigments. One USautomotive manufacturer hasreportedly recentlydiscontinued mercury as acolor concentrate in plasticcomponent manufacturing.

Mercury has also been used incombination with cadmium asa pigment in engineeringplastics where high temperaturestability is required. Reportedlythe only remainingmanufacturer is SLMC inFrance. Past uses of mercury asa pigment include: auto parts,vinyl, ABS, polycarbonate.Today’s cadmium sulfide basedpigments are more stable.

◆ CatalystsMercury is used as a catalystprimarily in the production ofurethane and vinyl.

✓ production of vinyl fromacetylene ??

✓ acetylene (probably nolonger used)

✓ anthraquinone production(no further or confirminginformation at this time)

✓ monomer production

✓ polymer curing

Enviro$en$e


Case Study:Ciba-Geigy Eliminates Mercury from its TomsRiver, NJ Plant

At the Toms River plant, mercury is used in the manufacture ofanthraquinone (AQ) dyes, commonly used for dyeing cotton. AQ is sentthrough a number of intermediate stages to produce aminoanthraquinone. Asulfonation reaction during this process requires the use of mercury as acatalyst, thus mercury wastes are produced. Ciba-Geigy’s corporate researchgroup in Switzerland developed a pathway for the production amino-anthraquinone that avoided the sulfonation step, thus eliminating the need formercury as a catalyst.The motivation for Ciba-Geigy to eliminate mercuryfrom their process is the serious environmental problems that mercuryproduces.

The Toms River plant employs 1050 people and produces approximately 500different products annually. The plant can produce 220,000 pounds per dayof dyes and 105,000 pounds per day of epoxy resins. The plant’s sales in1979 were $90 million.

The Toms River plant eliminated the use of 2,280 lb/yr of mercury. Theplant reduced mercury air emissions by 10 pounds per year, and alsoeliminated 58 lb/yr released to wastewater, 325 lb/yr of solid waste and39,500 lb/yr of mercury contaminated material (from process filteringoperation).

Industry/Program ContactINFORM, Inc.381 Park AvenueNew York, NY 10016212/689-4040

Sarokin, David J., Warren R Muir Ph.D., Catherine Miller Ph.D., and Sebastian R. Sperber,“Cutting Chemical Wastes, “ Inform. New York, New York. 1985.

Information found on Enviro$en$e P2 Commercial Case Studies Index


MERCURY SPILLS

It is essential to handle mercury and mercury-containing items safely. Smalldroplets of spilled mercury may lodge in cracks and sinks, mix with dust,accumulate on work surfaces, and adhere to knit fabrics, shoe soles,watches, gold, and other jewelry. This allows for mercury to potentially betransported to other locations, homes, or businesses.

The Costs of Mercury SpillsMercury spills can be expensive for a number of reasons. Here are someexamples:

The Cost of Clean-up◆ A mercury-containing sphygmomanometer broken on a carpeted

floor at Butterworth Hospital cost $2000 to clean up.

Labor costs◆ It took Riverside Hospital 8 to 16 hours to clean up a mercury

spill (the mercury had fallen in tile crevices).

Facility Down-Time◆ The room in which a mercury spill occurs will be unavailable for

use until the site is decontaminated. Riverside Hospital found thattheir room was out of service for at least one day.

Equipment Loss◆ A mercury-containing switch in an oven in a University of

Michigan Hospital cafeteria exploded. It cost $3500 to clean upthe spill. The oven, a $25,000 piece of equipment, was irreparablydamaged.

Training Time◆ Continuing to use mercury containing items can be expensive for

your facility because of the needed staff training for spill responseplans. However, if you are still using mercury-containingproducts, don’t neglect this important step! An improperlyhandled spill can end up costing even more to decontaminate.

Handle MercurySafely!

✔ Use mercury only in uncarpeted,well-ventilated areas. Providetroughs on smooth surfacedtables and benches to collectmercury spills. Reserve theroom for mercury use only;restrict traffic in the area.

✔ Ask workers to remove allwatches and other jewelry -especially gold jewelry sincemercury readily combines withgold - and have them wear amercury vapor respirator andprotective clothing: gloves,disposable gowns, and shoecoverings.

✔ Prohibit smoking, eating, anddrinking in the area.

✔ Train all workers to understandthe properties and hazards ofmercury and to carry out safehandling procedures andspecific policies related tomercury disposal.

✔ Clean and calibrate all mercury-containing equipment accordingto the manufacturer’srecommended handlingprocedures and the formalprocedures posed by yourcommunications or safetyprogram supervisors.

✔ Ask your safety supply vendorfor a mercury vacuum sweeperand spill cleanup kit. Having theright equipment on hand willlimit the amount of mercuryreleased into the atmosphere.

- From “The Case Against Mercury:Rx for Pollution Prevention,” TheTerrane Institute


ACTION STEPS FOR INDUSTRIES TO CONSIDER

Product Substitution✔ Contact each chemical supplier you use for material feedstock (e.g., caustic soda, sulfuric acid) and

request a mercury analysis of the product or a certification that the product is mercury free.

✔ If you find a chemical solution that contains a significant amount of mercury, contact the supplier for analternate material.

✔ Eliminate the use of mercury thermometers

✔ Eliminate the use of mercurochrome from first aid test kits.

✔ Check your quality control laboratory and eliminate any mercury containing chemicals.

✔ Replace mercury-containing compounds or reagents in your laboratories with mercury-free alternatives

✔ Substitute zinc air or silver oxide batteries for your mercuric oxide (mercury-zinc) batteries.

✔ Use safe, non-mercury cleaners and degreasers in labs, housekeeping departments, and maintenance areas.

✔ When remodeling or replacing old equipment, replace thermostats containing mercury switches withthermostats containing electronic type and snap switches, and replace “silent” light switches withmechanical light switches.

✔ Examine the use of mercury-containing switches in your facility. Consider replacing these switches whenreplacing old equipment or remodeling:

Tilt SwitchesIncluding SPST, SPDT, NO, NC, wide angle, omnidirectional, circuit board mount

- “man down” alarms- airflow/fan limit controls- fluid level control- pneumatic tube communication systems- pressure control- safety shut off- limit switches for industrial machinery- temperature control

✔ Purchase septic tank and sump pumps that contain magnetic dry reed switches, optic sensors, ormechanical switches instead of mercury tilt switches.

✔ Research your use of plunger or displacement relays; consider replacing these relays with mechanicalswitches.

Displacement/Plunger Relays:- industrial process controllers- high currant/voltage lighting- power supply switching- resistance heating- tungsten lighting- welding- wetted reed relay/wetted reed switch: test, calibration, measurement equipment


✔ Examine use of other mercury-containing products in your facility and consider the alternatives for these:

- generators- high intensity lamps- manometers

✔ Purchasing departments need to know the cost of alternatives and the suppliers for the alternatives. Theyshould consider disposal costs when evaluating a product; total product cost should include disposalcosts and costs for cleaning up accidents.

✔ Consider the use of an Administrative Directive, either formal or informal, to end the purchase ofmercury-containing products.

Loss prevention and housekeeping✔ Label instruments containing mercury.

✔ Be sure workers are familiar with the laboratory’s policies on the proper disposal practices whenworking with mercury solutions in a laboratory.

✔ Follow proper procedures when cleaning or refilling instruments that contain mercury. Instrumentcleaning or refilling should take place in a well ventilated area, and, if possible, over a tray to contain anyspills.

✔ Establish effective spill response measures to ensure the mercury already in your facility is handled in asafe and proper manner. To minimize the risk of an accidental spill, never handle mercury over a sink.The educational program for spill prevention and cleanup should be visual and simple. You may want toconsider a video.

✔ Clean or flush the traps, sumps, and pipes in your sewer lines to rid your facility of historical uses ofmercury. See excerpts from the MWRA/MASCO Infrastructure Subcommittee MaintenanceGuidebook that appear in the “Resources” section of this sourcebook for more information.

Recycling✔ Establish a battery collection program.

✔ Continue to use fluorescent lamps! Even though fluorescent lamps contain mercury, they are a goodchoice because they use much less energy than regular bulbs. Consider the use of low-m fluorescentlamps; recycle your fluorescent lamps currently in use. Try not to break these lamps because some of themercury will escape into the air.

✔ Recycle or dispose of mercury-containing products in your facility in an environmentally sound manner


SAMPLE PROCLAMATION

Your facility may wish to formally declare your commitment to mercury reduction. You may use theproclamation below, or adapt it to suit your needs.

WHEREAS mercury is an elemental substance, that once released into the environment, easily and rapidly changesforms to several organic and inorganic states that transfer from soil to air to water and back again;

WHEREAS the organic form of mercury, methylmercury, bioaccumulates in aquatic ecosystems to magnifyconcentrations in animal tissue in increasing degrees up to 250,000 times;

WHEREAS methylmercury, the most toxic form of mercury, can affect the reproductive efforts of toppredators in aquatic environments such as loons, otters, mink, and panthers;

WHEREAS the neurotoxic effects of high levels of methylmercury poisoning in humans has been established,and low-level doses of methylmercury consumption can potentially effect human health, especially that of a fetus;

WHEREAS elemental mercury is a highly toxic substance which can vaporize easily and cause both acute andchronic health effects including severe respiratory irritation and damage to the central nervous system;

WHEREAS mercury has been identified internationally as a toxic substance of concern, and mercurycontamination has led to fish consumption advisories for more than 235 lakes and 350 miles of rivers inWisconsin;

WHEREAS the majority of mercury entering Wisconsin comes from anthropogenic sources, and one-quarter ofthese emissions are the result of the purposeful use of mercury;

WHEREAS mercury is used widely in consumer and industrial products, where, in most cases, alternative,mercury-free products are available;

WHEREAS pollution prevention or product substitution is a progressive approach to protecting theenvironment that eliminates or minimizes the generation of mercury-bearing waste, making it one of the mostfavorable strategies for maintaining a clean environment;

WHEREAS pollution prevention for mercury can help environmental conditions, as well as protect the healthand safety of workers;

WHEREAS recognizing mercury minimization as an active opportunity to improve the environment ofWisconsin and the environment of our business, we, the undersigned, do hereby declare our business to be amercury minimization participant;


WE commit to research the following mercury minimization opportunities in our facility and implement thosewe find most feasible:

Product Substitution◆ Research chemical solutions used for material feedstock. Use a low-mercury alternative if a mercury

contamination is discovered.

◆ Eliminate the use of mercury thermometers

◆ Eliminate the use of mercurochrome from first aid test kits.

◆ Replace mercury-containing compounds or reagents in your laboratories with mercury-free alternatives

◆ Substitute zinc air or silver oxide batteries for your mercuric oxide (mercury-zinc) batteries.

◆ Use safe, non-mercury cleaners and degreasers in labs, housekeeping departments, and maintenance areas.

◆ Examine the use of mercury-containing switches and consider replacing these any mercury-containingitems with non-mercury alternatives when replacing old equipment or remodeling:

◆ Purchase septic tank and sump pumps that contain magnetic dry reed switches, optic sensors, ormechanical switches instead of mercury tilt switches.

◆ Research your use of plunger or displacement relays; consider replacing these relays with mechanicalswitches.

◆ Examine use of other mercury-containing products and consider the alternatives for these:

- generators- high intensity lamps- manometers

◆ Consider the use of an Administrative Directive, either formal or informal, to end the purchase ofmercury-containing products.

Loss prevention and housekeeping◆ Label instruments containing mercury.

◆ Familiarize workers with the laboratory’s policies on the proper disposal practices when working withmercury solutions in a laboratory.

◆ Follow proper procedures when cleaning or refilling instruments that contain mercury.

◆ Establish effective spill response measures to ensure the mercury already in the facility is handled in a safeand proper manner.


Recycling◆ Establish a battery collection program.

◆ Continue to use fluorescent lamps! Research the use of the new Alto™ bulb.

◆ Recycle or dispose of mercury-containing products in your facility in an environmentally sound manner

_________________________________________Facility

_________________________________________ ________________________Name Date Signed


BIBLIOGRAPHY

The information included in this pamphlet is essentially a compilation of the best mercury pollutionprevention work to date. Information was gathered from the documents below; some material may havebeen quoted directly from these sources:

“Best Management Practices for Hospitals and Medical Facilities,” Palo Alto Regional Water Quality Control Plant,September 1994

“Business Waste Reduction and Recycling: A Guide For The Workplace,” Wisconsin DNR, 1995

“Chlorine Industry Running Flat Out Despite Persistant Health Fears,” Bette Hileman, Janice R. Long, and ElisabethKirschner, C&EN, November 21, 1994

“DNR Briefing Paper: How to Handle Your Waste Fluorescent Lamps and Incandescent Bulbs,” Wisconsin DNR1995

enviroSen$e P2 fact sheet - metal finishers in industry

“Household Batteries Waste Management Study,” by Gershman, Brickner, and Bratton, Inc., 1992

“Household Fluorescent Lights: A Household Hazardous Waste Fact Sheet,” MPCA, August 1994

“Hospital Mercury Work Group Operations Subcommittee Final Report,” Massachusetts Water Resources Authority(MWRA) and MASCO Mercury Work Group, August 21, 1995

“Hospital Success Stories” (presentation), Jennifer Carver, University of Michigan Hospitals, presented at “MercuryPollution Prevention: Healthcare Providers Protecting People and the Great Lakes,” Novi, Michigan October 4, 1996

“How to Design and Administer a Hospital Mercury Reduction Plan” (presentation), David Smith, RiversideHospital, presented at “Mercury Pollution Prevention: Healthcare Providers Protecting People and the Great Lakes,”Novi, Michigan October 4, 1996

“Lake Superior Pollution Prevention Strategy Implementation Plan: Recommendations for Achieving Zero Dischargein Wisconsin, Minnesota, and Michigan,” Lake Superior Pollution Prevention Team, September 1995

“Managing Used Dry-Cell Batteries: A Household Hazardous Waste Fact Sheet,” MPCA

“Medical Waste Pollution Prevention: Keep Mercury Out of the Wastewater Stream,” USEPA Region 5, September1995

“Mercury and the Use of Mercury Cell Caustic,” Vulcan Chemicals Technical Data Sheet, June 1995

“Mercury Elimination and Reduction,” Pollution Probe, 1997

“Mercury Reduction Through Treatment Chemical Selection,” Carri Lohse-Hanson, MPCA, February 27, 1996

“Mercury Sources and Regulations: Background for the Virtual Elimination Project,” Ross and Associates, September12, 1994


“Mercury in Medical Waste,” fact sheets 1-3, USEPA Region 5, September 1995

“Mercury in Minnesota Slide Show Script,” Western Lake Superior Sanitary District, November 1995

“Mercury in the Environment: The Waste Connection,” MPCA, MDEQ, WDNR

“Mercury Pollution Prevention in the Health Care System,” conference notes compiled by Emily Moore, MPCA,April 1996

“Mercury Pollution Prevention Measures in Michigan Health Care Institutions,” Liz Krug and Guy Williams, TheNational Wildlife Federation

“Mercury Pollution Prevention in Michigan,” A Report by the Michigan Mercury Pollution Prevention Task Force,April, 1996

“Mercury Products Study,” John Gilkeson, Minnesota Pollution Control Agency, May 1996

“Mercury Pollution Prevention at a Bleached Kraft Pulp and Paper Mill,” Kevin Kangas, Tim Tuominen, Dr. DianneDorland

“Mercury, Power Plants and the Environment: Basic Facts about Mercury and Coal-fired Power Plants, theEnvironment, Fish and Wildlife, and Human Health,” compiled by Steven Ugoretz, WDNR

“Philips Unveils a Fluorescent Lamp With Less Mercury and a Long Life,” Wall Street Journal, June 9, 1995

“Preventing Mercury Waste Generation Through Comprehensive Environmental Management within the HealthcareIndustry,” Steering Committee Meeting Summary Notes, April 1996

“Potlatch Tracks Down Mercury in Sulfuric Acid at Supply Mill in Cloquet, Minnesota,” NCASI Bulletin Board, Vol.21 No.11, October 11, 1995

“Review of Defense National Stockpile Center Mercury Sales,” November 13, 1995

“Sources of Mercury in Healthcare Business,” Detroit Water and Sewerage Department, July 1995

“Strategies for Mercury Control in Minnesota,” MPCA Mercury Task Force, July 1994

“The Case Against Mercury: Rx for Pollution Prevention,” The Terrane Institute

“The Hunt for Quicksilver,” Frank Altmayer, Scientific Control Labs, Inc., speech presented at AERB’s “WastewaterDischarge Compliance Conference,” November 17, 1992.

“Waste Household Battery Management in Wisconsin,” SHWEC Waste Education Series

“Wisconsin Recycling Markets Directory,” Wisconsin DNR, May 1995

Current Mercury Work – Industry/Manufacturing

Business Outreach/Research

Project: Lake Superior PartnershipDescription: Multi-Media compliance and pollution prevention inspections in the Lake Superior

Basin

Agencies working on this project:MPCA/OEAWLSSD

Project: Minnesota Very Small Quantity Generator ProgramDescription: Provide pollution prevention information for very small quantity hazardous waste

generators in Minnesota

Agencies working on this project:MPCA/OEA

Project: RCRA Hazardous Waste Great Lakes InitiativeDescription: Technical assistance and multimedia pollution prevention audits of hazardous waste

generators in Lake Superior and Lake Michigan Basins

Agencies working on this project:WDNR

Project: Technical Assistance Audits for Municipalities and IndustriesDescription: Target industries to provide training on basic pollution prevention concepts; perform

free, non-regulatory pollution prevention audits and demonstration projects

Agencies working on this project:MDEQSHWEC

Project: Mercury Audit Fact SheetDescription: Mercury reduction audit fact sheet for manufacturing facilities

Agencies working on this project:SHWEC

Documents

MERCURY USE: INDUSTRY - Pollution Preventioninfohouse.p2ric.org/ref/04/03851/industry.pdf · DRAFT WISCONSIN MERCURY SOURCEBOOK: INDUSTRY 407 MERCURY USE: INDUSTRY Mercury has a number