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Mercury Lamp Drum-Top Crusher Study Document Number: EPA530-R-06-002

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Mercury Lamp Drum-Top Crusher Study Document Number: EPA530-R-06-002 MEMORANDUM SUBJECT: Mercury Lamp Drum-Top Crusher Study Document Number: EPA530-R-06-002 FROM: Matt Hale, Director Office of Solid Waste TO: State and Regional RCRA Waste Management Directors Users and Potential Users of Drum-Top Crusher Devices Lamp Recyclers and Manufacturers As part of ongoing efforts to encourage safe management of mercury-containing equipment and fluorescent lamps, the Environmental Protection Agency (EPA) is releasing a Mercury Lamp Drum-Top Crusher Study on the performance of mercury lamp drum-top crusher (DTC) devices. DTC devices fit on the top of a 55 gallon drum and crush fluorescent lamps into the drum below. DTC devices are designed to reduce the volume of waste lamps, while controlling the release of mercury vapors from crushed lamps. This volume reduction can facilitate storage and handling, decrease the possibility of subsequent breakage and release, and reduce shipping costs associated with fluorescent lamp recycling. We conducted the Mercury Lamp Drum-Top Crusher Study in order to gain more information about the performance of DTC devices. The objective of the study was to evaluate how well four DTC devices contained mercury releases from crushed lamps, focusing on worker exposure to airborne mercury. The study provides current information on the performance of DTC devices. The report presents our findings, which we believe will be helpful to states, users of fluorescent lamps, and lamp recyclers in making more informed management decisions when recycling fluorescent lamps. For more information and a copy of the Study, visit <http://www.epa.gov/epaoswer/hazwaste/id/univwast/drumtop/drum-top.htm>. If you have any questions, please contact Greg Helms at (703) 308-8845 or Cathy Davis at (703) 308-7271. Mercury Lamp Drum-Top Crusher Study Mercury Lamp Drum-Top Crusher Study TABLE OF CONTENTS 1. EXECUTIVE SUMMARY..............................................................................................1 1.1 Study Overview ....................................................................................................1 1.2 Observations ..........................................................................................................3 2. SCOPE OF STUDY.........................................................................................................5 2.1 Mercury Fluorescent Lamp Disposal.................................................................5 2.2 Study Overview ....................................................................................................5 2.2.1 Study Location...........................................................................................5 2.2.2 Containment Structure.............................................................................6 2.2.3 General Procedures...................................................................................8 2.2.4 Study Components ...................................................................................9 2.2.5 Equipment................................................................................................10 2.3 Testing Locations and Study Chronology.......................................................13 3. DATA COLLECTION METHODOLOGY................................................................15 3.1 Analytical Air Samples.......................................................................................16 3.1.1 Performance Validation Study..............................................................19 3.1.2 Extended Field Test #1...........................................................................21 3.1.3 Extended Field Test #2...........................................................................22 3.1.4 Extended Field Test #3...........................................................................24 3.2 Jerome Mercury Vapor Analyzer Samples......................................................26 3.3 Bulk Samples .......................................................................................................27 3.3.1 Unbroken Spent Lamps..........................................................................27 3.3.2 Pollution Control Media ........................................................................28 3.3.3 Crushed Lamps .......................................................................................28 3.4 Wipe Samples ......................................................................................................29 3.5 Test Protocol Deviations and Modifications...................................................30 4. RESULTS AND DATA EVALUATION....................................................................32 4.1 Exposure Evaluation Criteria............................................................................32 4.2 Background Air Samples ...................................................................................33 4.3 Blank Air Samples...............................................................................................36 4.4 Performance Validation Study..........................................................................37 4.4.1 Performance Validation Study - Phase I..............................................37 4.4.2 Performance Validation Study – Phase II............................................40 4.4.3 Comparison of Performance Validation Study Phases I and II........43 4.5 Extended Field Test Study.................................................................................45 4.5.1 Extended Field Test #1...........................................................................45 4.5.2 Extended Field Test #2...........................................................................50 4.5.3 Extended Field Test #3...........................................................................55 4.5.4 Comparison of Extended Field Tests ...................................................59 4.6 Box Tests...............................................................................................................61 4.6.1 AERC Melbourne Box Test....................................................................62 4.6.2 AERC Ashland Box Test ........................................................................63 4.7 Overnight Samples .............................................................................................63 4.8 U-Tube Test..........................................................................................................65 ii 5. MASS BALANCE STUDY ..........................................................................................66 5.1 Mass Balance Equation.......................................................................................66 5.2 Estimating Total Mercury Content of Unprocessed Lamps (HgT) ..............66 5.3 Estimating Mercury Mass Captured in the DTC Devices (HgC)..................69 5.4 Estimated Mercury Released To The Ambient Air (HgR).............................72 5.5 Mass Balance Results..........................................................................................73 5.6 Mass Balance Discussion....................................................................................74 5.6.1 Mercury Mass in Crushed Lamps ........................................................74 5.6.2 Mercury Mass in Air Filtration System Elements ..............................75 5.6.3 Mercury Mass Adhering to Surfaces....................................................77 5.6.4 Mercury Mass in Ambient Air ..............................................................77 5.7 Mass Balance Study Observations....................................................................77 6. LIMITATIONS..............................................................................................................79 6.1 Background Levels of Mercury.........................................................................79 6.2 Experimental Conditions ...................................................................................80 6.3 Contamination from Lamps Broken During Shipment.................................80 6.4 Contamination from Lamps Broken During DTC Device Operation .........81 7. DISCUSSION................................................................................................................82 7.1 Summary of Results............................................................................................82 7.1.1 Exposures during Routine Crushing Operations...............................83 7.1.2 Exposures during Routine Drum and Filter Changes.......................84 7.1.3 Exposures Resulting From DTC Device Malfunction .......................84 7.1.4 Changes in DTC Performance over Time............................................85 7.1.5 Overnight Tests .......................................................................................86 7.1.6 U-Tube Test..............................................................................................86 7.1.7 Exposures Resulting from Lamp Breakage.........................................86 7.2 Safety Concerns when Operating DTC Devices.............................................87 7.2.1 Operator Safety........................................................................................87 7.3 Potential DTC Design Modifications ...............................................................89 7.4 Future Areas for Study.......................................................................................90 7.5 Conclusions..........................................................................................................91
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