This site study was conducted in a chemical laboratory to evaluate nanomaterial emissions from 20–30-nm-diameter bundles of single-walled carbon nanotubes (CNTs) during product development activities. Direct-reading instruments were used to monitor the tasks in real time, and airborne particles were collected using various methods to characterize released nanomaterials using electron microscopy and elemental carbon (EC) analyses. CNT clusters and a few high-aspect-ratio particles were identified as being released from some activities. The EC concentration (0.87 μg/m3) at the source of probe sonication was found to be higher than other activities including weighing, mixing, centrifugation, coating, and cutting. Various sampling methods all indicated different levels of CNTs from the activities; however, the sonication process was found to release the highest amounts of CNTs. It can be cautiously concluded that the task of probe sonication possibly released nanomaterials into the laboratory and posed a risk of surface contamination. Based on these results, the sonication of CNT suspension should be covered or conducted inside a ventilated enclosure with proper filtration or a glovebox to minimize the potential of exposure.

Carbon nanotubes (CNTs) are being incorporated into structural composites to enhance material strength. During fabrication or repair activities, machining nanocomposites may release CNTs into the workplace air. An experimental study was conducted to evaluate the emissions generated by cutting and sanding on three types of epoxy-composite panels: Panel A containing graphite fibers, Panel B containing graphite fibers and carbon-based mat, and Panel C containing graphite fibers, carbon-based mat, and multi-walled CNTs. Aerosol sampling was conducted with direct-reading instruments, and filter samples were collected for measuring elemental carbon (EC) and fiber concentrations. Our study results showed that cutting Panel C with a band saw did not generate detectable emissions of fibers inspected by transmission electron microscopy but did increase the particle mass, number, and EC emission concentrations by 20–80 % compared to Panels A and B. Sanding operation performed on two Panel C resulted in fiber emission rates of 1.9 × 108 and 2.8 × 106 fibers per second (f/s), while no free aerosol fibers were detected from sanding Panels A and B containing no CNTs. These free CNT fibers may be a health concern. However, the analysis of particle and EC concentrations from these same samples cannot clearly indicate the presence of CNTs, because extraneous aerosol generation from machining the composite epoxy material increased the mass concentrations of the EC.

Because nanomaterials are thought to be more biologically active than their larger parent compounds, careful control of exposures to nanomaterials is recommended. Field studies were conducted at three sites to develop information about the effectiveness of control measures including process changes, a downflow room, a ventilated enclosure, and an enclosed reactor. Aerosol mass and number concentrations were measured during specific operations with a photometer and an electrical mobility particle sizer to provide concentration measurements across a broad range of sizes (from 5.6 nm to 30 mum). At site A, the dust exposure and during product harvesting was eliminated by implementing a wait time of 30 minutes following process completion. And, the dust exposure attributed to process tank cleaning was reduced from 0.7 to 0.2 mg/m3 by operating the available process ventilation during this task. At site B, a ventilated enclosure was used to control dust generated by the manual weigh-out and manipulation of powdered nanomaterials inside of a downflow room. Dust exposures were at room background (under 0.04 mg/m3 and 500 particles/cm3) during these tasks however, manipulations conducted outside of the enclosure were correlated with a transient increase in concentration measured at the source. At site C, a digitally controlled reactor was used to produce aligned carbon nanotubes. This reactor was a closed system and the ventilation functioned as a redundant control measure. Process emissions were well controlled by this system with the exception of increased concentrations measured during the unloading the product. However, this emission source could be easily controlled through increasing cabinet ventilation. The identification and adoption of effective control technologies is an important first step in reducing the risk associated with worker exposure to engineered nanoparticles. Properly designing and evaluating the effectiveness of these controls is a key component in a comprehensive health and safety program.