Performance of high flow rate samplers for respirable particle collection

Review of Published Laboratory-Based Aerosol Sampler Efficiency, Performance and Comparison Studies (1994-2021)

We provide a narrative review on the published peer-reviewed scientific literature reporting sampler efficiency, performance and comparison studies (where two or more samplers have been assessed) in laboratory settings published between 1994 and 2021 (27 year period). This review is a follow-up to our narrative review on the published peer-reviewed scientific literature reporting sampler comparison in workplace settings. Search terms were developed for Web of Science and PubMed bibliographic databases. The retrieved articles were then screened for relevance, with those studies meeting the inclusion criteria being taken forward to data extraction (25 studies). The most common fraction assessed has been the inhalable fraction, with the IOM sampler being the most studied inhalable sampler and the SKC Aluminium cyclone being the most studied respirable sampler from the identified relevant articles. The most common aerosol used has been aluminium oxide. It was evident that standardisation for these sampler performance experiments is lacking. It was not possible to identify any discernible trends for the performance of samplers when assessed with different aerosols. The need for more detailed and informative data sharing from authors is highlighted. This includes provision of clear identifiable information on the samplers used for testing, sampler flow rates (both manufacturer and those actually used in the study, with an explanation given of any differences), detailed information on the test aerosols used and the sampler substrate materials used. An identified gap in the literature is the potential to perform studies aimed at revaluating the performance of samplers to allow any longer-term temporal changes in performance to be assessed. One approach in advancing the field is to produce an updated protocol for the laboratory testing of samplers. This updated protocol would be beneficial for both the research and occupational hygiene community and would allow harmonised assessment and reporting of sampler comparison studies.

Benefits and limitations of field-based monitoring approaches for respirable dust and crystalline silica applied in a sandstone quarry

With the advent of new sensing technologies and robust field-deployable analyzers, monitoring approaches can now generate valuable hazard information directly in the workplace. This is the case for monitoring respirable dust and respirable crystalline silica concentration levels. Estimating the quartz amount of a respirable dust sample by nondestructive analysis can be carried out using portable Fourier transform infrared spectroscopy (FTIR) units. Real-time respirable dust monitors, combined with small video cameras, allow advanced assessments using the Helmet-CAM methodology. These two field-based monitoring approaches, developed by the National Institute for Occupational Safety and Health (NIOSH), have been trialed in a sandstone quarry. Twenty-six Helmet-CAM sessions were conducted, and forty-one dust samples were collected around the quarry and analyzed on-site during two events. The generated data generated were used to characterize concentration levels for the monitored areas and workers, to identify good practices, and to illustrate activities that could be improved with additional engineered control technologies. Laboratory analysis of the collected samples complemented the field finding and provided an assessment of the performance of the field-based techniques. Only a fraction of the real-time respirable dust monitoring sessions data could be corrected with laboratory analysis. The average correction factor ratio was 5.0. Nevertheless, Helmet-CAM results provided valuable information for each session. The field-based quartz monitoring approach overestimated the concentration by a factor of 1.8, but it successfully assessed the quartz concentration trends in the quarry. The data collected could be used for the determination of a quarry calibration factor for future events. The quartz content in the dust was found to vary from 14% to 100%, and this indicates the need for multiple techniques in the characterization of respirable dust and quartz concentration and exposure. Overall, this study reports the importance of the adoption of field-based monitoring techniques when combined with a proper understanding and knowledge of the capabilities and limitations of each technique.

Size Separation of Amosite by Filtration and Shaking Methods

The objectives of this study are (1) to separate fibrous grunerite (amosite) by its length using filtration and shaking techniques utilized in a previous study and (2) to create two distinct length groups (short and long) of the amosite with higher output in a cost-effective way. The shaking system included an electrodynamic exciter, a linear power amplifier, and an audio-frequency signal generator and was attached to a cowl sampler as a funnel loaded with a polycarbonate filter. A suspension of amosite was passed through the 10-μm pore size polycarbonate filter in the shaking system and was transferred to a filtration system through five different pore sizes of polycarbonate membrane filters in series from the top: 10-, 5-, 2-, 1-, and 0.2-μm pore sizes. Each polycarbonate filter was tightly clamped with two conductive 25-mm spacers with a 25-mm stainless steel support screen to prevent leakage. The amosite length and diameter were manually measured with images from a field emission scanning electron microscope (FESEM). A sequence of fields was selected at random locations, and an image of each field was acquired. The length and width of approximately 500 fibers for each sample were measured with ImageJ software. Two significantly different length groups (short and long) of amosite were collected (p <0.05). Approximately 95% of separated amosite (n = 499) using the filtration system were shorter than 5 μm (short fiber group), and approximately 80% of separated amosite (n = 503) using the shaking system were longer than 5 μm (long fiber group).

Occupational exposure during metal additive manufacturing: A case study of laser powder bed fusion of aluminum alloy

Occupational exposure during metal additive manufacturing (Laser Powder Bed Fusion) using an aluminum alloy (AlSi10Mg) was assessed. Background aerosols before manufacturing, powder sieving, machine loading, manufacturing, machine unloading, powder unpacking, and machine cleaning were analyzed. Measurements were taken simultaneously at the source, in the near field, and on the operator during five manufacturing cycles. Aerosol measurement devices and physico-chemical techniques were used to determine the particle number or mass concentration (DiSCmini, core particle counter and sampling cassette), particle size distribution (NanoScan, optical particle detector and impactor), and the shape/size and chemical compositions of the inhalable particles (laser diffraction, inductively coupled plasma spectroscopy, scanning electron microscopy, energy dispersive X-ray microanalysis, and Brunauer-Emmett-Teller Method). The laser powder-bed fusion machine emitted in the additive manufacturing room an inhalable fraction of 2.37 ± 0.35 mg/m3, with an aerosol number concentration ranging from 2 × 104 to 105 #/cm3 and a mass mean aerodynamic diameter of 318 nm. A relatively low concentration level was observed in the near field of the machine with an aerosol number concentration of ∼104 #/cm3. A higher concentration level on the operator was attained during the unpacking and cleaning steps, showing an inhalable fraction of 1.73 ± 0.30 mg/m3. Al and Mg nanoparticles were aerosolized at the source (inside the laser powder-bed fusion machine) with a particle size distribution of 153 nm for Al and 117 nm for Mg and an aerosol number concentration reaching ten times that of the background aerosol level. The number or mass concentration of particles in the room atmosphere was increased to double that of the background aerosol level at specific workstations during manufacturing. Metal additive manufacturing is a source of potential occupational exposure to airborne metal nanoparticles. Particle-counting instruments showed high numbers of nanoparticles and some important peaks of particles ranging from 10 nm to 10 µm or larger at specific work tasks in the Additive Manufacturing (AM) environment. A multimetric approach was used to characterize the particle emissions resulting from this type of additive manufacturing.

A novel sampling cassette for field-based analysis of respirable crystalline silica

Field-based methods for the analysis of respirable crystalline silica are now possible with the availability of portable instrumentation. Such methods also require the use of cassettes that facilitate direct-on-filter analysis of field samples. Conventional sampling cassettes can be modified such that they are amenable to direct-on-filter analysis while remaining compatible with common respirable dust samplers. The required modifications are described herein, and one version of such an analysis-ready cassette is described and evaluated in comparison to more traditional cassette designs. The novel cassette was found to result in a slightly higher mass of collected respirable material (for the same sampling duration), though this is likely due to the conductive material of the cassettes, which prevents particle wall losses in comparison to the more commonly used styrene cassette material. Both types of cassettes demonstrated comparable predictability in terms of respirable crystalline silica in a sample.

Characterizing particle emissions from a direct energy deposition additive manufacturing process and associated occupational exposure to airborne particles

This study aims to characterize airborne particles emitted from a metal additive manufacturing machine and related levels of occupational exposure. To achieve this, a complete measurement methodology was deployed around a direct energy deposition machine. Different operating conditions were investigated, based on configurations of two materials and two injection nozzles. Two replicates were performed for each condition. Airborne particles emitted during repeated manufacturing cycles were measured simultaneously at the source, in the near field, in the far field and on the operator. Real-time instruments were used to characterize the machine emissions (10 nm-10 µm) associated with respirable and inhalable samplers and cascade impactors. Measurements were made during both the manufacturing process and transient operating phases. In parallel, personal exposure to hexavalent chromium was assessed. The number of particles measured for the different machining phases show that high levels of particles (> 5 × 10⁵ # cm^-3, 0.3-1.3 mg m^-3 inhalable particles, 0.2-6 µg m^-3 Cr^VI) were emitted in the machine enclosure. The size distributions indicate that more than 90% of the particles are smaller than 250 nm. Occupational exposure to Cr^VI was found to be below the LOQ of 0.098 µg m^-3 for the two alloys investigated. During the machining process, near-field number and mass concentrations were ∼ 10⁴ # cm^-3, and below 0.04 mg m^-3, respectively. Far-field number concentrations were also on the order of 10⁴ # cm^-3 throughout the whole monitoring period. The transient phase of door opening was found to result in high levels of exposure (> 10⁵ # cm^-3), which were also detected in the near-field, confirming the need to implement preventative actions. To address this issue, a collective protective measure, consisting of setting a time delay of about 8 min between the end of the manufacturing process and opening of the door, could be employed. This collective measure should also be accompanied by the wearing of personal protective equipment by the operator when an intervention in the machine enclosure is necessary.

Modelling of exposure to respirable and inhalable welding fumes at German workplaces

The International Agency for Research on Cancer classified welding fumes as carcinogenic to humans, and occupational exposure limits should be established to protect welders. The aim of this study is to estimate exposure levels to inhalable and respirable welding fumes by welding process to use them for exposure assessment in epidemiological studies and to derive occupational exposure limits. In total, 15,473 mass concentrations of inhalable and 9,161 concentrations of respirable welding fumes could be analyzed along with welding-related and sampling information, which were compiled in the German database MEGA between 1983 and 2016. In both particle-size fractions, model-based geometric means of the concentrations were estimated by welding process and material for frequently used welding processes adjusted for sampling time and median-centered for calendar years. The inhalable concentrations were approximately twice the respirable concentrations, with medians of 3 mg/m³ (inter-quartile range: 1.2-7.0 mg/m³) and 1.5 mg/m³ (inter-quartile range: < limit of detection -3.8 mg/m³), respectively. The adjusted geometric means of flux-cored arc welding, metal inert and active gas welding, shielded metal arc welding and torch cutting ranged from 0.9 to 2.2 mg/m³ for respirable welding fumes and from 2.3 to 4.7 mg/m³ for inhalable fumes. In both particle-size fractions, geometric means were between 0.1 and 0.9 mg/m³ when performing tungsten inert gas, autogeneous, resistance, laser, and plasma welding or spraying. Results derived from this large dataset are useful for a quantitative exposure assessment to estimate health risks of welders.

Laboratory comparison of new high flow rate respirable size-selective sampler

A newly developed high flow rate respirable size-selective cyclone sampler (GK4.162-also known as the Respirable Air Sampling Cyclone Aluminum Large (RASCAL)) was calibrated to determine its optimum operating flow rate. The Health and Safety Laboratory in the United Kingdom and two laboratories from the National Institute for Occupational Safety and Health in the United States conducted experiments using two different methods: (1) polydisperse aerosol and time-of-flight direct reading instrument (Aerodynamic Particle Sizer (APS)) and (2) monodisperse aerosol and APS. The measured performance data for the cyclone was assessed against the international respirable convention using the bias map approach. Although the GK4.162 cyclone was tested using different aerosols and detection methods, the results from the three laboratories were generally similar. The recommended flow rate based on the agreement of results from the laboratories was 9.0 L/min.

Evaluating the use of a field-based silica monitoring approach with dust from copper mines

Monitoring worker exposure to respirable crystalline silica in dusty environments is an important part of a proactive health and safety program. This is the case for surface copper mines in Arizona and New Mexico. The spatial and temporal variability of respirable dust and crystalline silica concentrations in those mines, coupled with the time lapse in obtaining crystalline silica analysis results from accredited laboratories, present a challenge for an effective exposure monitoring approach and the resulting intervention strategies. The National Institute for Occupational Safety and Health (NIOSH) is developing a novel approach to be used at a mine site for the quantification of crystalline silica in respirable dust samples collected with traditional sampling techniques. The non-destructive analysis is carried out using a portable Fourier transform infrared spectroscopy (FTIR) unit. In this study, respirable dust samples were collected over two visits to each of five copper mines, for a total of 10 datasets. The silica in each respirable dust sample was estimated by analyzing the sample with the portable FTIR unit. The quality of the estimation was assessed using the results of the NIOSH 7500 method on the same samples. The confounding effect of other minerals present in the respirable dust in the mines was also assessed, and two quantification approaches were investigated to address it: a sector-specific and a mine-specific approach. The results showed that the sector-specific approach is not effective due to the high variability of relative composition of the minerals among mines. For this approach the combined average relative difference was -13% (-17.6%, -8.9% CI). When using the mine-specific quantification approach, the average relative difference was as low as 2.8% (-3.7%, 9.3% CI); however, this approach was still affected by the variable relative composition of the minerals in the dust in each mine. The use of a multivariate approach on the analysis of each sample was proposed as the next step to achieve consistent low relative differences. This study demonstrates the potential of using a portable FTIR for estimation of crystalline silica in respirable dust samples for in-field exposure monitoring.

Evaluation of Respiratory Symptoms among Workers in an Automobile Manufacturing Factory, Iran

BACKGROUND

This study estimated the prevalence of respiratory symptoms and disorders among workers exposed to exposure to volatile organic compound (VOCs) in an automobile manufacturing factory in Tehran, Iran in 2016.

METHODS

Subjects of this case-control research were included 80 samples including 40 workers exposed to different level of BTEX as well as 40 unexposed individuals were considered as control group. Methods 1501 and 7602 presented by the National Institute of Occupational Safety and Health (NIOSH) were used for the sampling and analysis of compounds in the air. Gas Chromatography-Flame Ionization Detector (GC-FID) was used for analysis of compounds of interest. Six silica samples were collected during the campaign. Silica analyses were performed by using visible absorption spectrophotometry system. Lung functions were evaluated for 80 workers (40 exposed, 40 nonexposed) using spirometry system.

RESULTS

The average amount of total dust and free silica measured in factory were 7.3±1.04 mg.m^-3 and 0.017±0.02 mg.m^-3 respectively. Average benzene, toluene, ethyl-benzene and xylene exposure levels in exposed subject's median were 0.775±0.12, 1.2±2.08, 45.8±8.5, and 42.5±23.9 ppm respectively. Statistical tests showed significant difference between pulmonary function tests (except PEF) of exposed and non-exposed individuals before and after employment (P<0.05). Workers exposed to VOCs presented lower levels of FVC, VC, and PEF than the control group except FEV1/FVC%, FEV1, FEF2575 and FEV1/VC%.

CONCLUSION

Decline in lung volumes and respiratory symptoms, significant difference associated with the exposure to dust or gas, duration of exposure, and smoking habit. Therefore, lung function tests should be performed before and after the employment to identify sensitive workers candidates.

Respirable size-selective sampler for end-of-shift quartz measurement: Development and performance

Aims of this study were to develop a respirable size-selective sampler for direct-on-filter (DoF) quartz measurement at the end-of-shift (EoS) using a portable Fourier transform infrared (FTIR) spectrometer and to determine its size-selective sampling performance. A new miniaturized sampler has been designed to have an effective particle deposition diameter close to the portable FTIR beam diameter (6 mm). The new sampler (named the EoS cyclone) was constructed using a 3D printer. The sampling efficiency of the EoS cyclone was determined using polydisperse glass sphere particles and a time-of-flight direct reading instrument. Respirable dust mass concentration and quartz absorbance levels of samples collected with the EoS cyclone were compared to those collected with the 10-mm nylon cyclone. The EoS cyclone operated at a flow rate of 1.2 l min^-1 showed minimum bias compared to the international standard respirable convention. The use of the EoS cyclone induced respirable dust mass concentration results similar but significantly larger (5%) than those obtained from samples collected with 10-mm nylon cyclones. The sensitivity of the DoF-FTIR analysis in estimating quartz was found increased more than 10 times when the samples were collected with the EoS cyclone. The average particle deposition diameter was 8.8 mm in 60 samples. The newly developed user friendly EoS cyclone may provide a better sampling strategy in quartz exposure assessment with faster feedback.

Treated and untreated rock dust: Quartz content and physical characterization

Rock dusting is used to prevent secondary explosions in coal mines, but inhalation of rock dusts can be hazardous if the crystalline silica (e.g., quartz) content in the respirable fraction is high. The objective of this study is to assess the quartz content and physical characteristics of four selected rock dusts, consisting of limestone or marble in both treated (such as treatment with stearic acid or stearates) and untreated forms. Four selected rock dusts (an untreated and treated limestone and an untreated and treated marble) were aerosolized in an aerosol chamber. Respirable size-selective sampling was conducted along with particle size-segregated sampling using a Micro-Orifice Uniform Deposit Impactor. Fourier Transform Infrared spectroscopy and scanning electron microscopy with energy-dispersive X-ray (SEM-EDX) analyses were used to determine quartz mass and particle morphology, respectively. Quartz percentage in the respirable dust fraction of untreated and treated forms of the limestone dust was significantly higher than in bulk samples, but since the bulk percentage was low the enrichment factor would not have resulted in any major change to conclusions regarding the contribution of respirable rock dust to the overall airborne quartz concentration. The quartz percentage in the marble dust (untreated and treated) was very low and the respirable fractions showed no enrichment. The spectra from SEM-EDX analysis for all materials were predominantly from calcium carbonate, clay, and gypsum particles. No free quartz particles were observed. The four rock dusts used in this study are representative of those presented for use in rock dusting, but the conclusions may not be applicable to all available materials.

Note: A portable laser induced breakdown spectroscopy instrument for rapid sampling and analysis of silicon-containing aerosols

A portable instrument has been developed for measuring silicon-containing aerosols in near real-time using laser-induced breakdown spectroscopy (LIBS). The instrument uses a vacuum system to collect and deposit airborne particulate matter onto a translatable reel of filter tape. LIBS is used to analyze the deposited material, determining the amount of silicon-containing compounds present. In laboratory testing with pure silica (SiO2), the correlation between LIBS intensity for a characteristic silicon emission and the concentration of silica in a model aerosol was determined for a range of concentrations, demonstrating the instrument's plausibility for identifying hazardous levels of silicon-containing compounds.

Performance of High Flow Rate Personal Respirable Samplers When Challenged with Mineral Aerosols of Different Particle Size Distributions

It is thought that the performance of respirable samplers may vary when exposed to dust aerosols with different particle sizes and wind speeds. This study investigated the performance of the GK 4.16 (RASCAL), GK 2.69, PPI 8, and FSP 10, high flow rate personal samplers when exposed to aerosols of mineral dust in a wind tunnel at two different wind speeds (1 and 2 m s(-1)) and orientations (towards and side-on to the source of emission). The mass median aerodynamic diameter of four aerosolized test dusts ranged from 8 to 25 µm with geometric standard deviations from 1.6 to 2 µm. The performance of each sampler type was compared with that of the SIMPEDS (Higgins-Dewell design) sampler. There was slight evidence to suggest that the performance of the FSP 10 is affected by the direction of the inlet relative to the air flow, although this was not significant when most respirable dust concentrations were compared, possibly due to the variability of paired dust concentration results. The GK 2.69, RASCAL, and PPI 8 samplers had similar performances, although the results when side-on to the emission source were generally slightly lower than the SIMPEDS. Despite slight differences between respirable dust concentrations the respirable crystalline silica values were not significantly different from the SIMPEDS. The GK family of cyclones obtained most precise results and more closely matched the SIMPEDS. A comparison with dust concentration results from previous calm air chamber studies (where wind speeds were < 0.4 m s(-1)) found that the relative performance between samplers was similar to those observed in this work indicating consistent performance relative to the SIMPEDS in both calm and moving air.

Calibration of high flow rate thoracic-size selective samplers

High flow rate respirable size selective samplers, GK4.126 and FSP10 cyclones, were calibrated for thoracic-size selective sampling in two different laboratories. The National Institute for Occupational Safety and Health (NIOSH) utilized monodisperse ammonium fluorescein particles and scanning electron microscopy to determine the aerodynamic particle size of the monodisperse aerosol. Fluorescein intensity was measured to determine sampling efficiencies of the cyclones. The Health Safety and Laboratory (HSL) utilized a real time particle sizing instrument (Aerodynamic Particle Sizer) and polydisperse glass sphere particles and particle size distributions between the cyclone and reference sampler were compared. Sampling efficiency of the cyclones were compared to the thoracic convention defined by the American Conference of Governmental Industrial Hygienists (ACGIH)/Comité Européen de Normalisation (CEN)/International Standards Organization (ISO). The GK4.126 cyclone showed minimum bias compared to the thoracic convention at flow rates of 3.5 l min(-1) (NIOSH) and 2.7-3.3 l min(-1) (HSL) and the difference may be from the use of different test systems. In order to collect the most dust and reduce the limit of detection, HSL suggested using the upper end in range (3.3 l min(-1)). A flow rate of 3.4 l min(-1) would be a reasonable compromise, pending confirmation in other laboratories. The FSP10 cyclone showed minimum bias at the flow rate of 4.0 l min(-1) in the NIOSH laboratory test. The high flow rate thoracic-size selective samplers might be used for higher sample mass collection in order to meet analytical limits of quantification.

Air sampling filtration media: Collection efficiency for respirable size-selective sampling

The collection efficiencies of commonly used membrane air sampling filters in the ultrafine particle size range were investigated. Mixed cellulose ester (MCE; 0.45, 0.8, 1.2, and 5 μm pore sizes), polycarbonate (0.4, 0.8, 2, and 5 μm pore sizes), polytetrafluoroethylene (PTFE; 0.45, 1, 2, and 5 μm pore sizes), polyvinyl chloride (PVC; 0.8 and 5 μm pore sizes), and silver membrane (0.45, 0.8, 1.2, and 5 μm pore sizes) filters were exposed to polydisperse sodium chloride (NaCl) particles in the size range of 10-400 nm. Test aerosols were nebulized and introduced into a calm air chamber through a diffusion dryer and aerosol neutralizer. The testing filters (37 mm diameter) were mounted in a conductive polypropylene filter-holder (cassette) within a metal testing tube. The experiments were conducted at flow rates between 1.7 and 11.2 l min-1. The particle size distributions of NaCl challenge aerosol were measured upstream and downstream of the test filters by a scanning mobility particle sizer (SMPS). Three different filters of each type with at least three repetitions for each pore size were tested. In general, the collection efficiency varied with airflow, pore size, and sampling duration. In addition, both collection efficiency and pressure drop increased with decreased pore size and increased sampling flow rate, but they differed among filter types and manufacturer. The present study confirmed that the MCE, PTFE, and PVC filters have a relatively high collection efficiency for challenge particles much smaller than their nominal pore size and are considerably more efficient than polycarbonate and silver membrane filters, especially at larger nominal pore sizes.

Promoting early exposure monitoring for respirable crystalline silica: Taking the laboratory to the mine site

The exposure to respirable crystalline silica (RCS) in the mining industry is a recognized occupational hazard. The assessment and monitoring of the exposure to RCS is limited by two main factors: (1) variability of the silica percent in the mining dust and (2) lengthy off-site laboratory analysis of collected samples. The monitoring of respirable dust via traditional or real-time techniques is not adequate. A solution for on-site quantification of RCS in dust samples is being investigated by the Office of Mine Safety and Health Research, a division of the National Institute for Occupational Safety and Health. The use of portable Fourier transform infrared analyzers in conjunction with a direct-on-filter analysis approach is proposed. The progress made so far, the necessary steps in progress, and the application of the monitoring solution to a small data set is presented. When developed, the solution will allow operators to estimate RCS immediately after sampling, resulting in timelier monitoring of RCS for self-assessment of compliance at the end of the shift, more effective engineering monitoring, and better evaluation of control technologies.

Silica Measurement with High Flow Rate Respirable Size Selective Samplers: A Field Study

High and low flow rate respirable size selective samplers including the CIP10-R (10 l min(-1)), FSP10 (11.2 l min(-1)), GK2.69 (4.4 l min(-1)), 10-mm nylon (1.7 l min(-1)), and Higgins-Dewell type (2.2 l min(-1)) were compared via side-by-side sampling in workplaces for respirable crystalline silica measurement. Sampling was conducted at eight different occupational sites in the USA and five different stonemasonry sites in Ireland. A total of 536 (268 pairs) personal samples and 55 area samples were collected. Gravimetric analysis was used to determine respirable dust mass and X-ray diffraction analysis was used to determine quartz mass. Ratios of respirable dust mass concentration, quartz mass concentration, respirable dust mass, and quartz mass from high and low flow rate samplers were compared. In general, samplers did not show significant differences greater than 30% in respirable dust mass concentration and quartz mass concentration when outliers (ratio <0.3 or >3.0) were removed from the analysis. The frequency of samples above the limit of detection and limit of quantification of quartz was significantly higher for the CIP10-R and FSP10 samplers compared to low flow rate samplers, while the GK2.69 cyclone did not show significant difference from low flow rate samplers. High flow rate samplers collected significantly more respirable dust and quartz than low flow rate samplers as expected indicating that utilizing high flow rate samplers might improve precision in quartz measurement. Although the samplers did not show significant differences in respirable dust and quartz concentrations, other practical attributes might make them more or less suitable for personal sampling.

Evaluation of Diffuse Reflection Infrared Spectrometry for End-of-Shift Measurement of α-quartz in Coal Dust Samples

The inhalation of toxic substances is a major threat to the health of miners, and dust containing respirable crystalline silica (α-quartz) is of particular concern, due to the recent rise in cases of coal workers' pneumoconiosis and silicosis in some U.S. mining regions. Currently, there is no field-portable instrument that can measure airborne α-quartz and give miners timely feedback on their exposure. The U.S. National Institute for Occupational Safety and Health (NIOSH) is therefore conducting studies to investigate technologies capable of end-of-shift or real-time measurement of airborne quartz. The present study focuses on the potential application of Fourier transform infrared (FT-IR) spectrometry conducted in the diffuse reflection (DR) mode as a technique for measuring α-quartz in respirable mine dust. A DR accessory was used to analyze lab-generated respirable samples of Min-U-Sil 5 (which contains more than 90% α-quartz) and coal dust, at mass loadings in the ranges of 100-600 μg and 600-5300 μg, respectively. The dust samples were deposited onto three different types of filters, borosilicate fiberglass, nylon, and polyvinyl chloride (PVC). The reflectance, R, was calculated by the ratio of a blank filter and a filter with deposited mine dust. Results suggest that for coal and pure quartz dusts deposited on 37 mm PVC filters, measurements of -log R correlate linearly with known amounts of quartz on filters, with R(2) values of approximately 0.99 and 0.94, respectively, for samples loaded up to ∼4000 μg. Additional tests were conducted to measure quartz in coal dusts deposited onto the borosilicate fiberglass and nylon filter media used in the NIOSH-developed Personal Dust Monitor (PDM). The nylon filter was shown to be amenable to DR analysis, but quantification of quartz is more accurate when the filter is "free," as opposed to being mounted in the PDM filter holder. The borosilicate fiberglass filters were shown to produce excessive interference, making quartz quantification impossible. It was concluded that, while the DR/FT-IR method is potentially useful for on-filter measurement of quartz in dust samples, the use of PVC filters produced the most accurate results.

Collection efficiencies of high flow rate personal respirable samplers when measuring Arizona road dust and analysis of quartz by x-ray diffraction

Prolonged exposure to respirable crystalline silica (RCS) causes silicosis and is also considered a cause of cancer. To meet emerging needs for precise measurements of RCS, from shorter sampling periods (<4h) and lower air concentrations, collaborative work was done to assess the differences between personal respirable samplers at higher flow rates. The performance of FSP10, GK2.69, and CIP 10 R samplers were compared with that of the Safety In Mines Personal Dust Sampler (SIMPEDS) sampler as a reference, which is commonly used in the UK for the measurement of RCS. In addition, the performance of the FSP10 and GK 2.69 samplers were compared; at the nominal flow rates recommended by the manufacturers of 10 and 4.2 l · min⁻¹ and with flow rates proposed by the National Institute for Occupational Safety and Health of 11.2 and 4.4 l · min⁻¹. Samplers were exposed to aerosols of ultrafine and medium grades of Arizona road dust (ARD) generated in a calm air chamber. All analyses for RCS in this study were performed at the Health and Safety Laboratory. The difference in flow rates for the GK2.69 is small and does not result in a substantial difference in collection efficiency for the dusts tested, while the performance of the FSP10 at 11.2 l · min⁻¹ was more comparable with samples from the SIMPEDS. Conversely, the GK2.69 collected proportionately more crystalline silica in the respirable dust than other samplers, which then produced RCS results most comparable with the SIMPEDS. The CIP 10 R collected less ultrafine ARD than other samplers, as might be expected based on earlier performance evaluations. The higher flow rate for the FSP10 should be an added advantage for task-specific sampling or when measuring air concentrations less than current occupational exposure limits.

Assessment of respirable crystalline silica analysis using Proficiency Analytical Testing results from 2003-2013

Analysis of Proficiency Analytical Testing (PAT) results between 2003 and 2013 suggest that the variation in respirable crystalline silica analysis is much smaller today than it was in the period 1990-1998, partly because of a change in sample production procedure and because the colorimetric method has been phased out, although quality improvements in the x-ray diffraction (XRD) or infrared (IR) methods may have also played a role. There is no practical difference between laboratories using XRD or IR methods or between laboratories which are accredited or those which are not. Reference laboratory means (assigned values) are not different from the means of all participants across the current range of mass loading, although there is a small difference in variance in the ratios of all participants to reference laboratory means based on method because the reference laboratories are much more likely to use XRD than are the others. Matrix interference does not lead to biases or substantially larger variances for either XRD or IR methods. Data from proficiency test sample analyses that include results from poorly performing laboratories should not be used to determine the validity of a method. PAT samples are not produced below 40 μg and variance may increase with lower masses, although this is not particularly predictable. PAT data from lower mass loadings will be required to evaluate analytical performance if exposure limits are lowered without change in sampling method. Task-specific exposure measurements for periods shorter than a full shift typically result in lower mass loadings and the quality of these analyses would also be better assured from being within the range of PAT mass loadings. High flow rate cyclones, whose performance has been validated, can be used to obtain higher mass loadings in environments of lower concentrations or where shorter sampling times are desired.

Performance of High-Flow-Rate Samplers for Respirable Crystalline Silica Measurement Under Field Conditions: Preliminary Study

Restoration stone work regularly involves work with high-silica-content materials (e.g., sandstone), but low-silica-content materials (<2 % quartz) such as limestone and lime mortar are also used. A combination of short sample duration and low silica content makes the quantification of worker exposure to respirable crystalline silica (RCS) difficult. This problem will be further compounded by the introduction of lower occupational exposure standards for RCS. The objective of this work was to determine whether higher-flow samplers might be an effective tool in characterizing lower RCS concentrations. A short study was performed to evaluate the performance of three high-flow samplers (FSP10, CIP10-R, and GK2.69) using side-by-side sampling with low-flow samplers (SIMPEDS and 10-mm nylon cyclones) for RCS exposure measurement at a restoration stonemasonry field site. A total of 19 side-by-side sample replicates for each high-flow and low-flow sampler pair were collected from work tasks involving limestone and sandstone.

RESULTS

Most of the RCS (quartz) masses collected with the high-flow-rate samplers were above the limit of detection (62 % to 84 %) relative to the low-flow-rate samplers (58 % to 78 %). The average of the respirable mass concentration ratios for CIP10-R/SIMPEDS, GK2.69/10-mm nylon, FSP10/SIMPEDS, and FSP10/10-mm nylon pairs and the range of the quartz concentration ratios for the CIP10-R/SIMPEDS, CIP10-R/10-mm nylon, GK2.69/10-mm nylon, FSP10/SIMPEDS, and FSP10/10-mm nylon pairs included unity with an average close to unity, indicating no likely difference between the reported values for each sampler. Workers reported problems related to the weight of the sampling pumps for the high-flow-rate samplers. Respirable mass concentration data suggest that the high-flow-rate samplers evaluated would be appropriate for sampling respirable dust concentrations during restoration stone work. Results from the comparison of average quartz concentration ratios between high-and low-flow samplers suggest that the higher mass collected by the high-flow-rate samplers did not interfere with the quartz measurement. A sig-nificant portion of the data collected with the high-flow-rate samplers (>82 %) were greater than the limit of detection, which indicates that these samplers are suitable for quantifying exposures, even with low-quartz materials.

Evaluation of pump pulsation in respirable size-selective sampling: part I. Pulsation measurements

Pulsations generated by personal sampling pumps modulate the airflow through the sampling trains, thereby varying sampling efficiencies, and possibly invalidating collection or monitoring. The purpose of this study was to characterize pulsations generated by personal sampling pumps relative to a nominal flow rate at the inlet of different respirable cyclones. Experiments were conducted using a factorial combination of 13 widely used sampling pumps (11 medium and 2 high volumetric flow rate pumps having a diaphragm mechanism) and 7 cyclones [10-mm nylon also known as Dorr-Oliver (DO), Higgins-Dewell (HD), GS-1, GS-3, Aluminum, GK2.69, and FSP-10]. A hot-wire anemometer probe cemented to the inlet of each cyclone type was used to obtain pulsation readings. The three medium flow rate pump models showing the highest, a midrange, and the lowest pulsations and two high flow rate pump models for each cyclone type were tested with dust-loaded filters (0.05, 0.21, and 1.25mg) to determine the effects of filter loading on pulsations. The effects of different tubing materials and lengths on pulsations were also investigated. The fundamental frequency range was 22-110 Hz and the magnitude of pulsation as a proportion of the mean flow rate ranged from 4.4 to 73.1%. Most pump/cyclone combinations generated pulse magnitudes ≥10% (48 out of 59 combinations), while pulse shapes varied considerably. Pulsation magnitudes were not considerably different for the clean and dust-loaded filters for the DO, HD, and Aluminum cyclones, but no consistent pattern was observed for the other cyclone types. Tubing material had less effect on pulsations than tubing length; when the tubing length was 183cm, pronounced damping was observed for a pump with high pulsation (>60%) for all tested tubing materials except for the Tygon Inert tubing. The findings in this study prompted a further study to determine the possibility of shifts in cyclone sampling efficiency due to sampling pump pulsations, and those results are reported subsequently.

Evaluation of pump pulsation in respirable size-selective sampling: part II. Changes in sampling efficiency

This second, and concluding, part of this study evaluated changes in sampling efficiency of respirable size-selective samplers due to air pulsations generated by the selected personal sampling pumps characterized in Part I (Lee E, Lee L, Möhlmann C et al. Evaluation of pump pulsation in respirable size-selective sampling: Part I. Pulsation measurements. Ann Occup Hyg 2013). Nine particle sizes of monodisperse ammonium fluorescein (from 1 to 9 μm mass median aerodynamic diameter) were generated individually by a vibrating orifice aerosol generator from dilute solutions of fluorescein in aqueous ammonia and then injected into an environmental chamber. To collect these particles, 10-mm nylon cyclones, also known as Dorr-Oliver (DO) cyclones, were used with five medium volumetric flow rate pumps. Those were the Apex IS, HFS513, GilAir5, Elite5, and Basic5 pumps, which were found in Part I to generate pulsations of 5% (the lowest), 25%, 30%, 56%, and 70% (the highest), respectively. GK2.69 cyclones were used with the Legacy [pump pulsation (PP) = 15%] and Elite12 (PP = 41%) pumps for collection at high flows. The DO cyclone was also used to evaluate changes in sampling efficiency due to pulse shape. The HFS513 pump, which generates a more complex pulse shape, was compared to a single sine wave fluctuation generated by a piston. The luminescent intensity of the fluorescein extracted from each sample was measured with a luminescence spectrometer. Sampling efficiencies were obtained by dividing the intensity of the fluorescein extracted from the filter placed in a cyclone with the intensity obtained from the filter used with a sharp-edged reference sampler. Then, sampling efficiency curves were generated using a sigmoid function with three parameters and each sampling efficiency curve was compared to that of the reference cyclone by constructing bias maps. In general, no change in sampling efficiency (bias under ±10%) was observed until pulsations exceeded 25% for the DO cyclone. However, for three models of pumps producing 30%, 56%, and 70% pulsations, substantial changes were confirmed. The GK2.69 cyclone showed a similar pattern to that of the DO cyclone, i.e. no change in sampling efficiency for the Legacy producing 15% pulsation and a substantial change for the Elite12 producing 41% pulsation. Pulse shape did not cause any change in sampling efficiency when compared to the single sine wave. The findings suggest that 25% pulsation at the inlet of the cyclone as measured by this test can be acceptable for the respirable particle collection. If this test is used in place of that currently in European standards (EN 1232-1997 and EN 12919-1999) or is used in any International Organization for Standardization standard, then a 25% pulsation criterion could be adopted. This work suggests that a 10% criterion as currently specified in the European standards for testing may be overly restrictive and not able to be met by many pumps on the market. Further work is recommended to determine which criterion would be applicable to this test if it is to be retained in its current form.

Deposition Uniformity of Coal Dust on Filters and Its Effect on the Accuracy of FTIR Analyses for Silica

Miners are exposed to silica-bearing dust which can lead to silicosis, a potentially fatal lung disease. Currently, airborne silica is measured by collecting filter samples and sending them to a laboratory for analysis. Since this may take weeks, a field method is needed to inform decisions aimed at reducing exposures. This study investigates a field-portable Fourier transform infrared (FTIR) method for end-of-shift (EOS) measurement of silica on filter samples. Since the method entails localized analyses, spatial uniformity of dust deposition can affect accuracy and repeatability. The study, therefore, assesses the influence of radial deposition uniformity on the accuracy of the method. Using laboratory-generated Minusil and coal dusts and three different types of sampling systems, multiple sets of filter samples were prepared. All samples were collected in pairs to create parallel sets for training and validation. Silica was measured by FTIR at nine locations across the face of each filter and the data analyzed using a multiple regression analysis technique that compared various models for predicting silica mass on the filters using different numbers of "analysis shots." It was shown that deposition uniformity is independent of particle type (kaolin vs. silica), which suggests the role of aerodynamic separation is negligible. Results also reflected the correlation between the location and number of shots versus the predictive accuracy of the models. The coefficient of variation (CV) for the models when predicting mass of validation samples was 4%-51% depending on the number of points analyzed and the type of sampler used, which affected the uniformity of radial deposition on the filters. It was shown that using a single shot at the center of the filter yielded predictivity adequate for a field method, (93% return, CV approximately 15%) for samples collected with 3-piece cassettes.

Consideration of kaolinite interference correction for quartz measurements in coal mine dust

Kaolinite interferes with the infrared analysis of quartz. Improper correction can cause over- or underestimation of silica concentration. The standard sampling method for quartz in coal mine dust is size selective, and, since infrared spectrometry is sensitive to particle size, it is intuitively better to use the same size fractions for quantification of quartz and kaolinite. Standard infrared spectrometric methods for quartz measurement in coal mine dust correct interference from the kaolinite, but they do not specify a particle size for the material used for correction. This study compares calibration curves using as-received and respirable size fractions of nine different examples of kaolinite in the different correction methods from the National Institute for Occupational Safety and Health Manual of Analytical Methods (NMAM) 7603 and the Mine Safety and Health Administration (MSHA) P-7. Four kaolinites showed significant differences between calibration curves with as-received and respirable size fractions for NMAM 7603 and seven for MSHA P-7. The quartz mass measured in 48 samples spiked with respirable fraction silica and kaolinite ranged between 0.28 and 23% (NMAM 7603) and 0.18 and 26% (MSHA P-7) of the expected applied mass when the kaolinite interference was corrected with respirable size fraction kaolinite. This is termed "deviation," not bias, because the applied mass is also subject to unknown variance. Generally, the deviations in the spiked samples are larger when corrected with the as-received size fraction of kaolinite than with the respirable size fraction. Results indicate that if a kaolinite correction with reference material of respirable size fraction is applied in current standard methods for quartz measurement in coal mine dust, the quartz result would be somewhat closer to the true exposure, although the actual mass difference would be small. Most kinds of kaolinite can be used for laboratory calibration, but preferably, the size fraction should be the same as the coal dust being collected.

Evaluation of laser-induced breakdown spectroscopy (LIBS) for measurement of silica on filter samples of coal dust

Airborne silica dust (quartz) is common in coal mines and represents a respiratory hazard that can lead to silicosis, a potentially fatal lung disease. With an eye toward developing a portable monitoring device for rapid analysis of silica dust, laser-induced breakdown spectroscopy (LIBS) was used to quantify quartz in coal dust samples collected on filter media. Pure silica (Min-U-Sil™ 5), Georgia kaolin, and Pittsburgh-4 and Illinois-6 coal dusts were deposited separately and at multiple mass loadings onto 37-mm polyvinylchloride (PVC) filters. LIBS-generated silicon emission was monitored at 288.16 nm, and non-silica contributions to that signal from kaolinite were removed by simultaneously detecting aluminum. Measurements of the four samples were used to calculate limits of detection (LOD) for silicon and aluminum of approximately 0.08 μg/cm(2) and 0.05 μg/cm(2), respectively (corresponding to 0.16 μg/cm(2) and 0.20 μg/cm(2) for silica and kaolinite, respectively). Relative errors of prediction are around 10%. Results demonstrate that LIBS can dependably quantify silica on filter samples of coal dust and confirm that accurate quantification can be achieved for very lightly loaded samples, which supports the potential application of LIBS for rapid, in-field monitoring.

Quartz measurement in coal dust with high-flow rate samplers: laboratory study

A laboratory study was performed to measure quartz in coal dust using high-flow rate samplers (CIP10-R, GK2.69 cyclone, and FSP10 cyclone) and low-flow rate samplers [10-mm nylon and Higgins-Dewell type (BGI4L) cyclones] and to determine whether an increased mass collection from high-flow rate samplers would affect the subsequent quartz measurement by Fourier transform infrared (FTIR) and X-ray diffraction (XRD) analytical procedures. Two different sizes of coal dusts, mass median aerodynamic diameter 4.48 μm (Coal Dust A) and 2.33 μm (Coal Dust B), were aerosolized in a calm air chamber. The mass of coal dust collected by the samplers was measured gravimetrically, while the mass of quartz collected by the samplers was determined by FTIR (NIOSH Manual of Analytical Method 7603) and XRD (NIOSH Manual of Analytical Method 7500) after one of two different indirect preparations. Comparisons between high-flow rate samplers and low-flow rate samplers were made by calculating mass concentration ratios of coal dusts, net mass ratios of coal dusts, and quartz net mass. Mass concentrations of coal dust from the FSP10 cyclone were significantly higher than those from other samplers and mass concentrations of coal dust from 10-mm nylon cyclone were significantly lower than those from other samplers, while the CIP10-R, GK2.69, and BGI4L samplers did not show significant difference in the comparison of mass concentration of coal dusts. The BGI4L cyclone showed larger mass concentration of ∼9% compared to the 10-mm nylon cyclone. All cyclones provided dust mass concentrations that can be used in complying with the International Standard Organization standard for the determination of respirable dust concentration. The amount of coal dust collected from the high-flow rate samplers was found to be higher with a factor of 2-8 compared to the low-flow rate samplers but not in direct proportion of increased flow rates. The high-flow rate samplers collected more quartz compared to low-flow rate samplers in the range of 2-10. There was no significant difference between the per cent (%) quartz in coal dust between the FTIR and XRD analyses. The findings of this study indicated that the increased mass of quartz collected with high-flow rate samplers would provide precise analytical results (i.e. significantly above the limit of detection and/or limit of quantification) compared to the mass collected with low-flow rate samplers, especially in environments with low concentrations of quartz or where short sampling times are desired.

Evaluating portable infrared spectrometers for measuring the silica content of coal dust

Miners face a variety of respiratory hazards while on the job, including exposure to silica dust which can lead to silicosis, a potentially fatal lung disease. Currently, field-collected filter samples of silica are sent for laboratory analysis and the results take weeks to be reported. Since the mining workplace is constantly moving into new and often different geological strata with changing silica levels, more timely data on silica levels in mining workplaces could help reduce exposures. Improvements in infrared (IR) spectroscopy open the prospect for end-of-shift silica measurements at mine sites. Two field-portable IR spectrometers were evaluated for their ability to quantify the mass of silica on filter samples loaded with known amounts of either silica or silica-bearing coal dust (silica content ranging from 10-200 μg/filter). Analyses included a scheme to correct for the presence of kaolin, which is a confounder for IR analysis of silica. IR measurements of the samples were compared to parallel measurements derived using the laboratory-based U.S. Mine Safety and Health Administration P7 analytical method. Linear correlations between Fourier transform infrared (FTIR) and P7 data yielded slopes in the range of 0.90-0.97 with minimal bias. Data from a variable filter array spectrometer did not correlate as well, mainly due to poor wavelength resolution compared to the FTIR instrument. This work has shown that FTIR spectrometry has the potential to reasonably estimate the silica exposure of miners if employed in an end-of-shift method.

Size-selective sampling of particulates using a physiologic sampling pump

Recent laboratory research indicates physiologic sampling of gas and vapor may provide more representative estimates of personal exposures than traditional methods. Modifications to the physiologic sampling pump (PSP) used in that research are described which extend its usefulness to size-selective sampling of particulates. PSPs used in previous research varied motor speed to keep sampling proportional to the subject's inhalation. This caused airflow and particle velocities through the collection device to continually change making those pumps unsuitable for sampling particulates. The modified implementation of the PSP pulls a constant airflow into and through a cyclone, then uses valves to either direct the airflow through, or divert the airflow around, the sampling filter. By using physiologic inputs to regulate the fraction of each second that air flows through the sampling filter, samples may be collected in proportion to inhalation rate. To evaluate the performance of a functional prototype 5 different sizes of monodisperse aerosols of ammonium fluorescein were generated by a vibrating orifice aerosol generator and introduced into a calm air chamber. To simulate different inhalation rates the valves of the PSP were energized using 9 different duty cycles. Efficiency curves are presented and compared to a standard respirable convention by bias mapping. The performance of the modified cyclone used in the PSP sampling head compared favorably with a commercially available cyclone of the same model, operating at a constant airflow (± 10% over almost all the size distributions of concern). The new method makes physiologic sampling of the respirable fraction of particulates feasible.