Evaluation of organic-vapor respirator cartridge efficiency for toluene diisocyanate vapor in the presence of methylenechloride or acetone solvent.

Toluene diisocyanate (TDI) is a widely used raw material in the manufacture of flexible polyurethane foams. Acetone (ACE) and/or methylenechloride (MECL) solvents are the most commonly used solvent-based blowing agents for TDI foams. ACGIH has recommended a TWA exposure limit of 5 ppb for TDI and 500 ppm for ACE. For MECL, OSHA mandates a TWA-exposure limit of 25 ppm. This study evaluated the ability of the organic-vapor respirator cartridges (OVC) to block TDI, as well as the effect of airborne MECL or ACE on the OVCs' efficiency to capture TDI. An aluminum/stainless steel exposure chamber was constructed for simultaneously challenging OVCs in triplicate with a dynamic atmosphere of TDI and ACE or MECL vapor. The challenge atmosphere was generated by combining a TDI-laden nitrogen stream from the headspace of a heated impinger with a humidified stream of the indicated solvent in air. The average challenge concentration for TDI was 275 ppb. The average MECL or ACE concentrations were 547 and 581 ppm, respectively. The challenge atmosphere at room temperature (approximately 24 degrees C) and at 25 or 80 percent relative humidity was drawn through each cartridge at 32 L/min for 40+ hours. During the last 8 hours of the challenge, the atmosphere had only TDI vapor. The pre- and post-cartridge atmospheres were periodically sampled for TDI and solvent. Five tests were conducted--two with MSA and three with North OVCs. Under these extreme test conditions no TDI breakthrough was detected from any OVC. The average-calculated efficiency of the OVCs for TDI was >99.9+ percent. Within the first 6 hours of the challenge the cartridges were saturated with ACE or MECL; nevertheless, continued challenging with TDI and solvents did not cause any TDI breakthrough. The study demonstrates that with an OSHA-compliant respiratory protection program, an OVC can safely be used for 40 hours in most polyurethane foam operations. In typical occupational environments using TDI and solvents, the solvent breakthrough, rather than TDI breakthrough, would be the determining factor for the calculation of respirator cartridge change-out schedules.