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The OSHA and EPA programs on preventing chemical accidents and potential applications in the photovoltaic industry

Description: OSHA issued in 1992, the Process Safety Management (PSM) of Highly Hazardous Substances. This rule requires owners/operators of facilities that handle hazardous chemicals in quantities greater than the listed thresholds to establish all the elements of a PSM. EPA has issued in June 1996, the rules for a Risk Management Program which also refers to specific substances and threshold quantities. These rules are applicable to all the facilities that use or store any of 139 regulated substances at quantities ranging from 100 lb to 10,000 lb. The RMP rule covers off-site hazards, while the OSHA Process Safety Management (PSM) rule covers worker safety issues within the plant boundary. Some of the listed substances may be found in photovoltaic manufacturing facilities. This brief report presents the basic elements of these two rules and discusses their potential applicability in the photovoltaic industry.
Date: August 1, 1996
Creator: Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

Mitigation options for accidental releases of hazardous gases

Description: The objective of this paper is to review and compare technologies available for mitigation of unconfined releases of toxic and flammable gases. These technologies include: secondary confinement, deinventory, vapor barriers, foam spraying, and water sprays/monitors. Guidelines for the design and/or operation of effective post-release mitigation systems and case studies involving actual industrial mitigation systems are also presented.
Date: May 1, 1995
Creator: Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

A review of accidents, prevention and mitigation options related to hazardous gases

Description: Statistics on industrial accidents are incomplete due to lack of specific criteria on what constitutes a release or accident. In this country, most major industrial accidents were related to explosions and fires of flammable materials, not to releases of chemicals into the environment. The EPA in a study of 6,928 accidental releases of toxic chemicals revealed that accidents at stationary facilities accounted for 75% of the total number of releases, and transportation accidents for the other 25%. About 7% of all reported accidents (468 cases) resulted in 138 deaths and 4,717 injuries ranging from temporary respiratory problems to critical injuries. In-plant accidents accounted for 65% of the casualties. The most efficient strategy to reduce hazards is to choose technologies which do not require the use of large quantities of hazardous gases. For new technologies this approach can be implemented early in development, before large financial resources and efforts are committed to specific options. Once specific materials and options have been selected, strategies to prevent accident initiating events need to be evaluated and implemented. The next step is to implement safety options which suppress a hazard when an accident initiating event occurs. Releases can be prevented or reduced with fail-safe equipment and valves, adequate warning systems and controls to reduce and interrupt gas leakage. If an accident occurs and safety systems fail to contain a hazardous gas release, then engineering control systems will be relied on to reduce/minimize environmental releases. As a final defensive barrier, the prevention of human exposure is needed if a hazardous gas is released, in spite of previous strategies. Prevention of consequences forms the final defensive barrier. Medical facilities close by that can accommodate victims of the worst accident can reduce the consequences of personnel exposure to hazardous gases.
Date: May 1, 1993
Creator: Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department

Cross-flow versus counter-current flow packed-bed scrubbers: a mathematical analysis

Description: Little is known about the mass transfer properties of packing media exposed to a crossflow of gas and liquid, whereas there is abundant information related to counter-current scrubbers. This paper presents a theoretical analysis of mass transfer and hydrodynamics in cross- flow packed bed scrubbers and compares those with information available for counter current towers, so that the first can be evaluated and/or designed based on data derived for the second. Mathematical models of mass transfer in cross-flow and counter- current packed bed scrubbers are presented. From those, one can predict the removal effectiveness of a crossflow scrubber from the number of transfer units (NTU) calculated for a similar counterflow operation; alternatively, when the removal effectiveness in counterflow is known, one can predict the corresponding NTU in crossflow.
Date: February 1, 1996
Creator: Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

LIFE CYCLE INVENTORY ANALYSIS IN THE PRODUCTION OF METALS USED IN PHOTOVOLTAICS.

Description: Material flows and emissions in all the stages of production of zinc, copper, aluminum, cadmium, indium, germanium, gallium, selenium, tellurium, and molybdenum were investigated. These metals are used selectively in the manufacture of solar cells, and emission and energy factors in their production are used in the Life Cycle Analysis (LCA) of photovoltaics. Significant changes have occurred in the production and associated emissions for these metals over the last 10 years, which are not described in the LCA databases. Furthermore, emission and energy factors for several of the by-products of the base metal production were lacking. This report aims in updating the life-cycle inventories associated with the production of the base metals (Zn, Cu, Al, Mo) and in defining the emission and energy allocations for the minor metals (Cd, In, Ge, Se, Te and Ga) used in photovoltaics.
Date: March 30, 2007
Creator: Fthenakis, V. M.; Kim, H. C. & Wang, W.
Partner: UNT Libraries Government Documents Department

Model institutional infrastructures for recycling of photovoltaic modules

Description: This paper describes model approaches to designing an institutional infrastructure for the recycling of decommissioned photovoltaic modules; more detailed discussion of the information presented in this paper is contained in Reaven et al., (1996)[1]. The alternative approaches are based on experiences in other industries, with other products and materials. In the aluminum, scrap iron, and container glass industries, where recycling is a long-standing, even venerable practice, predominantly private, fully articulated institutional infrastructures exist. Nevertheless, even in these industries, arrangements are constantly evolving in response to regulatory changes, competition, and new technological developments. Institutional infrastructures are less settled for younger large- scale recycling industries that target components of the municipal solid waste (MSW) stream, such as cardboard and newspaper, polyethylene terephthalate (PET) and high-density polyethylene (HDPE) plastics, and textiles. In these industries the economics, markets, and technologies are rapidly changing. Finally, many other industries are developing projects to ensure that their products are recycled (and recyclable) e.g., computers, non-automotive batteries, communications equipment, motor and lubrication oil and oil filters, fluorescent lighting fixtures, automotive plastics and shredder residues, and bulk industrial chemical wastes. The lack of an an adequate recycling infrastructure, attractive end-markets, and clear the economic incentives, can be formidable impediments to a self- sustaining recycling system.
Date: July 1, 1996
Creator: Moscowitz, P.D.; Reaven, J. & Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

Mitigation of unconfined releases of hazardous gases via liquid spraying

Description: The capability of water sprays in mitigating clouds of hydrofluoric acid (HF) has been demonstrated in the large-scale field experiments of Goldfish and Hawk, which took place at the DOE Nevada Test Site. The effectiveness of water sprays and fire water monitors to remove HF from vapor plume, has also been studied theoretically using the model HGSPRAY5 with the near-field and far-field dispersion described by the HGSYSTEM models. This paper presents options to select and evaluate liquid spraying systems, based on the industry experience and mathematical modeling.
Date: February 1, 1997
Creator: Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

Approaches for preventing and mitigating accidental gaseous chemical releases

Description: This paper presents a review of approaches to prevent and mitigate accidental releases of toxic and flammable gases. The prevention options are related to: choosing safer processes and materials, preventing initiating events, preventing or minimizing releases, and preventing human exposures. the mitigation options include: secondary confinement, de-inventory, vapor barriers, and water sprays/monitors. Guidelines for the design and operation of effective post-release mitigation systems are also presented.
Date: December 31, 1996
Creator: Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

Environmental, health and safety issues related to commercializing CuInSe{sub 2}-based photovoltaics

Description: Photovoltaics technology is rapidly evolving towards a new generation of low-cost thin film technologies. One of the most promising materials in this new generation is copper indium selenide (CuInSe{sub 2} or CIS). As with any new material, successful commercialization of CIS photovoltaic (PV) technology will require attention to environmental, health and safety issues, including consideration of the sources, usage, and end-of-product-life disposal and/or recycling of the constituent materials. This work focuses on three specific environmental, health and safety (EH and S) issues related to CIS PV: (1) economics are analyzed to determine their impact on materials use and re-use; (2) Federal and California State environmental disposal and waste handling regulations are analyzed to evaluate their impact on PV module manufacturing and end-of-life module handling; and (3) the logistics and economics of product recycling and waste disposal by industries with comparable EH and S issues are examined to quantify the corresponding options available for handling, disposing of and/or recycling manufacturing by-products and end-of-life modules.
Date: July 1, 1996
Creator: Eberspacher, C.; Fthenakis, V.M. & Moskowtiz, P.D.
Partner: UNT Libraries Government Documents Department

Waste reduction options for manufacturers of copper indium diselenide photovoltaic cells

Description: This paper identifies general waste reduction concepts and specific waste reduction options to be used in the production of copper indium diselenide (CIS) photovoltaic cells. A general discussion of manufacturing processes used for the production of photovoltaic cells is followed by a description of the US Environmental Protection Agency (EPA) guidelines for waste reduction (i.e., waste minimization through pollution prevention). A more specific discussion of manufacturing CIS cells is accompanied by detailed suggestions regarding waste minimization options for both inputs and outputs for ten stages of this process. Waste reduction from inputs focuses on source reduction and process changes, and reduction from outputs focuses on material reuse and recycling.
Date: March 1, 1994
Creator: DePhillips, M.P.; Fthenakis, V.M. & Moskowitz, P.D.
Partner: UNT Libraries Government Documents Department

Environmental issues related to commercialization of CulnSe{sub 2}- based photovoltaics

Description: One of the most promising materials for low-cost thin film photovoltaic cells is copper indium selenide (CuInSe{sub 2} or CIS). As with any new material, successful commercialization of CIS photovoltaic (PV) technology will require attention to environmental issues related to the sources of raw materials, their usage, and the disposal and/or recycling of products at the end of their useful life. This paper focuses on three specific environmental issues related to CIS technology: (i) Economics of the use and re-use of materials; (ii) regulations on environmental disposal and waste handling, and (iii) logistics and economics of recycling and disposing of products by industries faced with comparable environmental issues.
Date: July 1, 1996
Creator: Eberspacher, C.; Fthenakis, V.M. & Moskowitz, P.D.
Partner: UNT Libraries Government Documents Department

Modelling absorption and dilution of unconfined releases of hazardous gases by water curtains or monitors

Description: OSHA Process Safety Management guidelines suggest that a facility operator investigate and document a plan for installing systems to detect, contain, or mitigate accidental releases if such systems are not already in place. In addition, proposed EPA 112(r) regulations would require such analysis. This paper illustrates how mathematical modelling can aid such an evaluation and describes some recent enhancements of the HGSPRAY model: (1) Adding algorithms for modeling NH{sub 3} and LNG mitigation; (2) Modeling spraying of releases with fire water monitors encircling the point of release; (3) Combining wind tunnel modeling with mathematical modeling; and (4) Linking HGSPRAY and BEGADAS. Case cases are presented as examples of how HGSPRAY can aid the design of water spray systems for initiation of toxic gases (e.g., BF, NH,) or dilution/dispersion of flammable vapors (e.g., LNG).
Date: May 1, 1995
Creator: Fthenakis, V.M.; Blewitt, D.N. & Hague, W.J.
Partner: UNT Libraries Government Documents Department

An update on environmental, health and safety issues of interest to the photovoltaic industry

Description: There is growing interest in the environmental, health, and safety issues related to new photovoltaic technologies as they approach commercialization. Such issues include potential toxicity of II--VI compounds; the impacts of new environmental regulations on module manufacturers; and, the need for recycling of spent modules and manufacturing wastes. This paper will review these topics. 20 refs.
Date: January 1, 1992
Creator: Moskowitz, P.D.; Viren, J. & Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

Safety analysis report for the use of hazardous production materials in photovoltaic applications at the National Renewable Energy Laboratory

Description: To ensure the continued safety of SERI's employees, the community, and the environment, NREL commissioned an internal audit of its photovoltaic operations that used hazardous production materials (HPMS). As a result of this audit, NREL management voluntarily suspended all operations using toxic and/or pyrophoric gases. This suspension affected seven laboratories and ten individual deposition systems. These activities are located in Building 16, which has a permitted occupancy of Group B, Division 2 (B-2). NREL management decided to do the following. (1) Exclude from this SAR all operations which conformed, or could easily be made to conform, to B-2 Occupancy requirements. (2) Include in this SAR all operations that could be made to conform to B-2 Occupancy requirements with special administrative and engineering controls. (3) Move all operations that could not practically be made to conform to B-2 occupancy requirements to alternate locations. In addition to the layered set of administrative and engineering controls set forth in this SAR, a semiquantitative risk analysis was performed on 30 various accident scenarios. Twelve presented only routine risks, while 18 presented low risks. Considering the demonstrated safe operating history of NREL in general and these systems specifically, the nature of the risks identified, and the layered set of administrative and engineering controls, it is clear that this facility falls within the DOE Low Hazard Class. Each operation can restart only after it has passed an Operational Readiness Review, comparing it to the requirements of this SAR, while subsequent safety inspections will ensure future compliance. This document contains the appendices to the NREL safety analysis report.
Date: July 1, 1992
Creator: Crandall, R.S.; Nelson, B.P.; Moskowitz, P.D. & Fthenakis, V.M.
Partner: UNT Libraries Government Documents Department

The Clean Air Act Amendments of 1990: Hazardous Air Pollutant Requirements and the DOE Clean Coal Technology Program

Description: The purpose of the US Department of Energy -- Office of Fossil Energy (DOE FE) Clean Coal Technology Program (CCTP) is to provide the US energy marketplace with advanced, efficient, and environmentally sound coal-based technologies. The design, construction, and operation of Clean Coal Technology Demonstration Projects (CCTDP) will generate data needed to make informed, confident decisions on the commercial readiness of these technologies. These data also will provide information needed to ensure a proactive response by DOE and its industrial partners to the establishment of new regulations or a reactive response to existing regulations promulgated by the US Environmental Protection Agency (EPA). The objectives of this paper are to: (1) Present a preliminary examination of the potential implications of the Clean Air Act Amendments (CAAA) -- Title 3 Hazardous Air Pollutant requirements to the commercialization of CCTDP; and (2) help define options available to DOE and its industrial partners to respond to this newly enacted Legislation.
Date: December 31, 1991
Creator: Moskowitz, P. D.; DePhillips, M.; Fthenakis, V. M. & Hemenway, A.
Partner: UNT Libraries Government Documents Department

An assessment of mercury emissions and health risks from a coal-fired power plant

Description: Title 3 of the 1990 Clean Air Act Amendments (CAAA) mandated that the US Environmental Protection Agency (EPA) evaluate the need to regulate mercury emissions from electric utilities. In support of this forthcoming regulatory analysis the U.S. DOE, sponsored a risk assessment project at Brookhaven (BNL) to evaluate methylmercury (MeHg) hazards independently. In the US MeHg is the predominant way of exposure to mercury originated in the atmosphere. In the BNL study, health risks to adults resulting from Hg emissions from a hypothetical 1,000 MW coal-fired power plant were estimated using probabilistic risk assessment techniques. This study showed that the effects of emissions of a single power plant may double the background exposures to MeHg resulting from consuming fish obtained from a localized area near the power plant. Even at these more elevated exposure levels, the attributable incidence in mild neurological symptoms was estimated to be quite small, especially when compared with the estimated background incidence in the population. The current paper summarizes the basic conclusions of this assessment and highlights issues dealing with emissions control and environmental transport.
Date: December 1, 1994
Creator: Fthenakis, V. M.; Lipfert, F. & Moskowitz, P.
Partner: UNT Libraries Government Documents Department

An overview of safety assessment, regulation, and control of hazardous material use at NREL

Description: This paper summarizes the methodology we use to ensure the safe use of hazardous materials at the National Renewable Energy Laboratory (NREL). First, we analyze the processes and the materials used in those processes to identify the hazards presented. Then we study federal, state, and local regulations and apply the relevant requirements to our operations. When necessary, we generate internal safety documents to consolidate this information. We design research operations and support systems to conform to these requirements. Before we construct the systems, we perform a semiquantitative risk analysis on likely accident scenarios. All scenarios presenting in unacceptable risk require system or procedural modifications to reduce the risk. Following these modifications, we repeat the risk analysis to ensure that the respective accident scenarios present acceptable risk. Once all risks are acceptable, we conduct an operational readiness review (ORR). A management appointed panel performs the ORR ensuring compliance with all relevant requirements. After successful completion of the ORR, operations can begin.
Date: July 1, 1992
Creator: Nelson, B. P.; Crandall, R. S.; Moskowitz, P. D. & Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department

SUNRAYCE 95: Working safely with lead-acid batteries and photovoltaic power systems

Description: This document is a power system and battery safety handbook for participants in the SUNRAYCE 95 solar powered electric vehicle program. The topics of the handbook include batteries, photovoltaic modules, safety equipment needed for working with sulfuric acid electrolyte and batteries, battery transport, accident response, battery recharging and ventilation, electrical risks on-board vehicle, external electrical risks, electrical risk management strategies, and general maintenance including troubleshooting, hydrometer check and voltmeter check.
Date: May 27, 1994
Creator: DePhillips, M. P.; Moskowitz, P. D. & Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department

Guidelines for accident prevention and emergency preparedness

Description: This report reviews recent developments in the guidelines on chemical accident prevention, risk assessment, and management of chemical emergencies, principally in the United States and Europe, and discusses aspects of their application to developing countries. Such guidelines are either in the form of laws or regulations promulgated by governments, or of recommendations from international, professional, or non governmental organizations. In many cases, these guidelines specify lists of materials of concern and methods for evaluating safe usage of these materials and recommend areas of responsibility for different organizations; procedures to be included in planning, evaluation, and response; and appropriate levels of training for different classes of workers. Guidelines frequently address the right of communities to be informed of potential hazards and address ways for them to participate in planning and decision making.
Date: May 1, 1993
Creator: Fthenakis, V. M.; Morris, S. C. & Moskowitz, P. D.
Partner: UNT Libraries Government Documents Department

SUNRAYCE 93: Working safely with lead-acid batteries and photovoltaic power systems

Description: The US Department of Energy (DOE) is sponsoring SUNRAYCE 93 to advance tile technology and use of photovoltaics and electric vehicles. Participants will use cars powered by photovoltaic modules and lead-acid storage batteries. This brochure, prepared for students and faculty participating in this race, outlines the health hazards presented by these electrical systems, and gives guidance on strategies for their safe usage. At the outset, it should be noted that working with photovoltaic systems and batteries requires electric vehicle drivers and technicians to have {open_quotes}hands-on{close_quotes} contact with the car on a daily basis. It is important that no one work near a photovoltaic energy system or battery, either in a vehicle or on the bench, unless they familiarize themselves with the components in use, and know and observe safe work practices including the safety precautions described in the manuals provided by the various equipment vendors and this document.
Date: November 3, 1992
Creator: DePhillips, M. P.; Moskowitz, P. D. & Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department

An update on environmental, health and safety issues of interest to the photovoltaic industry

Description: There is growing interest in the environmental, health, and safety issues related to new photovoltaic technologies as they approach commercialization. Such issues include potential toxicity of II--VI compounds; the impacts of new environmental regulations on module manufacturers; and, the need for recycling of spent modules and manufacturing wastes. This paper will review these topics. 20 refs.
Date: August 1, 1992
Creator: Moskowitz, P. D.; Viren, J. & Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department

Safety Analysis Report for the use of hazardous production materials in photovoltaic applications at the National Renewable Energy Laboratory

Description: To ensure the continued safety of SERI`s employees, the community, and the environment, NREL commissioned an internal audit of its photovoltaic operations that used hazardous production materials (HPMs). As a result of this audit, NREL management voluntarily suspended all operations using toxic and/or pyrophoric gases. This suspension affected seven laboratories and ten individual deposition systems. These activities are located in Building 16, which has a permitted occupancy of Group B, Division 2 (B-2). NREL management decided to do the following. (1) Exclude from this SAR all operations which conformed, or could easily be made to conform, to B-2 Occupancy requirements. (2) Include in this SAR all operations that could be made to conform to B-2 Occupancy requirements with special administrative and engineering controls. (3) Move all operations that could not practically be made to conform to B-2 Occupancy requirements to alternate locations. In addition to the layered set of administrative and engineering controls set forth in this SAR, a semiquantitative risk analysis was performed on 30 various accident scenarios. Twelve presented only routine risks, while 18 presented low risks. Considering the demonstrated safe operating history of NREL in general and these systems specifically, the nature of the risks identified, and the layered set of administrative and engineering controls, it is clear that this facility falls within the DOE Low Hazard Class. Each operation can restart only after it has passed an Operational Readiness Review, comparing it to the requirements of this SAR, while subsequent safety inspections will ensure future compliance.
Date: July 1, 1992
Creator: Crandall, R. S.; Nelson, B. P.; Moskowitz, P. D. & Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department

Assessment of mercury health risks to adults from coal combustion

Description: The U.S. Environmental Protection Agency (EPA) is preparing, for the U.S. Congress, a report evaluating the need to regulate mercury (Hg) emissions from electric utilities. This study, to be completed in 1995, will have important health and economic implications. In support of these efforts, the U.S. Department of Energy, Office of Fossil Energy, sponsored a risk assessment project at Brookhaven National Laboratory (BNL) to evaluate methylmercury (MeHg) hazards independently. In the BNL study, health risks to adults resulting from Hg emissions from a hypothetical 1000 MW{sub e} coal-fired power plant were estimated using probabilistic risk assessment techniques. The approach draws on the extant knowledge in each of the important steps in the calculation chain from emissions to health effects. Estimated results at key points in the chain were compared with actual measurements to help validate the modeled estimates. Two cases were considered: the baseline case (no local impacts), and the impact case (maximum local power-plant impact). The BNL study showed that the effects of emissions of a single power plant may double the background exposures to MeHg resulting from consuming fish obtained from a localized area near the power plant. Many implicit and explicit sources of uncertainty exist in this analysis. Those that appear to be most in need of improvement include data on doses and responses for potentially sensitive subpopulations (e.g., fetal exposures). Rather than considering hypothetical situations, it would also be preferable to assess the risks associated with actual coal-fired power plants and the nearby sensitive water bodies and susceptible subpopulations. Finally, annual total Hg emissions from coal burning and from other anthropogenic sources are still uncertain; this makes it difficult to estimate the effects of U.S. coal burning on global Hg concentration levels, especially over the long term.
Date: May 1, 1994
Creator: Lipfert, F. W.; Moskowitz, P. D.; Fthenakis, V. M.; DePhillips, M. P.; Viren, J. & Saroff, L.
Partner: UNT Libraries Government Documents Department

Safety analysis report for the use of hazardous production materials in photovoltaic applications at the National Renewable Energy Laboratory. Volume 2, Appendices

Description: To ensure the continued safety of SERI`s employees, the community, and the environment, NREL commissioned an internal audit of its photovoltaic operations that used hazardous production materials (HPMS). As a result of this audit, NREL management voluntarily suspended all operations using toxic and/or pyrophoric gases. This suspension affected seven laboratories and ten individual deposition systems. These activities are located in Building 16, which has a permitted occupancy of Group B, Division 2 (B-2). NREL management decided to do the following. (1) Exclude from this SAR all operations which conformed, or could easily be made to conform, to B-2 Occupancy requirements. (2) Include in this SAR all operations that could be made to conform to B-2 Occupancy requirements with special administrative and engineering controls. (3) Move all operations that could not practically be made to conform to B-2 occupancy requirements to alternate locations. In addition to the layered set of administrative and engineering controls set forth in this SAR, a semiquantitative risk analysis was performed on 30 various accident scenarios. Twelve presented only routine risks, while 18 presented low risks. Considering the demonstrated safe operating history of NREL in general and these systems specifically, the nature of the risks identified, and the layered set of administrative and engineering controls, it is clear that this facility falls within the DOE Low Hazard Class. Each operation can restart only after it has passed an Operational Readiness Review, comparing it to the requirements of this SAR, while subsequent safety inspections will ensure future compliance. This document contains the appendices to the NREL safety analysis report.
Date: July 1, 1992
Creator: Crandall, R. S.; Nelson, B. P.; Moskowitz, P. D. & Fthenakis, V. M.
Partner: UNT Libraries Government Documents Department