Cost and Performance Report: Innovative Welding Technologies Using Silicon Additives to Control Hazardous Air Pollutant (HAP) Emissions.

摘要

The welding process results in the formation of high concentrations of nano-sized particles loaded with toxic metals such as hexavalent chromium (Cr6+), nickel (Ni), and manganese (Mn). Welding fumes pose serious health risks to welders because fumes can cause respiratory and neurological ailments as well as cancer. Tightened occupational standards require an exposure reduction of at least 90% that is not satisfied by current control technologies. There is also potential public concern about the environmental risks associated with the release of welding fumes into ambient air. The overall objective of this demonstration was to develop an innovative silica precursor technology that can limit the oxidation of chromium by quenching oxygen species and coating metal particles in welding fumes with a thin, amorphous silica layer. An additional objective was to assess the benefit of increased particle size distribution. The demonstration verified the feasibility and practicality of implementing silica precursor technology into DOD welding operations. Silica precursor technology was demonstrated to be an effective means of controlling metal emissions in welding fumes. The two-fold approach of limiting oxidation potential and coating metal particles with an amorphous silica layer goes beyond previous control technologies by addressing all the toxic metals, regardless of their oxidation state. This project demonstrated, through both a laboratory study and field tests, the benefits of adding silica precursor during the welding process.