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Airborne nanoparticles released during the synthesis of single-walled and multi-walled carbon nanotubes were measured and characterized. This study reported the field measurements during the development of carbon nanotube production. Monitoring data were taken and the sampling methods to characterize aerosol release were developed along with the modification of carbon nanotube production in a time period from 2006 to 2009. Particle number concentrations for diameters from 5 nm to 20 microm were measured using the fast mobility particle sizer and the aerodynamic particle sizer; the particles released from the furnace were found to be less than 500 nm in diameter. The morphology and elemental composition of the released nanoparticles were characterized by scanning and transmission electron microscopy and energy dispersive spectroscopy. Different operating conditions of multi-walled carbon nanotubes (MWCNT) production were studied to evaluate their effects on the number and morphology of aerosol particles, and the number of particles released. Carbon nanotube filaments and carbon particles in clusters were found among the released aerosol particles during production of multiwalled carbon nanotubes.

Polymer nanocomposites, which contain nanoparticles dispersed in a polymer matrix, provide improved properties at low filler loadings. These materials are already produced commercially, with twin-screw extrusion being the preferred process for compounding the nanoparticles and polymer melts. Several recent studies have demonstrated that nanoparticles can enter the body through inhalation, but the risk assessments for nanoparticle exposures are incomplete. Recently, concerns had been expressed that airborne nanoparticles released during compounding might present significant exposure to extruder operators. To assess the impact of the nanoparticles during twin-screw compounding of nanocomposites, researchers with experience in occupational and environmental health and polymer manufacturing monitored the compounding process for a model nanoalumina-containing nanocomposite using a TSI Fast Mobility Particle Spectrometer (FMPS). FMPS measurements were taken at background locations, source locations, and operators' breathing zones. In parallel to the FMPS real time measurement, airborne nanoparticles were collected using polycarbonate filters fitted with filmed grids driven by a personal air sampling pump. Filter samples were analyzed for particle morphology and elemental composition, and the results were found to be in good agreement with particle measurements by FMPS. Engineering controls and administrative controls were applied to reduce particle release from the compounding process and other operations in the laboratory. The administrative controls dramatically eliminated nanoparticles in the laboratory air, reducing total concentration by as much as 53 000 particles/cm3. Engineering controls were investigated and significant reductions of particle release were attained. The primary solution to reduce exposure level of nanoalumina is to isolate the releasing source. Overall, the engineering controls and administrative controls were effective in reducing airborne nanoparticle release during compounding.

Tsai et al. (Airborne nanoparticle exposures associated with the manual handling of nanoalumina and nanosilver in fume hoods. J Nanopart Res 2009; 11: 147-61) found that the handling of dry nanoalumina and nanosilver inside laboratory fume hoods can cause a significant release of airborne nanoparticles from the hood. Hood design affects the magnitude of release. With traditionally designed fume hoods, the airflow moves horizontally toward the hood cupboard; the turbulent airflow formed in the worker wake region interacts with the vortex in the constant-flow fume hood and this can cause nanoparticles to be carried out with the circulating airflow. Airborne particle concentrations were measured for three hood designs (constant-flow, constant-velocity, and air-curtain hoods) using manual handling of nanoalumina particles. The hood operator's airborne nanoparticle breathing zone exposure was measured over the size range from 5 nm to 20 mum. Experiments showed that the exposure magnitude for a constant-flow hood had high variability. The results for the constant-velocity hood varied by operating conditions, but were usually very low. The performance of the air-curtain hood, a new design with significantly different airflow pattern from traditional hoods, was consistent under all operating conditions and release was barely detected. Fog tests showed more intense turbulent airflow in traditional hoods and that the downward airflow from the double-layered sash to the suction slot of the air-curtain hood did not cause turbulence seen in other hoods.