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Chemical Process Operators: The risks and solutions

As a Chemical Process Operator, your role involves monitoring and guiding chemical reactions and processes that are essential to industrial production. In doing so, you may be exposed to a range of substances that require careful handling and attention to safeguard your health. Among these, certain gases and intermediates, such as 1,3-Butadiene, are of particular concern due to their hazardous and potentially carcinogenic properties.

Exposure to such substances can occur through inhalation or direct contact, leading to both acute effects, such as irritation or dizziness, and long-term risks, including respiratory issues and an elevated risk of certain cancers. Awareness of these occupational hazards is vital to ensure a safe and sustainable working environment.

To minimize potential exposure, it is essential to follow strict safety protocols, ensure effective ventilation and containment systems, and make consistent use of personal protective equipment such as masks, gloves, and protective clothing. By prioritising these preventive measures, you actively contribute to reducing risks and promoting a healthier workplace within chemical process operations.

Note: The CarcCheck is based on data collected for the EU. Therefore, uses of a substance might not be of equal relevance in all member states. The CarcCheck indicates were a carcinogen can potentially be involved or released; exposure potential will also vary in different sectors. Only the risk assessment will show whether this is the case in a real workplace or in a user situation.

Chemical Process Operators:
The risks and solutions

As a Chemical Process Operator, your role involves monitoring and guiding chemical reactions and processes that are essential to industrial production. In doing so, you may be exposed to a range of substances that require careful handling and attention to safeguard your health. Among these, certain gases and intermediates, such as 1,3-Butadiene, are of particular concern due to their hazardous and potentially carcinogenic properties.

Exposure to such substances can occur through inhalation or direct contact, leading to both acute effects, such as irritation or dizziness, and long-term risks, including respiratory issues and an elevated risk of certain cancers. Awareness of these occupational hazards is vital to ensure a safe and sustainable working environment.

To minimize potential exposure, it is essential to follow strict safety protocols, ensure effective ventilation and containment systems, and make consistent use of personal protective equipment such as masks, gloves, and protective clothing. By prioritising these preventive measures, you actively contribute to reducing risks and promoting a healthier workplace within chemical process operations.

Note: The CarcCheck is based on data collected for the EU. Therefore, uses of a substance might not be of equal relevance in all member states. The CarcCheck indicates were a carcinogen can potentially be involved or released; exposure potential will also vary in different sectors. Only the risk assessment will show whether this is the case in a real workplace or in a user situation.

Which carcinogen(s) are present?

The following (process-generated) carcinogens in your occupation could be a potential risk for your health.

1,3-Butadiene
According to the latest estimates, 27,600 workers in the EU are potentially exposed to 1,3-Butadiene (1,3-BD). Data from 1990-1993 indicated that approximately 31,600 workers were exposed. The exposure occurs mainly...
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Chloroprene (2-chloro-1,3-butadiene)
No estimates of current numbers of exposed workers to Chloroprene (2-chloro-1,3-butadiene) in the EU are available. Typically, occupational exposure to chloroprene occurs through inhalation and dermal contact. Chloroprene has a...
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Ethylene dibromide (1,2-dibromoethane)
Available estimates of the number of workers currently exposed to ethylene dibromide (1,2‑dibromoethane) in the EU are very scarce. Approximately 8.000 workers were estimated in 2006 to be exposed to...
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Can the carcinogen(s) or process(es) be replaced?

Substitution is the first and top prevention measure to avoid exposure to carcinogens. The following substances or processes are considered safer alternatives for these carcinogens or represent less exposure potential.

Substitute for: All carcinogens
Recommended
Substitution Support Portal (SUBSPORTplus)
Read more
Substitute for: All carcinogens
EU‑OSHA Dangerous Substances e‑tool
Read more
Substitute for: All carcinogens
Factsheets for identifying and substituting carcinogens
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Are technical prevention measures in place?

Technical measures have to be used first, when substitution was not possible. The first technical measure of choice is the use of a closed, encapsulated system. Various possibilities and technical solutions are available that might be suitable to reduce exposure to as low as technically possible. These risk reduction measures vary in their effectiveness and need to be assessed for your working environment individually.

Furthermore, the following list provides you with general or technically targeted solutions provided by others within your occupation.

Plastics Processing. Injection or molding of thermosets - FAR 35 (FR)
Is a good measure to reduce exposure to: o-Toluidine
Read more (external link)
Plastics Processing. Injection, thermoforming and extrusion of thermoplastics - FAR 36 (FR)
Is a good measure to reduce exposure to: o-Toluidine
Read more (external link)
Self-assessment tool for working with hazardous substances
Is a good measure to reduce exposure to: All carcinogens
Employers are often motivated to minimise the exposure of their employees to hazardous substances, but often don’t know where to start. Therefore, the Dutch Labour Inspectorate has developed an assessment...
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Are organisational prevention measures in place?

Organisational measures can support your exposure reduction strategy. Organisational measures must be used only when substitution was not possible, and all technical measures have been exhausted. Various organisational measures are available that might be suitable to reduce exposure. These risk reduction measures vary in their effectiveness and need to be assessed for your working environment individually.
 
Furthermore, the following list provides you with general or organisational targeted solutions provided by others within your occupation/branch.
Creating Control Guidance Sheets (CGSs)
Recommended
Is a good measure to reduce exposure to: All carcinogens
Control Guidance Sheets (CGSs) are essential tools designed to help employers manage and mitigate the risks associated with exposure to carcinogenic substances in the workplace. These documents serve as practical...
Read more
Managing the risks of carcinogens in the workplace through an educational game
Recommended
Is a good measure to reduce exposure to: All carcinogens
True to the motto ‘You can’t teach an old dog new tricks’ it is necessary to start with integrating activities that raise awareness in primary schools and in vocational educational...
Read more
Basic training module 'Chemicals Hazards at the Workplace'
Is a good measure to reduce exposure to: All carcinogens
...
Read more
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Are limit values in place?

Limit values for carcinogens are one mean to assess the exposure situation and to assess whether minimum requirements are met, or further risk reduction strategies have to be applied. The links provided above can support assessment whether technical and organisational measures have been sufficiently exhausted to minimise exposure. Please be aware that you can also assess internal exposure by biomonitoring.

Independent whether there is an European limit value in place or not, it is mandatory to minimise exposure to carcinogens as low as technically achievable. Please refer to your national legislation how to comply with minimisations duties.

As Chemical Process Operators, the following (process-generated) carcinogens could be a potential risk for your health and the following EU limit values are in place.
1,3-Butadiene EU Limit values
Exposure limit: A BOELV is under preparation
Read more
Chloroprene (2-chloro-1,3-butadiene) EU Limit values
Exposure limit: A BOELV is under preparation
Read more
Ethylene dibromide (1,2-dibromoethane) EU Limit values
Exposure limit: Unknown, but national limits values might apply.
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Is exposure determined?

1,3-Butadiene on the GESTIS substance database.
You should check the likelihood of exposure and route of exposure by checking the GESTIS substance database.
Read more (External link)
Chloroprene (2-chloro-1,3-butadiene) on the GESTIS substance database.
You should check the likelihood of exposure and route of exposure by checking the GESTIS substance database.
Read more (External link)
Ethylene dibromide (1,2-dibromoethane) on the GESTIS substance database.
You should check the likelihood of exposure and route of exposure by checking the GESTIS substance database.
Read more (External link)
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If you come to the conclusion that exposure is likely, there are multiple options to assess your exposure situation.

Descriptions by the occupational prevention organisation or insurances, in practice approved control guidance sheets, REACH exposure scenarios or exposure modelling are further and eligible sources that help assessing the exposure situation as well as by comparing workplace situations. This must be documented in the risk assessment. Finally, if these methods do not allow for a conclusive exposure assessment, exposure measurements with the help of your respective insurance organisation or an external company can be performed.

Furthermore, you might want to check exposure data sources compiled here.

Is personal protective equipment provided?

You should be aware that personal protection equipment (PPE) should be used only after technical and organisational measures have been used to reduce exposure as much as possible.

Furthermore, there are strict rules for the use of PPE. For respiratory protection equipment (RPE), the filter class needs to fit the purpose, the size of the mask needs to fit the individual worker, maximal wearing time needs to be defined and workers need training for correctly equipping/un-equipping RPE.

For dermal protective equipment, adequate glove material and size needs to be assessed. Commonly, there are very rare situation when handling carcinogens, that PPE is not necessary to fulfil minimisation duties. When you decide to not use PPE, this has to be well-documented.

Furthermore, the following list provides you with solutions provided by others:

Plastics Processing. Injection or molding of thermosets - FAR 35 (FR)
Is a good measure to reduce exposure to: 4,4′-Methylenedianiline (MDA), Acrylonitrile, Azodyes, Cadmium compounds, Cobalt compounds, Epichlorohydrine, Isoprene, Lead compounds, Nitrosamines, o-Toluidine, Polycyclic aromatic hydrocarbons (PAHs), Trichloroethylene, Vinyl Chloride
Read more (external link)
Plastics Processing. Injection, thermoforming and extrusion of thermoplastics - FAR 36 (FR)
Is a good measure to reduce exposure to: 4,4′-Methylenedianiline (MDA), Acrylonitrile, Azodyes, Cadmium compounds, Cobalt compounds, Epichlorohydrine, Isoprene, Lead compounds, Nitrosamines, o-Toluidine, Polycyclic aromatic hydrocarbons (PAHs), Trichloroethylene, Vinyl Chloride
Read more (external link)
Short videos on carcinogenic substances and hygiene in the workplace
Is a good measure to reduce exposure to: All carcinogens
The Austrian Workers’ Compensation Board (AUVA) has translated two of their short instructional videos on carcinogenic substances and hygiene in the workplace to English. This way, other countries and organisations...
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Further duties and additional helpful measures

Ensuring the well-being of your employees is further guaranteed by certain duties laid down in the Carcinogens, Mutagens and Reprotoxicants Directive (CMRD). Additionally, other measures have a positive impact on workplace safety and workers health by boosting awareness of all involved actors.

The following list provides support for these important aspects. However, national requirements might deviate from the Directive and therefore, please consult with your national authorities about regulatory requirements for hazardous substances:

  • Performing a risk assessment is mandatory.
  • Instructing and training before workers start a task is mandatory.
  • Documentation of tasks involving carcinogens is mandatory.
  • Offering medical surveillance is mandatory.
  • Organising the chemicals within a substance inventory is regarded as very helpful.
  • Getting ‘external expertise’ from occupational physician or safety experts is regarded as very helpful.
Read more

Your well-being is further guaranteed by certain duties of your employer laid down in the Carcinogens, Mutagens and Reprotoxicants Directive (CMRD). However, it is also important that you act according to i.e. workplace instructions.

  • Performing a risk assessment is mandatory for your employer and serves to identify all potential health risks and install countermeasures to prevent or reduce these risks.
  • You have to be instructed and trained before you start a task. Repetition of training and adaption of operational instructions help you to stay alert to the risks.
  • Should you ever experience health problems that might be work-related even after changing the company or retirement, the documentation duty for tasks involving carcinogens will ensure that you receive recognition for an occupational disease.
  • Offering medical surveillance to you is your employers duty and serves to inform you about potential health risks related to your task.
  • Please be aware that cooperation with your employer is your duty as well. Workplace and personal hygiene protocols (for example, do not carry work clothes home) are one key factor to ensure your health and that of your family and should be followed at any time.
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Relevance

Carcinogens involved

1,3 Butadiene
Chloroprene
Ethylene dibromide
o-Toluidine
Oximes
Pyrocatechol
Volatile Organic Compounds (VOC)

Sector(s) involved

Manufacture of chemicals and chemical products
Manufacture of other chemical products n.e.c. (incl. catalysts)
Manufacture of other organic basic chemicals
Manufacture of paints, varnishes and similar coatings, printing ink and mastics (incl. frits)
Manufacture of pesticides and other agrochemical products
Manufacture of plastics in primary forms
Manufacture of refined petroleum products
Manufacture of refined petroleum products (catalysts)
Manufacture of synthetic rubber in primary forms
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Understand the risks
Know the risks for your occupation

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