Polychlorinated Biphenyl - History

History

In 1865 the first "PCB-like" chemical was discovered, and was found to be a byproduct of coal tar. Years later in 1881, German chemists synthesized the first PCB in a laboratory. From the initial synthesis of PCB until 1914, large amounts of PCB were released into the environment, to the extent that there are still measurable amounts of PCB in feathers of birds currently held in museums.

PCBs, originally termed "chlorinated diphenyls," were commercially produced as complex mixtures containing multiple isomers at different degrees of chlorination. In the United States, commercial production of PCBs was taken over in 1929 by Monsanto Company from Swann Chemical Company. Manufacturing levels increased in response to the electrical industry's need for a safer (than flammable mineral oil) cooling and insulating fluid for industrial transformers and capacitors. PCBs were also commonly used as stabilizing additives in the manufacture of flexible PVC coatings for electrical wiring and electronic components to enhance the heat and fire resistance of the PVC.

The toxicity associated with PCBs and other chlorinated hydrocarbons, including polychlorinated naphthalenes, was recognized very early due to a variety of industrial incidents. Between 1936 and 1937, there were several medical cases and papers released on the possible link between PCBs and its detrimental health effects. One of the earlier cases in 1936 described an incident where a U.S. Public Health Service official described a wife and child of a worker from the Monsanto Industrial Chemical Company who exhibited blackheads and pustules on their skin. The official attributed these symptoms to contact with the worker's clothing after he returned from work. A conference about the hazards was organized at Harvard School of Public Health in 1937, and a number of publications referring to the toxicity of various chlorinated hydrocarbons were published before 1940. Robert Brown reminded chemists in 1947 that Arochlors were "objectionably toxic. Thus the maximum permissible concentration for an 8-hr. day is 1 mg/m3 of air. They also produce a serious and disfiguring dermatitis". However, PCB manufacture and use continued with few restraints until the 1970s.

PCBs are persistent organic pollutants and have entered the environment through both use and disposal. The environmental transport of PCBs is complex and nearly global in scale. The public, legal, and scientific concerns about PCBs arose from research indicating they are likely carcinogens having the potential to adversely impact the environment and, therefore, undesirable as commercial products. Despite active research spanning five decades, extensive regulatory actions, and an effective ban on their production since the 1970s, PCBs still persist in the environment and remain a focus of attention.

The only North American producer, Monsanto Company, marketed PCBs under the trade name Aroclor from 1930 to 1977. These were sold under trade names followed by a 4-digit number. In general, the first two digits refer to the number of carbon atoms in the biphenyl skeleton (for PCBs this is 12); the second two numbers indicate the percentage of chlorine by mass in the mixture. Thus, Aroclor 1260 has 12 carbon atoms and contains 60% chlorine by mass. An exception is Aroclor 1016, which also has 12 carbon atoms, but has 42% chlorine by mass. Different Aroclors were used at different times and for different applications. In electrical equipment manufacturing in the USA, Aroclor 1260 and Aroclor 1254 were the main mixtures used before 1950; Aroclor 1242 was the main mixture used in the 1950s and 1960s until it was phased out in 1971 and replaced by Aroclor 1016.

Manufacture peaked in the 1960s, by which time the electrical industry had lobbied the U.S. Congress to make them mandatory safety equipment. In 1966, they were determined by Swedish chemist Dr. Soren Jensen to be an environmental contaminant, and it was Dr. Jensen, according to a 1994 article in Sierra, who named them PCBs. Previously, they had simply been called "phenols" or referred to by various trade names, such as Aroclor, Kennechlor, Pyrenol, Chlorinol and others.

Their commercial utility was based largely on their chemical stability, including low flammability, and desirable physical properties, including electrical insulating properties. Their chemical and physical stability has also been responsible for their continuing persistence in the environment, and the lingering interest decades after regulations were imposed to control environmental contamination.

In 1972, PCB production plants existed in Austria, the then Federal Republic of Germany, France, Great Britain, Italy, Japan, Spain, USSR, and USA.

In 1973, the use of PCBs was banned in "open" or "dissipative" sources, such as:

• Plasticisers in paints and cements
• Casting agents
• Fire retardant fabric treatments and heat stabilizing additives for PVC electrical insulation
• Adhesives
• Paints and water-proofing
• Railway sleepers

However, they continued to be allowed in "totally enclosed uses" such as transformers and capacitors, which, in certain failure modes or out-of-specification conditions, can leak, catch fire, or explode. It was Ward B. Stone of the New York State Department of Environmental Conservation (NYSDEC) who first published his findings in the early 1970s that PCBs were leaking from transformers and had contaminated the soil at the bottom of utility poles. Concern over the toxicity and persistence (chemical stability) of PCBs in the environment led the United States Congress to ban their domestic production in 1979, although some use continues in closed systems such as capacitors and transformers.

"Enclosed uses" of PCBs include:

• Capacitors
• Insulating fluids in transformers
• Vacuum pump fluids
• Hydraulic fluids

In the UK, closed uses of PCBs in new equipment were banned in 1981, when nearly all UK PCB synthesis ceased, but closed uses in existing equipment containing in excess of 5 litres of PCBs were not stopped until December 2000.

In Japan, PCBs were first produced by Kanegafuchi Chemical Co. Ltd. (Kaneka) in 1954 and production continued until 1972 when the Japanese government banned the production, use, and import of PCBs.

Estimates have put the total global production of PCBs on the order of 1.5 million tons. The United States was the single largest producer with over 600,000 tons produced between 1930 and 1977. The European region follows with nearly 450,000 tons through 1984. It is unlikely that a full inventory of global PCB production will ever be accurately tallied, as there were factories in Poland, East Germany, and Austria that produced unknown amounts of PCBs.