PROJECT DESCRIPTION
BACKGROUND
Formaldehyde is a carcinogenic compound used in the manufacture of resins and adhesives for the treatment of wood products, pulp, paper, glass wool and rock, and for the finishing of plastics and coatings, textiles and insulation. It is also used as a disinfectant and preservative, and as a precursor and industrial additive. As a hazardous substance, the use of formaldehyde is strictly controlled. Formaldehyde is classified in the EU as carcinogenic.
Annual production of formaldehyde in the EU exceeds 3.6 million tonnes, around 22% of worldwide production, according to IHS Markit’s Chemicals Economic Handbook. According to the European Chemical Industry Council, 22 of the current EU28 produce and process formaldehyde, giving rise to the direct employment of 30 000 workers and 100 000 indirectly. Secondary industries, such as the manufacture of chipboard and furniture, employ more than 5 million people. Many other sectors also use formaldehyde.
Formaldehyde is a colourless gas at room temperature and is soluble in water. It is characterised by its high reactivity, toxicity and capacity to cause irritation to the mucous membrane, resulting in breathing difficulties. If exposure is high, there is a risk of pulmonary enema and pneumonitis. Ingestion can be fatal while long-term, low-level exposure can cause respiratory complications.
OBJECTIVES
The main objective of the SENSSEI project was to minimise environmental and health impacts linked to occupational exposure to formaldehyde in various sectors, especially through indoor air concentrations. The project planned to develop and demonstrate a real-time formaldehyde monitoring and alarm system to be tested in the timber industry. The system would consist of:
- A detection unit that operates continuously in the factory, retrieving formaldehyde samples;
- A process unit that analyses formaldehyde concentration levels;
- An alarm unit, which is triggered when formaldehyde concentration limits are exceeded; and
- A data storage and business intelligence unit, which enables analysis of the collected data (coloured maps, operation reports, statistics, etc.).
Data from the monitoring system would be used to develop new health protection strategies and protocols for industry. In addition, the project planned to develop a series of methodological guidelines to underpin the replication of the approach in three other sectors: tyre manufacturing, the automotive industry and hospitals.
The project would contribute towards the implementation of the EU Safety and Health at Work Directive and the Industrial Emissions Directive, and its results would help update Best Available Techniques Reference Documents (BREFs) for the production of wood-based panels, surface treatment using organic solvents and the production of pulp, paper and cardboard.
RESULTS
The LIFE SENSSEI project developed a system for managing and monitoring levels of formaldehyde in order to reduce the exposure of workers in the timber sector to carcinogens. It developed a sensor that measures levels of formaldehyde in different areas of a timber plant continuously and in real time. However, the project did not succeed in reducing levels by 80% as planned.
The project was nevertheless able to demonstrate that it is possible to improve the early detection of formaldehyde levels compared to traditional mechanisms. Such early detection allows companies to develop more effective control mechanisms and to reduce the risk of contamination.
Finally, the sensor has great potential for replication and transferability, although some aspects of the prototype must be improved. The project coordinator has developed a five-year Business Plan, in order to adapt the solution to the company’s well-defined market strategy. The commercialisation of the prototype has been proposed as a service, made up of three basic components: Prevention advice, distribution of the product and technical Support; with three operational models (own, mixed and outsourced).
