The importance of pyrophoric safety precautions in laboratories, manufacturing plants, and other workplaces cannot be understated. While pyrophoric materials have wide-reaching commercial and industrial applications, they pose a significant threat to the health and safety of workers.

Exposure to air or water can trigger violent chemical reactions that include flash fires and explosions. Adding to the risk, skin contact and the inhalation of these toxins can result in compromised internal organs. Industry leaders would be well served to review the safety precautions and best practices associated with pyrophoric materials in the workplace.

What are Pyrophoric Materials?

This class of industrial materials can spontaneously combust when exposed to air, leading to explosions and fires. Derived from the Greek term for fire, “pyro,” materials that fall into this category possess unique qualities that make them a top choice in wide-reaching industries.

However, they are so inherently dangerous that even contact with water can trigger a chemical reaction. These are pyrophoric materials and their common uses.

  • Alkyl Lithium Compounds:This group is commonly used in organic synthesis.
  • Arsine: Used in the production of semi-conductors, arsine is both highly combustible and toxic. It is a combination of sometimes deadly arsenic and hydrogen.
  • Grignard Reagents:They are widely used in the formation of carbon-carbon bonds that produce alcohol.
  • Metal Powders:A variety of sharply divided metals such as aluminum, zinc, titanium, magnesium and iron are considered pyrophoric materials.
  • Hydrides: These materials have been adopted by industries to facilitate hydrogen gas storage for power cells that present an alternative to engines that use fossil fuels.
  • Phosphines: This colorless gas is used in fumigation processes for pest control. It also has applications in agricultural storage and manufacturing semi-conductors.
  • Silanes: Considered a coupling agent, silanes are common materials that improve the adhesion and bonding of organic and inorganic materials. They help develop dental materials, composites, and coatings, among others.
  • Iron Pentacarbonyl:This metal carbonyl continues to be used in the magnetic parts of high-frequency coils in modern radar materials and televisions.
  • Nickel Tetracarbonyl: This metal carbonyl, with a pyrophoric aspect, has applications in creating highly pure nickel.
  • White Phosphorus: This highly reactive material can ignite when coming into contact with air. Its most famous use is in creating military smoke screens.

It’s essential to understand that extreme pyrophoric safety precautions are necessary when handling or storing materials in this class. They are all defined by their ability to ignite even with passive contact with air and water. Pyrophoric materials also pose significant health hazards due to varying toxicity levels.

What Health and Safety Hazards are Associated with Pyrophoric Materials?

When controlled, handled, and stored properly, pyrophoric materials do not necessarily present a health and safety concern for workers. When something allows these materials to release harmful gases around workers, the materials threaten their health and life. These rank among the ways pyrophoric materials put everyday people at risk.

Spontaneous Ignition

The threat of fire or explosion means that plant workers who store, transport, or use pyrophoric materials for manufacturing remain in constant danger. Adding to the health and safety risk, many of these materials are dissolved in other flammable solvents, making burns a massive concern.

Chemical Reactions

Water, even moisture, can trigger a chemical reaction, producing sudden and intense heat. When these and other chemical reactions occur, the heat throw can ignite other items in close proximity and severely burn unprotected workers.

Fume Inhalation

The vapors released present a health hazard. They can be inhaled into the lungs, introducing toxins into the body. These materials have been linked to kidney and liver disease, along with lung damage.

Handling Pyrophoric Materials: Best Practices

The Occupational Safety and Health Administration (OSHA) defines pyrophoric materials as chemicals that ignite spontaneously at 130 degrees Fahrenheit or hotter.

Under OSHA’s Hazard Communication Standard (1910.1200), guidelines are established for the proper storage and handling of these highly volatile and toxic materials. These are ways employers can minimize the risk of ignition and workplace injuries and ailments.

  • Fume Elimination: A ventilation hood with a low sash can be positioned above areas where pyrophoric materials are being used or stored. Safely moving vapors away from heat sources and workers enhances safety.
  • Glove Box:Handling pyrophoric materials in an inert environment reduces the risk of fire, explosion, and chemical reactions. A glove box filled with argon or nitrogen is recommended for syringe disposal. This method minimizes the risk of air contact.
  • Dry Glassware: The glassware used in conjunction with pyrophoric materials should be oven-dried and completely free of any moisture.
  • Transfer Method: Safety dictates that making a greater number of materials transfers typically proves safer than making fewer, high quantity moves. This stems from the volatility of the materials and reduces the likelihood of a spill or skin contact.

All personnel tasked with storing, handling, or disposing of these compounds need to fully appreciate and follow stringent pyrophoric safety precautions. Mislabeling containers, storing vats near windows, or transporting materials in an unsafe manner can have disastrous consequences.

The same holds true for people working with small quantities in laboratories. Skin contact, inhalation, and improper disposal put unsuspecting co-workers in danger.

Emergency Pyrophoric Safety Precautions and Response

In the event physical contact with pyrophoric materials occurs, it’s critical to take immediate precautionary measures. If one or more of these compounds make skin contact, thoroughly and repeatedly rinse the affected area with water.

The same holds true of a chemical reaction resulting in a flash fire that caused a skin burn. Consider rinsing the impacted skin for upwards of 20 minutes. These are other emergency precautions and responses.

Stop-Drop-and-Roll

Fire and explosions are among the greatest pyrophoric safety risks. People who — mistakenly — wear street attire or disposable protective clothing that isn’t fire retardant are advised to drop to the ground and roll over until the burning area is smothered.

Evacuation

Because pyrophoric materials are often colorless and sometimes difficult to detect through the sense of smell, it may be safer to evacuate the facility as a precautionary measure. Only after safety professionals deem the space safe should workers resume their duties.

Anytime such hazardous or toxic substances land on PPE or disposable personal protective clothing, workers should remove and replace the items. Organizations that utilize these and other potentially harmful materials usually provide workers with safe and secure changing spaces.

One area is used for removing and disposing of PPE properly. After washing, staff members proceed to a separate location where they can don street clothes and exit the building.

Pyrophoric Materials Protective Clothing Options

The PPE and disposable protective clothing required for the safe handling and storage of pyrophoric materials must possess high-quality chemical splash resistance and prevent seepage. By providing workers with a comprehensive inventory of the following protective clothing for pyrophoric materials, incidents and injuries can be prevented.

  • Gloves: Splash-resistant gloves should be worn in laboratories, storage areas, and during transport.
  • Coveralls: Chemical splash coveralls are perhaps the best protection against skin burns to the extremities and torso. Some industry-leading protective clothing lines offer coveralls with hoodies and attachable options. It’s essential to use certified products that resist seepage with features like taped seams and / or a storm flap zipper cover.
  • Eye Protection: Face shields and goggles are considered standard protection in work environments that use harsh and dangerous chemicals. 
  • Respirators:Depending on proximity and process, respirators with high-quality filters may be necessary. In some settings, breathable masks may be acceptable.
  • Footwear Coverings: People working in laboratories typically use slip-on shoe coverings to prevent cross-contamination or burns to the feet. Workers who use relatively large quantities of pyrophoric materials may be best served wearing thick rubber boots.