What is Ethylene Oxide Used For and Why is it Dangerous? [2025 Guide]

An Overview of Ethylene Oxide (EtO) and Its Industrial Uses

Ethylene oxide (EtO) is a colorless, flammable gas widely utilized in various industrial applications.

EtO is manufactured through processes such as direct oxidation of ethylene gas using oxygen and a silver catalyst.

Historically, it was also made via the chlorohydrin process, which has been largely replaced due to inefficiencies and safety concerns.

Liquid ethylene oxide is highly volatile, contributing to its capacity to disperse into the environment during production and sterilization activities.

Ethylene oxide’s primary use is as a chemical intermediate in the production of other chemicals, notably ethylene glycol, which is essential for manufacturing antifreeze, polyester fibers, and polyethylene terephthalate (PET) plastics.

EtO is also employed in the synthesis of diethylene glycol, glycol ethers, and ethanolamines, which serve as solvents, detergents, and emulsifiers in numerous products.

EtO is also used to produce ethylene dichloride, a precursor for vinyl chloride monomer, and sulfuric acid, a vital industrial chemical.

In the medical field, EtO’s ability to sterilize heat-sensitive equipment makes it indispensable for ensuring the sterility of medical devices.

Ethylene oxide (EtO) is classified as a hazardous substance and a group 1 human carcinogen by the Environmental Protection Agency (EPA) due to its carcinogenic properties.

It is listed under the Toxic Substances Control Act (TSCA) and is regulated to limit emissions from industrial facilities.

The Occupational Safety and Health Administration (OSHA) has established exposure limits to minimize occupational exposure risks.

Despite these measures, community exposure remains a concern, particularly near facilities that emit EtO, due to its potential health hazards.

Industrial Applications of Ethylene Oxide:

• Sterilization of medical equipment: Ensures the sterility of heat-sensitive medical devices.
• Production of ethylene glycol: Used in antifreeze and polyester manufacturing.
• Synthesis of diethylene glycol and glycol ethers: Serve as solvents and in the production of paints and coatings.
• Manufacture of ethanolamines: Utilized in detergents, emulsifiers, and gas treatment.
• Creation of ethylene dichloride: A precursor for PVC plastics.
• Production of sulfuric acid: An essential chemical in various industrial processes.
• Fumigation of spices and cosmetics: Used to eliminate microbial contaminants.
• Production of glycol ethers: Applied in brake fluids, cleaners, and as solvents.

Given its widespread use and potential health risks, understanding EtO’s applications and associated hazards is crucial for both industry professionals and communities.

The Regulatory Framework for Ethylene Oxide (EtO)

Ethylene oxide (EtO) is a highly regulated chemical due to its carcinogenic properties and the environmental risks it poses.

Federal agencies like the Environmental Protection Agency (EPA), the Occupational Safety and Health Administration (OSHA), and state-level environmental protection departments enforce strict guidelines to control EtO emissions and protect public health.

The Environmental Protection Agency (EPA) classifies ethylene oxide as a hazardous air pollutant (HAP) under the Clean Air Act (CAA).

This designation subjects EtO-emitting facilities to stringent emissions controls under the National Emission Standards for Hazardous Air Pollutants (NESHAP).

• NESHAP regulations mandate the use of emissions control technologies, like scrubbers and dry bed systems, to capture and neutralize EtO before it enters the atmosphere.
• Facilities are required to report emissions annually under the Toxic Release Inventory (TRI) program, which tracks the release of hazardous chemicals.
• In 2022, the EPA proposed new amendments to further limit emissions from commercial sterilizers, citing enhanced scientific evidence of EtO’s carcinogenic risks.

The Occupational Safety and Health Administration (OSHA) enforces safety standards to protect workers from ethylene oxide exposure.

OSHA’s Permissible Exposure Limit (PEL) for EtO is set at:

• 1 part per million (ppm) as an 8-hour time-weighted average (TWA).
• 5 ppm as a short-term exposure limit (STEL) for 15-minute periods.
• OSHA also requires the use of personal protective equipment (PPE), regular air monitoring, and medical surveillance for employees working in environments where EtO is present.

Some states have adopted even stricter regulations in response to community concerns.

For instance:

• Illinois EPA: Requires enhanced air monitoring near the Sterigenics Willowbrook facility and mandates periodic reporting of EtO emissions.
• Georgia Environmental Protection Division (GA EPD): Enforces additional emission controls at the Sterigenics Smyrna plant and requires compliance with the state’s air quality regulations.
• California Air Resources Board (CARB): Sets lower EtO emission limits and conducts community air monitoring near sterilization facilities.

Facilities using EtO must regularly report their emissions to the EPA’s TRI program, which publicly discloses data on hazardous air pollutants.

The Agency for Toxic Substances and Disease Registry (ATSDR) also tracks community exposure and assesses long-term health impacts.

Due to the growing body of evidence linking EtO exposure to increased cancer risks, federal agencies are reviewing current standards.

Proposed changes may include:

• Lowering the PELs for occupational exposure.
• Increasing the frequency of air quality monitoring in high-risk areas.
• Expanding community right-to-know programs to ensure residents are informed of potential health risks.
• Facilities that fail to meet regulatory standards face fines, mandatory emission reduction plans, and potential shutdowns.

How Ethylene Oxide Is Used to Sterilize Medical Equipment and Why It Poses a Risk to Communities

Ethylene oxide (EtO) is a potent alkylating agent widely used to sterilize medical equipment and supplies that are sensitive to heat and moisture.

Its molecular properties allow it to disrupt the DNA and protein structures of microorganisms, rendering them inactive and preventing the risk of infection.

This makes EtO particularly effective for sterilizing single-use medical devices, surgical instruments, and complex electronic components that cannot withstand the high temperatures of steam sterilization.

The process relies on EtO’s high vapor pressure, which enables the gas to permeate tightly sealed packaging and reach internal cavities of medical devices.

The EtO Sterilization Process

The EtO sterilization process involves several key steps:

1. Preconditioning: Medical devices are placed in sealed chambers where temperature and humidity are carefully regulated. This stage typically lasts 12 to 24 hours, allowing the materials to acclimate and preventing condensation during sterilization. Preconditioning helps optimize the absorption of EtO during the exposure phase by removing excess moisture that could interfere with the sterilization process.
2. Gas Introduction: Once preconditioned, ethylene oxide gas is introduced into the chamber. EtO is often blended with inert gases such as carbon dioxide or nitrogen to maintain controlled pressure levels and reduce flammability risks. The gas mixture is maintained at specific concentrations, generally ranging from 450 to 1200 mg/L, depending on the equipment and required sterilization strength. EtO’s high vapor pressure allows it to permeate the entire chamber, including tightly sealed packages and device components.
3. Exposure: The exposure phase typically lasts two to six hours, depending on the complexity and density of the items being sterilized. During this time, EtO reacts with the amino acids, proteins, and nucleic acids of microorganisms, breaking down their biological functions. The chemical reaction between EtO and microbial DNA is known as alkylation, which blocks replication and destroys the pathogen’s ability to reproduce. This stage is conducted under tightly regulated temperature (generally 37°C to 63°C) and humidity levels (30-80%) to optimize EtO’s reactivity.
4. Aeration: After exposure, devices undergo aeration to eliminate residual EtO. This is a critical phase, as ethylene oxide residues can be harmful if not properly removed. Aeration occurs in a separate, ventilated chamber where devices are exposed to circulating air, sometimes heated, for 12 hours to several days, depending on the material’s absorption properties. Strict regulatory guidelines set limits for ethylene oxide residue to prevent toxic exposure during use.

This method is particularly effective for sterilizing complex devices, such as catheters, surgical instruments, and electronic equipment, which cannot withstand high-temperature steam sterilization.

Community Exposure to Ethylene Oxide: Long-Term Health Effects and Environmental Impact

Ethylene oxide (EtO) emissions from commercial sterilization facilities are a major source of community exposure.

Unlike industrial settings where workers face direct contact, community exposure occurs through airborne emissions of the colorless gas that travel beyond facility boundaries.

Medical sterilization plants, chemical manufacturing facilities, and other industrial sites emit EtO into the atmosphere during sterilization cycles and aeration phases.

These emissions can occur during the sterilization process or from leaks and venting.

This release allows the gas to disperse into surrounding neighborhoods, where residents may unknowingly inhale contaminated air.

Residential areas, schools, and workplaces within close proximity—typically within a 1 to 5-mile radius—are considered high-risk zones.

Studies have shown that areas within several miles of EtO-emitting facilities may experience elevated concentrations of the gas.

For instance, in Louisiana’s “Cancer Alley,” EtO levels were found to be significantly higher than previously estimated, posing increased cancer risks to nearby communities.

Short-Term Health Effects and Symptoms of EtO Exposure

Acute exposure to ethylene oxide (EtO), particularly at elevated concentrations, can lead to immediate health concerns affecting multiple body systems.

Individuals living near emission sites often report symptoms such as:

• Respiratory System: Inhalation of EtO can cause irritation of the nasal passages, throat, and lungs. In severe cases, this may progress to pulmonary edema, a condition characterized by fluid accumulation in the lungs, leading to difficulty breathing and reduced oxygen exchange.
• Nervous System: Short-term exposure may result in central nervous system depression, manifesting as headaches, dizziness, nausea, fatigue, and lack of coordination.
• Gastrointestinal Tract: Symptoms such as nausea, vomiting, and diarrhea have been reported, often secondary to the neurotoxic effects of EtO rather than direct irritation of the gastrointestinal tract.
• Sensory Irritation: Exposure can lead to eye irritation and skin rashes.

These symptoms are more pronounced in individuals with existing respiratory conditions such as asthma or chronic obstructive pulmonary disease (COPD).

Children, the elderly, and those with compromised immune systems are especially vulnerable to the acute effects of EtO inhalation.

It’s important to note that the threshold for Ethylene Oxide odor is relatively high, meaning that harmful concentrations may be present without a noticeable smell, posing a risk of unrecognized exposure.

Long-Term Health Effects and Conditions Linked to Ethylene Oxide Exposure

Chronic exposure to EtO, even at lower concentrations, has been associated with several serious health outcomes

The long-term health risks of inhalation exposure to EtO are well-documented.

Chronic inhalation of EtO has been linked to various forms of cancer, including:

• Lymphohematopoietic Cancers: An elevated incidence of cancers affecting white blood cells, such as lymphocytic leukemia, non-Hodgkin lymphoma, multiple myeloma, and leukemia, has been observed in populations with prolonged EtO exposure.
• Breast Cancer: Studies have indicated a higher risk of breast cancer mortality among women exposed to EtO over extended periods
• Nervous System Effects: Long-term exposure can lead to peripheral neuropathy, characterized by numbness, tingling, and weakness in the extremities. Additionally, cognitive impairments such as memory loss and difficulty concentrating have been reported.
• Reproductive and Developmental Toxicity: Animal studies have demonstrated that EtO exposure can result in reproductive issues, including miscarriages and developmental defects in offspring.
• Hematological Effects: Exposure has been linked to hematological abnormalities, such as changes in white blood cell counts and hemoglobin levels, potentially impacting the body’s ability to fight infections and transport oxygen.
• Stomach Cancer: Research has shown potential links between chronic EtO exposure and increased risks of stomach cancer, particularly in communities near industrial sterilization plants.
• Pancreatic Cancer: Long-term inhalation of EtO has been associated with an elevated risk of pancreatic cancer, linked to the compound’s genotoxic properties and its ability to damage DNA over time.

Beyond cancer, long-term exposure has been associated with neurological damage, reproductive toxicity, and genetic mutations.

Studies have demonstrated that even low-dose, long-term exposure can lead to DNA damage, cellular mutations, and increased risks of miscarriage and infertility.

Scientific Research on Community Exposure

Scientific studies on community exposure have extensively examined the health impacts on individuals chronically exposed to environmental and chemical hazards.

The National Toxicology Program (NTP), under the National Institute of Environmental Health Sciences (NIEHS), has conducted numerous assessments to evaluate human exposure to various chemicals and their potential health effects.

The NTP’s monograph on fluoride exposure concluded with moderate confidence that higher levels of fluoride are associated with lower IQ in children, though data were insufficient to determine effects at the recommended community water supply level of 0.7 mg/L.

The Environmental Protection Agency (EPA) has established Acute Exposure Guideline Levels (AEGLs) to describe the human health effects of once-in-a-lifetime or rare exposures to airborne chemicals.

These guidelines are crucial for emergency responders dealing with chemical spills or catastrophic exposures.

The National Institute for Occupational Safety and Health (NIOSH) conducts risk assessments to make recommendations for safely working in the presence of chemical hazards, thereby protecting workers who are routinely exposed to chemicals over longer durations.

Biomonitoring studies have been instrumental in assessing human exposure to environmental chemicals.

The Centers for Disease Control and Prevention (CDC) publishes the National Report on Human Exposure to Environmental Chemicals, which provides ongoing assessments of the U.S. population’s exposure using biomonitoring data.

The World Health Organization (WHO) contributes to this field through its Environmental Health Criteria monographs, which provide comprehensive data for establishing safety standards and regulations related to chemical exposures.

Several specific studies have highlighted the health effects of chronic chemical exposures:

• Fluoride Exposure and Neurodevelopment: The NTP found moderate confidence in the association between higher fluoride levels and lower IQ in children, though effects at recommended water levels remain unclear.
• AEGLs for Airborne Chemicals: The EPA’s AEGLs provide guidance on the health effects of acute exposures to airborne chemicals, aiding in emergency response planning.
• Occupational Risk Assessments by NIOSH: NIOSH conducts risk assessments to recommend safe working conditions for workers exposed to chemical hazards.
• CDC’s Biomonitoring Reports: These reports offer data on the U.S. population’s exposure to environmental chemicals, assisting in evaluating public health risks.
• WHO’s Environmental Health Criteria: These monographs provide scientific data for establishing safety standards concerning chemical exposures.

These studies collectively enhance our understanding of the risks associated with environmental and chemical exposures, informing guidelines and policies to protect public health.

Radius of Exposure and Environmental Factors

The radius of exposure to EtO emissions can vary based on multiple environmental factors.

Generally, communities within a 1 to 5-mile radius are at the highest risk, with air modeling showing detectable levels of EtO far beyond facility boundaries.

Wind patterns, atmospheric stability, and local topography all influence how EtO disperses.

For example, higher wind speeds can carry emissions further, while valleys or low-lying areas may trap EtO, leading to prolonged and cumulative exposure.

Ambient air monitoring around facilities like the Sterigenics plant in Smyrna, Georgia, has recorded fluctuating levels of EtO at various distances, underscoring the need for continuous environmental assessments.

Understanding the scope and scale of community exposure to EtO is crucial for assessing health risks and building strong legal claims.

Individuals living near known emission sites may be entitled to compensation if diagnosed with cancer or other serious health conditions linked to EtO exposure.

Ethylene Oxide Exposure Lawsuits: Overview

TorHoerman Law is actively investigating Ethylene Oxide Exposure Lawsuits on behalf of individuals and communities affected by emissions from sterilization facilities across the United States.

Ethylene Oxide Lawsuits focus on allegations that companies like Sterigenics negligently released hazardous levels of EtO, exposing nearby residents and workers to a known carcinogen linked to serious illnesses such as breast cancer, leukemia, and lymphoma.

Communities residing near EtO-emitting facilities, such as those in Willowbrook, Illinois, and Smyrna, Georgia, have reported elevated cancer rates and other health issues attributed to long-term exposure.

TorHoerman Law is committed to holding these companies accountable for failing to adequately control emissions and warn the public about the associated health risks.

We are currently accepting new clients who have been diagnosed with EtO-related illnesses and lived or worked near facilities known for EtO emissions.

If you or a loved one has been affected, our legal team offers free consultations to evaluate your case and discuss potential compensation for medical expenses, lost wages, and other damages.

There are no upfront costs—we only get paid if we win your case.

Contact TorHoerman Law today to learn more about your rights and options regarding Ethylene Oxide Exposure Lawsuits.

You can also use the chat feature on this page to find out if you qualify for an Ethylene Oxide Exposure claim instantly.

Gathering Evidence for an Ethylene Oxide Exposure Lawsuit

To build a strong claim in an Ethylene Oxide (EtO) Exposure Lawsuit, thorough and well-documented evidence is crucial.

This includes proof of exposure, medical documentation linking health conditions to EtO, and records of the facility’s emission history.

Gathering this information helps establish causation and supports claims for compensation.

Evidence for an EtO Exposure Lawsuit:

• Proof of Residence or Employment: Documentation showing proximity to EtO-emitting facilities during critical exposure periods.
• Medical Records: Diagnosis of conditions linked to EtO exposure, such as breast cancer, lymphoma, or leukemia.
• Air Monitoring Data: Records of EtO levels in the air from local environmental reports or community monitoring.
• Facility Emission Records: Documentation of emissions from facilities, including compliance reports and violations.
• EPA and State Reports: Information from the Environmental Protection Agency (EPA) and state agencies on identified high-risk zones.
• Expert Testimonies: Environmental scientists or medical professionals who can link exposure to diagnosed conditions.
• Personal Testimonies: Statements from affected individuals detailing symptoms and experiences.

Damages in Ethylene Oxide Exposure Claims

In a legal claim, damages refer to the financial compensation sought by an individual who has suffered harm or loss due to another party’s negligence or wrongdoing.

For those affected by ethylene oxide (EtO) exposure, damages may include costs related to medical treatment, lost income, emotional suffering, and long-term health complications.

These claims are intended to provide financial relief for both immediate and future expenses tied to health issues caused by toxic exposure.

Types of Damages in Ethylene Oxide Exposure Claims:

• Medical Expenses: Coverage for hospital visits, ongoing treatments, surgeries, medications, and specialized care.
• Lost Wages and Future Earnings: Compensation for time missed from work due to illness, as well as projected loss of income if the condition affects long-term employment.
• Pain and Suffering: Financial relief for physical pain, mental anguish, and decreased quality of life resulting from chronic health conditions.
• Permanent Disability or Impairment: Compensation for life-altering conditions that impact daily functioning and long-term independence.
• Wrongful Death Damages: In cases where EtO exposure leads to death, families may pursue claims for funeral costs, loss of companionship, and financial support.
• Environmental Cleanup Costs: In certain cases, damages may also cover the costs of environmental remediation if contamination has affected residential areas.

Thorough documentation of these damages is crucial for building a strong case and ensuring fair compensation for those affected by EtO exposure.

Past Ethylene Oxide Exposure Lawsuits

Ethylene oxide (EtO) exposure lawsuits have been filed across the United States, with significant legal actions highlighting the dangers of emissions from sterilization facilities and chemical plants.

These lawsuits primarily focus on the harmful health effects linked to EtO exposure, including cancer, neurological damage, and respiratory illnesses.

A number of high-profile cases have set legal precedents, bringing attention to the accountability of companies that release hazardous levels of EtO into surrounding communities.

One of the most notable cases involved the Sterigenics Willowbrook Facility in Illinois.

Residents living near the facility reported unusually high rates of cancer, leading to a surge of lawsuits against Sterigenics for allegedly releasing toxic levels of EtO.

In 2022, a jury awarded $363 million in damages to a plaintiff who claimed that exposure to emissions from the Willowbrook facility caused her breast cancer.

Another lawsuit against the Willowbrook facility was resolved for $408 million, settling 800 individual cases.

This case marked one of the largest verdicts for environmental toxic exposure in recent history.

Lawsuits have been filed in Georgia, Texas, and other states where facilities are known to emit EtO.

Many of these lawsuits cite violations of the Clean Air Act and failures to comply with environmental safety standards.

Plaintiffs argue that companies did not take adequate measures to control emissions or inform communities of the risks associated with long-term EtO exposure.

Beyond individual lawsuits, class-action claims have also emerged, representing entire communities impacted by the toxic emissions.

TorHoerman Law: Investigating Ethylene Oxide Claims

TorHoerman Law is actively investigating claims from individuals and communities exposed to hazardous levels of ethylene oxide (EtO) near commercial sterilization facilities and chemical plants.

Our firm has a long-standing commitment to holding corporations accountable for environmental contamination that leads to severe health consequences.

With significant experience in environmental litigation and toxic exposure cases, we understand EtO Lawsuits and the profound impact exposure can have on individuals and families.

Communities living near facilities in Illinois, Georgia, Texas, California, and others across the United States have experienced elevated cancer rates and other serious health issues linked to EtO emissions.

Our team is dedicated to fighting for those who have suffered from cancer, neurological conditions, and respiratory illnesses due to corporate negligence.

If you or a loved one lived or worked near a facility known for emitting ethylene oxide and have been diagnosed with a related illness, you may be eligible to file an Ethylene Oxide Lawsuit.

At TorHoerman Law, we are committed to seeking justice for those harmed by toxic exposure, working to make sure responsible parties are held accountable for the damage they’ve caused.

Contact TorHoerman Law today for a free consultation or use the chat feature on this page.

Our experienced team is ready to evaluate your case, explain your legal options, and help you pursue the compensation you deserve.

There are no upfront costs—we only get paid if we win your case.