How Scientific Discovery Transformed the World, and Led to Global Contamination
EPA's historic drinking water regulations highlight the urgent need to address per- and polyfluoroalkyl substances decades after scientists first warned of their dangers
Abstract
Bottom Line: PFAS "forever chemicals" now contaminate 95-98% of Americans and ecosystems worldwide, linked to cancer and immune dysfunction, because chemical companies hid decades of toxicity research while regulators failed to act. The EPA's 2024 drinking water limits—4 parts per trillion—reflect these chemicals' extreme danger, but implementation has been delayed to 2031 amid industry pressure.
PFAS contamination represents the largest environmental health crisis in modern history. What began as an accidental 1938 discovery of Teflon has become a global catastrophe: these chemicals persist forever in the environment, accumulate in human bodies, and cause serious health effects at extraordinarily low concentrations. Internal documents show DuPont and other manufacturers knew of PFAS toxicity since the 1960s but continued massive environmental releases while suppressing research. Today, PFAS appear in 45% of U.S. tap water, all rainfall globally, and virtually every human blood sample tested. The crisis exemplifies systematic regulatory failure—allowing widespread chemical use before establishing safety—that has created trillion-dollar cleanup costs while companies profit. Comprehensive chemical reform is urgently needed to prevent similar future disasters.
In 1938, a 27-year-old DuPont chemist named Roy J. Plunkett made an accidental discovery that would transform industries—and eventually threaten human health worldwide. While attempting to create safer refrigerants, Plunkett found that tetrafluoroethylene gas in a pressurized cylinder had mysteriously polymerized into a slippery white powder. This substance, later branded as Teflon, possessed seemingly magical properties: it resisted virtually all chemicals, withstood extreme temperatures, and repelled water and oil.
What Plunkett couldn't have foreseen was that the very properties that made his discovery so useful—the strength of carbon-fluorine bonds—would eventually create one of the most pervasive environmental contaminants in history. Today, per- and polyfluoroalkyl substances (PFAS), the chemical family that includes Teflon's production aids, are found in the blood of nearly every person on Earth and in ecosystems from Arctic ice caps to remote mountain springs.
The Chemical Revolution and Its Hidden Costs
The story of PFAS contamination begins with genuine scientific progress. During World War II, Teflon's exceptional resistance to corrosive uranium hexafluoride made it indispensable for the Manhattan Project. Post-war, the chemical industry expanded PFAS applications dramatically, using them in everything from non-stick cookware to waterproof clothing, stain-resistant carpets, and firefighting foams.
Critical to Teflon production was perfluorooctanoic acid (PFOA), also known as C8—a surfactant that allowed the polymerization process to occur safely in water rather than exploding under high pressure. By the 1960s, DuPont and other manufacturers were producing thousands of tons of PFAS annually, with little understanding of their environmental persistence or health effects.
The carbon-fluorine bond, among the strongest in chemistry, that made PFAS so industrially valuable also meant they would persist in the environment virtually forever. Unlike natural organic compounds that bacteria and other organisms can break down, PFAS resist all known biological and chemical degradation processes, earning them the ominous nickname "forever chemicals."
Early Warning Signs Ignored
The first red flags emerged in the 1960s and 1970s. DuPont's own internal studies from 1961 showed that PFOA caused liver abnormalities in rats at doses as low as 1.5 milligrams per kilogram of body weight—making it roughly as toxic as sodium cyanide by some measures. Subsequent company studies found similar effects in dogs and monkeys, with some animals dying from toxic effects to multiple organ systems.
In 1975, researchers examining fluoride levels in American blood samples discovered unexpected organic fluorine compounds that didn't correlate with water fluoridation patterns. When they approached 3M about these findings, the company initially pleaded ignorance before internal analysis confirmed the chemicals matched their PFAS products. However, 3M chose not to inform the researchers of this match, keeping the contamination secret.
Meanwhile, DuPont's own testing revealed that workers at their Washington Works plant in Parkersburg, West Virginia, had PFAS blood levels 1,000 times higher than the general population. Medical records showed many workers exhibited signs of liver disease. Despite this evidence, the company continued dumping approximately 10 tons of PFOA into the Ohio River annually while publicly claiming their operations posed no environmental threat.
The Whistleblower's Discovery
The corporate veil of secrecy began to crack in the 1990s when Earl Tennant, a cattle farmer near DuPont's Washington Works facility, noticed his livestock were dying under mysterious circumstances. The animals exhibited tumors, blackened teeth, and other abnormalities, often found standing in white foam flowing from a pipe marked with DuPont's name.
Attorney Rob Bilott, initially representing DuPont in other matters, took on Tennant's case and uncovered a trove of internal company documents revealing decades of environmental contamination and health studies that were never shared with regulators or the public. The documents showed that DuPont had established its own "safe" drinking water level for PFOA—one part per billion—while allowing contamination in nearby communities to reach 1,600 parts per billion.
Bilott's investigation revealed that by 2000, PFAS contamination had become truly global. Blood samples from thousands of Americans across the country showed 100% tested positive for PFAS, with average levels of five parts per billion—far above what DuPont privately considered safe.
The Science Emerges
A landmark health study of 69,000 residents near the Washington Works plant, completed in 2013, provided the first definitive evidence linking PFOA exposure to human disease. An independent science panel found "probable links" between PFOA and six conditions: kidney cancer, testicular cancer, thyroid disease, ulcerative colitis, high cholesterol, and pregnancy-induced hypertension.
The study revealed that people with PFOA blood levels above 30 parts per billion had roughly double the risk of developing kidney cancer compared to the general population—a significant finding given that Americans at the time averaged 28 parts per billion. These conclusions likely underestimated the true health impact, as the analysis only included survivors and excluded those who may have already died from PFAS-related diseases.
Recent Scientific Developments
Research into PFAS health effects has accelerated dramatically in recent years. A 2024 study published in eBioMedicine found that higher PFAS exposure was associated with a 31% increased risk of developing Type 2 diabetes, adding to mounting evidence of metabolic disruption. The National Academies of Sciences 2022 comprehensive review concluded that PFAS exposure below two parts per billion in blood should pose minimal harm, but levels between 2-20 parts per billion create potential health risks, with higher levels posing even greater danger.
A major 2023 U.S. Geological Survey study found that at least 45% of American tap water contains detectable PFAS, with higher concentrations typically found in urban areas near potential sources like airports, military bases, and industrial facilities. Global studies reveal the contamination extends far beyond the United States—PFAS now contaminate surface and groundwater worldwide, often exceeding safe drinking water guidelines even in pristine wilderness areas.
Perhaps most troubling, recent research indicates that current rainfall contains unsafe levels of at least four PFAS species virtually everywhere on Earth. Even precipitation over the remote Tibetan Plateau carries PFAS contamination, demonstrating the truly global scope of the problem.
Corporate Shell Games
As scientific evidence mounted against PFOA in the 2000s, DuPont and other manufacturers engaged in what critics describe as a "chemical shell game." In 2006, facing regulatory pressure, DuPont agreed to phase out PFOA by 2015. However, the company simultaneously began producing GenX (HFPO-DA), a shorter-chain replacement chemical.
When DuPont spun off its fluorochemicals division to create Chemours in 2015, GenX production continued at the same facilities. Subsequent studies revealed that GenX caused the same three types of tumors in laboratory animals as PFOA—liver, testicular, and pancreatic cancers. Moreover, GenX's shorter molecular structure made it more mobile in the environment, potentially contaminating larger areas than its predecessor.
This pattern has repeated across the industry. As regulations target specific PFAS, manufacturers simply develop new variants—sometimes changing just a single carbon atom—that fall outside existing restrictions. Today, more than 14,000 distinct PFAS chemicals are in use, with new ones regularly entering the market before their safety has been established.
Regulatory Response
The regulatory response to PFAS contamination has been painfully slow. It wasn't until April 2024 that the U.S. Environmental Protection Agency finalized the first enforceable federal drinking water standards for PFAS, setting limits of 4 parts per trillion for PFOA and PFOS—dramatically lower than DuPont's original "safe" level of one billion parts per trillion.
The new EPA standards also establish limits for four additional PFAS: PFNA, PFHxS, GenX, and PFBS at 10 parts per trillion each, along with a mixture limit for combinations of these chemicals. Water utilities have until 2027 to begin monitoring and until 2029 to implement treatment systems if levels exceed these standards.
However, the regulatory landscape remains in flux. In May 2025, the new EPA administrator announced delays to the implementation timeline for PFOA and PFOS standards, extending compliance deadlines from 2029 to 2031. The agency also indicated it would reconsider regulations for the four other PFAS chemicals, creating uncertainty about future protections.
Current Exposure and Treatment
Today, PFAS exposure occurs primarily through three pathways: contaminated drinking water, food packaging and products, and occupational contact. While consumer products like non-stick cookware receive significant media attention, the actual Teflon coating poses minimal risk since the large polymer molecules cannot enter the bloodstream. The greater concern lies with processing aids and shorter-chain PFAS that can migrate from packaging into food and water.
Personal blood testing reveals the ubiquity of contamination. Testing of the video's narrator showed PFAS levels of 17.92 parts per billion—more than double the U.S. median and approaching levels where health monitoring is recommended. Elevated levels of PFOS (8.93 ppb vs. 4.3 ppb average) and PFHxS (nearly 7 ppb vs. 1 ppb average) suggested historical exposure to products containing these chemicals.
Current treatment options for PFAS-contaminated water include granular activated carbon, reverse osmosis, and ion exchange systems. For individuals, donating blood or plasma may help reduce body burden—a 2022 study of firefighters found that regular blood donations reduced PFAS levels by up to 30% within a year.
Looking Forward
The PFAS crisis illustrates fundamental problems with chemical regulation. Unlike pharmaceuticals, which undergo extensive testing before approval, industrial chemicals often enter widespread use based on limited safety data. By the time health effects become apparent, contamination may be irreversible.
Current efforts focus on developing PFAS-free alternatives for essential applications while eliminating unnecessary uses in consumer products. A 2025 database identified over 530 potential alternatives for PFAS applications, though 83 applications still lack suitable replacements, particularly in industrial processes.
The cost of PFAS contamination to society has been estimated at $17.5 trillion annually, while manufacturers earn approximately $4 billion in profits from PFAS production. This massive imbalance between social costs and private benefits underscores the need for comprehensive regulatory reform that evaluates chemicals' full lifecycle impacts before they enter commerce.
Sidebar: San Diego's Water Conundrum
How one city exemplifies the challenges facing water utilities nationwide
San Diego's struggle with PFAS contamination illustrates the complex decisions water utilities face as regulations tighten and cleanup costs soar. The city confronts PFAS from multiple sources: military bases where firefighting foams were used extensively, industrial facilities, and imported water from increasingly contaminated regional supplies.
Recent testing revealed elevated PFAS levels in the Sweetwater Reservoir, which supplies 200,000 residents in South County communities. Sweetwater Authority officials face stark choices: install treatment systems costing at least $40 million, purchase replacement water for up to $10 million annually, or potentially decommission the reservoir entirely.
The contamination particularly affects military communities. PFAS levels at nearby bases including Camp Pendleton, Coronado, and Twentynine Palms ranged from 35 to 650 parts per trillion—well above the 70 ppt level health agencies previously considered unsafe and far exceeding the EPA's new 4 ppt standard.
A Silver Lining in Wastewater
Paradoxically, San Diego's ambitious Pure Water program—a $5 billion wastewater recycling initiative—may actually help solve the PFAS problem rather than worsen it. The program uses advanced treatment including reverse osmosis, which removes up to 99% of PFAS compounds from wastewater before converting it to drinking water.
"The calculus on PFAS treatment is different in potable reuse, in which cost- and energy-intensive processes are the norm," notes water treatment research. While conventional water sources become increasingly contaminated, advanced wastewater treatment can produce water cleaner than many natural supplies.
The city has filed lawsuits against more than 20 companies including 3M, DuPont, and Raytheon, seeking to recover cleanup costs from manufacturers who allegedly concealed knowledge of PFAS dangers for decades. The litigation states that PFAS have been detected in wastewater from both the Point Loma and South Bay treatment plants.
San Diego's situation reflects a nationwide challenge: water utilities must invest billions to remove chemicals they didn't create while manufacturers who profited from PFAS production face limited financial liability. The city's dual approach—advanced treatment technology combined with legal action against polluters—may become a model for other communities grappling with forever chemical contamination.
Sidebar: Breakthrough Technologies to Destroy Forever Chemicals
Scientists race to develop methods that permanently eliminate PFAS rather than just moving them around
While conventional PFAS treatment simply captures and concentrates these chemicals, breakthrough technologies aim to permanently destroy them by breaking the ultra-strong carbon-fluorine bonds that make them "forever." Here are the most promising approaches emerging from laboratories worldwide:
Heat and Pressure Methods
The most advanced destruction technologies use extreme heat and pressure to force PFAS molecules apart. General Atomics' PERSES system utilizes industrial Supercritical Water Oxidation (iSCWO) technology, operating at 4000 psi and 650°C to ensure high destruction efficiency of organic materials. Under these conditions, organic materials, oxidation reactants, and oxidation products are rendered miscible in water, allowing complete oxidation to take place at a high rate. The EPA issued a detailed report documenting test results and verifying GA-EMS' commercial industrial Supercritical Water Oxidation (iSCWO) system's effectiveness in the destruction of per-and polyfluoroalkyl substances (PFAS) with a destruction efficiency greater than 99.99%. This represents the first EPA-verified commercial PFAS destruction technology.
Hydrothermal alkaline treatment, or HALT, involves adding a low-cost chemical reagent such as sodium hydroxide to superheated liquid water. The technology, which researchers have compared to a "pressure cooker on steroids," has been licensed by a company headquartered in Tacoma, Washington.
The PERSES waste destruction process results in the breakdown of waste into benign byproducts including carbon dioxide, water, and salts, all of which can be safely released into existing treatment works, into the environment, or reused for other industrial purposes.
Light-Based Destruction
Ultraviolet light technologies show particular promise for on-site treatment. When these micelles are exposed to ultraviolet light, they generate a highly reactive electron, which acts like a hammer to break the stubborn carbon-fluoride bonds in the PFAS particles. The process, called micelle-accelerated photoactivated reductive defluorination, traps PFAS in bubble-like molecular structures before destroying them.
Michigan State University researchers developed a UV-based system that "can attack any carbon-fluorine bond" across a broad spectrum of PFAS compounds. The technology has been licensed for commercial development.
Plasma and Sound Wave Technologies
Emerging approaches explore exotic physics to break PFAS bonds. Plasma-based systems generate high-energy electrons that can cleave carbon-fluorine bonds, though they currently require significant energy input. Researchers are also experimenting with a process that uses sound waves. High-intensity sound waves create small bubbles in a water system or liquid waste stream that can destroy PFAS through cavitation effects.
On-Site Mobile Solutions
The most promising technologies are being designed for deployment at contaminated sites rather than requiring transport to centralized facilities. The company recently received a small business innovation research grant from the NIEHS Superfund Research Program (SRP) to develop an innovative technology to permanently destroy PFAS contaminants in water using mobile treatment units.
General Atomics' PERSES systems are available for installation today and have been successfully tested across multiple waste streams. The iSCWO system's modular, compact footprint allows for convenient on-site installation into existing infrastructure. The system is simple to operate and easy to maintain. Over the past decade, GA-EMS systems have destroyed more than 6 million gallons of waste with greater than 99.99% destruction efficiency across more than 200 different waste types, including highly concentrated PFAS Aqueous Film-Forming Foam (AFFF), diluted groundwater, biosolids, landfill leachate, and filter media like granular activated carbon and resin beads.
Key Challenges
Despite progress, significant hurdles remain. The chemicals also don't always fully break down during attempts at destruction, which can lead to the problematic creation of smaller PFAS or other toxic by-products. Effective technologies must handle thousands of different PFAS compounds with varying properties.
The team also introduced a new energy metric called electrical energy per order of defluorination (EEOD) to fairly compare how efficiently different catalytic systems break fluorine-carbon bonds. Unlike traditional removal metrics, EEOD focuses on true degradation, not just separation.
Market Reality
Most destruction technologies remain in early development stages. However, the most desirable techniques, ideally capable of effective separation and complete PFAS destruction and mineralization, have not progressed beyond bench-scale testing. The race intensifies as regulations tighten and cleanup costs soar, driving demand for permanent solutions to the forever chemical crisis.
Fact-Check Assessment
The video's presentation of the PFAS crisis is largely accurate and well-documented. Key facts align with scientific literature:
- Roy Plunkett's Discovery: The video correctly states Plunkett discovered Teflon accidentally in 1938 at age 27, not 1936 as stated. Historical sources confirm the discovery occurred on April 6, 1938.
- DuPont's Internal Studies: Company documents reveal the extensive toxicological testing described, including the 1961 rat study showing liver effects at 1.5 mg/kg doses.
- Settlement Amounts: The 2017 DuPont/Chemours settlement was indeed $670.7 million for approximately 3,550 cases, not "over $600 million" as stated in the video.
- EPA Water Standards: The April 2024 regulations correctly set limits at 4 parts per trillion for PFOA and PFOS, with 10 ppt limits for four other PFAS.
- Blood Contamination: Studies consistently find PFAS in 95-98% of Americans, supporting the video's claims about ubiquitous exposure.
The video's narrative effectively illustrates how a beneficial scientific discovery evolved into a global environmental crisis through inadequate regulation and corporate secrecy—a cautionary tale for the chemical age.
Sources
- U.S. Environmental Protection Agency. (2024, April 10). Biden-Harris Administration Finalizes First-Ever National Drinking Water Standard to Protect 100M People from PFAS Pollution. https://www.epa.gov/newsreleases/biden-harris-administration-finalizes-first-ever-national-drinking-water-standard
- U.S. Environmental Protection Agency. (2025, May 14). EPA Announces It Will Keep Maximum Contaminant Levels for PFOA, PFOS. https://www.epa.gov/newsreleases/epa-announces-it-will-keep-maximum-contaminant-levels-pfoa-pfos
- Smalling, K.L., et al. (2023). Per- and polyfluoroalkyl substances in drinking water from U.S. Geological Survey monitoring. Science of the Total Environment, 881, 163258. https://www.usgs.gov/news/national-news-release/tap-water-study-detects-pfas-forever-chemicals-across-us
- Ackerman Grunfeld, D., et al. (2024). Underestimated burden of per- and polyfluoroalkyl substances in global surface waters and groundwaters. Nature Geoscience, 17, 340-346. https://www.sciencedaily.com/releases/2024/04/240408130619.htm
- Midya, V., et al. (2024). Per- and polyfluoroalkyl substance exposure and Type 2 diabetes risk. eBioMedicine, 106, 105242. https://www.military.com/daily-news/2025/07/23/study-finds-pfas-forever-chemicals-linked-type-2-diabetes.html
- National Academies of Sciences, Engineering, and Medicine. (2022). Guidance on PFAS Exposure, Testing, and Clinical Follow-Up. The National Academies Press. https://doi.org/10.17226/26156
- Environmental and Energy Law Program, Harvard Law School. (2025). PFAS in Drinking Water. https://eelp.law.harvard.edu/tracker/pfas-in-drinking-water/
- DuPont. (2017, February 13). DuPont reaches global settlement of multi-district PFOA litigation. https://www.dupont.com/news/dupont-reaches-global-settlement-of-multi-district-pfoa-litigation.html
- Science History Institute. (2016). Roy J. Plunkett. https://www.sciencehistory.org/education/scientific-biographies/roy-j-plunkett/
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- Environmental and Energy Law Program. (2024). The State of PFAS Forever Chemicals in America. https://www.eesi.org/papers/view/issue-brief-the-state-of-pfas-forever-chemicals-in-america-2024
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- How One Company Secretly Poisoned The Planet - YouTube