Here's something actually relevant on the safety of inhaling diacetyl (vs. just eating or drinking it). I found this by following the links in the footnotes from the OSHA document referenced earlier in this thread.
http://www.toxicology.org/AI/Pub/tox/2004Tox.pdf
pp. 439
2127 INHALATION TOXICITY OF THE FLAVORING AGENT,
DIACETYL (2, 3-BUTANEDIONE), IN THE UPPER
RESPIRATORY TRACT OF RATS.
A. F. Hubbs, L. A. Battelli, R. R. Mercer, M. Kashon, S. Friend, D. Schwegler-
Berry and W. T. Goldsmith. HELD, NIOSH, Morgantown, WV. Sponsor: D.
Porter.
Diacetyl (2, 3-butanedione) is a diketone found naturally in foods such as butter
and generally recognized as safe for use in low concentrations as a food additive.
Diacetyl imparts the odor and flavor of butter to foods and also has industrial applications.
Recently, an increased prevalence of fixed airways obstruction was reported
in workers at a microwave popcorn plant and the lung disease correlated
SOT 2004 ANNUAL MEETING 439
with diacetyl exposure. In a previous study, inhalation of diacetyl-containing artificial
butter flavoring caused necrosis of the nasal, bronchial, and bronchiolar epithelium
in rats. We have now investigated the hypothesis that inhalation of diacetyl
produces epithelial injury. Therefore, male Sprague-Dawley rats were exposed in a
whole-body inhalation chamber for 6 hours to 0, 99.3 ± 0.07, 198.4 ± 0.10, or
294.6 ± 0.20 ppm diacetyl and euthanized the next day. Four levels of nose, three
levels of trachea, and two lung sections were examined by light microscopy. In addition,
the nose was examined by transmission electron microscopy (TEM) and the
trachea was examined by TEM and scanning electron microscopy (SEM). At 198.4
ppm or higher, diacetyl inhalation resulted in significant necrosis of nasal epithelium
with associated neutrophilic inflammation. At 294.6 ppm, diacetyl inhalation
also caused significant necrosis of tracheal epithelium with associated neutrophilic
inflammation. By SEM, diacetyl-induced tracheal changes included multifocal denuding
of basement membrane with cell swelling, loss of microvilli, and loss of ciliated
cells in the remaining epithelium. By TEM, tracheal changes included epithelial
necrosis, denuded basement membrane, and elongation of epithelial cells near
foci of exposed basement membrane. Diacetyl did not produce significant changes
in the lung under these exposure conditions.
These findings suggest that acute exposure
to diacetyl alone is sufficient to cause upper respiratory tract epithelial
necrosis in rats at concentrations of 198.4 ppm or higher.
So, 198 ppm (parts per million) has been established to be a harmful level
when inhaled.
That's about .02%, folks.