Chemistry Reference
In-Depth Information
workers was 3.8. Workers in chemical manufacturing and in resin manufac-
turing each had 2.4 reportables, about 35% lower than the average for all
industries [3].
One reason for the relatively good safety record of the chemical indus-
try is the focus on training and procedures. Each of the companies that
I have worked for had an emphasis on safety. There were safety committees,
safety inspections, mandatory safety training, and an overall safety culture.
Many things are formalized. For example, new processes undergo a for-
malized Process Hazard Analysis (PHA) conducted by experienced people.
Also, a Hazard and Operability Analysis (HAZOP) is done. Operating
procedures are standardized (SOP) to prevent mishaps.
Inherently Safer Design (ISD) [4] incorporates several safety measures
including the elimination or reduction of the hazard by using less hazardous
materials or conditions or by using process or equipment design features
that reduce either the likelihood or consequence of an incident. The risk is
managed by using process control systems, safety instrumental systems, and
mitigation systems such as sprinklers. Operating procedures, safety rules,
training, emergency response procedures, and management systems are used
to manage risk.
The concept of ISD is not new; it was introduced in the 1970s by Trevor
Kletz [5]. One example is DuPont's response to the Bhopal tragedy [6]. At
the time, DuPont was purchasing methyl isocyanate, the same chemical that
killed so many in Bhopal, and shipping it over a thousand miles to a plant near
a metropolitan center. That facility routinely stored several million pounds
of methyl isocyanate on site. DuPont devised a new process based upon the
ISD principles of minimization and substitution. They developed alternate
chemistry that was based on another chemical which was converted
in-situ
to methyl isocyanate. This new approach reduced the amount of in-process
inventory of methyl isocyanate to about ten to twenty pounds, a reduction of
about five orders of magnitude.
Another example is an unloading system for hydrogen fluoride that was
built by OxyChem at a Niagara Falls, NY facility. Hydrogen fluoride has
a boiling point of 19.5 C. It is a severe pulmonary irritant. It is estimated
that the lowest lethal concentration for a 5-minute human exposure to hydro-
gen fluoride is in the range of 50 to 250 ppm [7]. A 1987 release of HF [8]
from the alkylation unit of a Marathon Oil refinery in Texas City resulted
in the evacuation of about 4,000 residents and hospitalization of about 100.
Fortunately, there were no fatalities. Another example that illustrates the dan-
gers was an accident on September 27, 2012 when workers at Hube Global
in South Korea were unloading hydrofluoric acid. There was a leak of HF.
Five people died and more than 3,000 people were sickened [9]. In order to
minimize the chances of a gas leak, OxyChem built an enclosed refrigerated
Search WWH ::
Custom Search