Hazardous production material

Scope. As with gases, the avoidanee of mixing reactive chemieals is important. Chapter 5 of NFPA 318 eoneems itself with methods for storage and use of liquids and solids of a hazardous nature. NFPA uses the term Hazardous Chemicals and the Model Building Codes use Hazardous Production Materials. These are chemieals with speeified ratings of health, flammability, or reaetivity when tested in aceordanee with NFPA 704, Identification of the Fire Hazard of Materials. Flammable liquids and oxidizers are the two types of chemicals that present the greatest fire hazard in a cleanroom. 

When the facility uses or stores hazardous chemicals or gases in sufficient quantity, it must be considered a Hazardous, Group H occupancy. A summary of the quantity, location and type of hazardous materials located within a given control area is required in order to make the correct occupancy classifications. If a review of the hazardous production material (HPM) inventory indicates quantities above the exempt amounts set in UBC Tables 3-D or 3-E (pgs. 1-62 to 1-64) for a control area, an H occupancy classification is mandated. Refer to Tables 1 and 2 which have been taken from the 1994 UBC. 

Division 6. Semiconductor fabrication facilities and comparable research and development areas where hazardous production materials (HPMs) are used, and the aggregate amount exceeds that listed in Tables 3-D or 3-E... 

Hazardous Production Material (HPM) is a solid, liquid or gas that has a degree-of-hazard rating in health, flammability or reactivity of Class 3 or 4 as ranked by UFC Standard No. 79-3, and which is used directly in research, laboratory or production processes which have as their end-product materials which are not hazardous. 

Area smoke and heat detectors. Hazardous production material storage rooms are required to have a supervised smoke detection system in accordance with the above UFC requirements. We recommend the installation of heat detectors in all electrical rooms. 

The foremost consideration is that hazardous production material pipelines do not penetrate areas which are not classified as an H exposure. If they do, they must be double-contained such that the armrrlar space only commimicates with a hazard classification area. Process gas lines should be as short as possible corrsisterrt with efficient grouping and reasonable support requirements. 

Many semiconductor gas storage room or rooms from which gas is dispensed are considered Hazardous Production Material (HPM) storage rooms depending on the amounts and t5 es of gases contained inside them. The UFC Article 80 deals most directly with specific requirements for storage and use of gaseous chemicals. 

Chloroformates are shipped in nonretumable 208-L (55-gal) polyethylene dmms with carbon steel overpacks or high density polyethylene dmms. Eor bulk shipments, insulated stainless-steel tank containers and tmcks provide secure protection. Tank tmck and rail car quantities are shipped using equipment dedicated for these types of products. Materials such as isopropyl chloroformate, benzyl chloroformate, and j -butyl chloroformate that require refrigeration are precooled when shipped in bulk containers. Bulk shipments that are precooled must proceed to the destination without layover. Dmm shipments of IPCE, BCE, and SBCE must be shipped in refrigerated containers. Many of the chloroformates are only shipped in tmck load shipments. The U.S. Department of Transportation (DOT) Hazardous Materials Regulations control the shipments of chloroformates, as described in Table 3. 

Substitution If intensification is not possible, then an alternative is to consider using a safer material in place of a hazardous one. Thus it may be possible to replace flammaole solvents, refrigerants, and heat-transfer media by nonflammable or less flammable (high-boiling) ones, hazardous products by safer ones, and processes which use hazardous raw materials or intermediates by processes which do not. As an example of the latter, the product manufactured at Bhopal (carbatyl) was made from three raw materials. Methyl isocyanate is formed as an intermediate. It is possible to react the same raw materials in a different order so that a different and less hazardous intermediate is formed. 

In general, the environmental consequences resulting from emissions generated by the combustion of treated wood and the chemicals used to treat them are not well understood. Combustion of the materials involved in the incident unquestionably produced hazardous products of incomplete combustion emissions (e.g., dioxins and furans). 

Replacement of volatile organic solvents with aqueous systems or less hazardous organic materials improves safety of many processing operations and final products. In evaluating the hazards of a solvent, or any other process chemical, it is essential to consider the properties... 

Is it possible to completely eliminate hazardous raw materials, process intermediates, or by-products by using an alternative process or chemistry ... 

Safety in transport and storage. Liquid-stabilized S03, 65% oleum, 20% oleum, 98% sulfuric acid, and chlorosulfonic acid are hazardous chemicals in transport, handling, and storage. Sulfur in liquid or solid form is a far less hazardous starting material for the production of S03. 

Reduction in VOC emissions Reduced user exposure to harmful materials Reduced hazardous production waste Possibly less expensive Stability of formulation at low temperatures Acceptability of drying rate Energy costs for drying Adequacy of corrosion resistance Wear properties High gloss properties Storage stability Water resistance... 

Consider the case of the production of peroxy esters (e.g. tert-buty] peroxy 2-ethyl hexanoate), based on the reaction between the corresponding acid chloride and the hydroperoxide in the presence of NaOH or KOH. These are highly temperature sensitive and violently unstable, and solvent impurities are detrimental in their applications for polymerization. Batch operations to produce even 1000 tpa will be unsafe. A continuous reactor can overcome most of the problems and claims have been made for producing purer chemicals at lower capital and operation cost the use of solvent can be avoided. Continuous reactors can produce seven to ten times more material per unit volume than batch processes. Since the amount of hazardous product present in the unit at any given time is small, protective barrier walls may be unneccessary (Kohn, 1978). 

Zinc fertilizers made from recycled hazardous secondary materials. U.S. EPA promulgated a conditional exclusion from the definition of solid waste for hazardous secondary materials that are recycled to make zinc fertilizers or zinc fertilizer ingredients. Zinc, an important micronutrient for plants and animals, can be removed from zinc-rich manufacturing residue and used to produce zinc micronutrient fertilizer. A second conditional exclusion applies to the zinc fertilizer products made from these secondary materials. 

D. High hazard product warehouses lun oid unstable materials, law flash fiammebie liquids, or highly combustible solid. These require special consideration. 

Because of the lack of suitable standard rate of heat, smoke and toxic gas generation tests, the 1988 UK regulations are based on ignition resistance of individual materials. This contradicts the basic requirements for the fire testing of composites and of hazard related tests and as such it may be possible to develop materials which meet the requirements but which produce hazardous products. 

Many hazardous operations require the use of pipelines to convey product material from one location to another. In time, these pipelines become lined with the hazardous product to the extent they could serve as a media for propagation of an incident from station to station. Therefore, periodically cleaning these lines of the hazardous residue is important to operational safety. Additionally, removing accumulations of residue in the pipelines will increase flow volume, operating efficiency, and will minimize the possibility of product contamination. 

The means by which a quench system works depends on the nature of the reactive material e.g., for water-reactive materials, a quench system will destroy the material in a last-resort situation and generally form less-hazardous products, and will at the same time absorb some of the heat of reaction. Most quench systems are designed to both cool down and dilute a material that may be reacting uncontrollably the quenching medium may also actually interfere with the chemical reaction or deactivate a catalyst. 

Do the following strategies reduce inventories of hazardous raw materials, intermediates, and/or finished products ... 

In 1990-1991, American industries involved in hazardous chemicals/materials production, shipping, storing, and usage were scrutinized from both a safety and security viewpoint, to the point where OSHA s Process Safety Management Standard (PSM) 29 CFR 1910.119 was generated to address these concerns. PSM was promulgated in 1992, to be fully complied with by May of 1997. 

Reduction of Inventories Advancements in process control and changing acceptable risk standards may have removed the initial justification for large inventories of hazardous raw materials or products. For example, tight quality control of on-time deliveries of hazardous raw materials may allow for a one or two day supply on hand versus a one- or two-week supply. 

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