Safety processes

The chemical industry uses numerous and often complex equipment and processes. In the fine chemical industries (including pharmaceuticals), the plants often have a multi-purpose character, that is, a given plant may be used for different products. When we consider a chemical process, we must do it in an extensive way, including not only the production itself but also storage and transportation. This includes not only the product, but also the raw material. 

Risks linked with chemical processes are diverse. As already discussed, product risks include toxicity, flammability, explosion, corrosion, etc. but also include additional risks due to chemical reactivity. A process often uses conditions (temperature, pressure) that by themselves may present a risk and may lead to deviations that can generate critical effects. The plant equipment, including its control equipment, may also fail. Finally, since fine chemical processes are work-intensive, they may be subject to human error. All of these elements, that is, chemistry, energy, equipment, and operators and their interactions, constitute what we call process safety. 

The completion of the EDS test program is expected to provide a much more complete understanding of the hydrolysis process, control systans, maintenance requirements, and other considerations necessary for determining the applicability of this technology to assembled chemical weapon demilitarization. However, EDS experiments being conducted with tetry tol, which contains TNT, will not be repre- 

In this section, the findings and recommendations on energetic hydrolysis from the two ACW I Committee reports are reviewed to determine the extent to which they are still valid as a result of EDS testing (NRC, 1999, 2000). 

Review of Findings and Recommendations from the 1999 initiai ACW I Committee Report 

This finding is being addressed by the ACWA EDS program. 

This finding is being addressed by the ACWA EDS program. The assessment of the particle size reduction needed for proper operation was limited to a single particle size, which was acceptable for the operation. No attempt to identify an optimum particle size is included in the program. 

1972-76 1977-81 1982-86 1987- 1 1992-96 1997-01 2002-06 2007-11 Source M M s 100 largest losses to 2011 Includes refining, petrochem, gas processing, terminals, upstream 

Throughout history, the chemical and pharmaceutical industries have gained mind-boggling unexpected experience in the hazards of working with chemicals. The safety literature provides a sobering and dark commentary with regard to explosions, runaway reactions, fires, toxic emissions, asphyxiations, spills, and so on, and their consequences. Consequences are seen in the injuries and deaths of people and in physical, social, and environmental damage around the world. 

The Management of Chemical Process Development in the Pharmaceutical Industry by Derek Walker Copyright 2008 John Wiley Sons, Inc. 

Numerous books on the hazards and safety aspects of handling chemicals have been published. Two of the now standard works to be found in most technical libraries are under the original authorship of Sax7 and of Bretherick.8 Those engaged in assessing health risks can gain further insight into the variability of human response to chemical exposure from the book by Neumann and Kimmel.9 

This chapter provides an introduction, which, hopefully, will enable chemists and engineers to appreciate the major Safety/Health issues faced by people working with chemicals. The most immediately devastating are obviously explosion and fire. Adverse health effects resulting from the exposure of people to certain chemicals can also be immediate (e.g., exposure to methyl isocyanate in Bhopal), but health effects can also take time to manifest themselves. In view of the unknowns, it is best to maintain caution in all situations even though, putting matters into perspective, exposure to many chemicals (solvent vapors are the most common) can be tolerated 

chemsafety.gov/circ—tins site provides often detailed reports on incidents and accidents. 

If a U.S.-based toll project requires threshold quantities of feedstock, intermediate or finished product that are considered  

-based operations may reference the same documents or alternative local references, such as  

Whether or not a firm is subject to these regulatory requirements, examples of questions to ask candidate tollers at this stage of initial qualification are  

One excellent sign that a candidate toller has an understanding of process safety is the existence of a written management system that describes how each applicable requirement is met. 

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Growl, D. A., and Louvar, J. F., Chemical Process Safety Fundamentals with Applications, Prentice-Hall, Englewood Cliffs, N.J., 1990. 

Process safety management of highly hazardous chemicals... 

As is evident from the listing in Table 3, the fertilizer manufacturer has a wide array of compounds from which to choose. Final choices of products and processes therefore rest heavily on such other factors as availabiUty and cost of raw materials, economy of processing, safety of product, economy of handling and shipping, acceptabiUty of physical form and physical behavior of the product, and farmer acceptance. 

Guidelines for Hazards Ena/uation Procedures Second Edition with WorkedExampks American Institute of Chemical Engineers, Center for Chemical Process Safety, New York, 1992. 

The state of Louisiana amended its air quaUty regulations (26) to incorporate requirements for chemical accident prevention, and several other states, including Michigan and New York, are considering process safety regulations. 

One of the six elements of Responsible Care is the Codes of Management Practice, and one of the codes is the Process Safety Code of Management Practices (34). This code emphasi2es management commitment and accountabiUty, information sharing, and community relations, but also includes 11 of the 14 specific elements of the legislated process safety management standards developed later. 

Protection of Employees. In 1986, shortly after the Bhopal disaster, OSHA contracted to develop a federal standard on process ha2ards management. A proposed standard was issued in 1990, and the Process Safety Management of Highly Ha2ardous Chemicals standard was issued and implemented in 1992 (36). 

Center for Chemical Process Safety. In 1985, the American Institute of Chemical Engineers estabHshed the Center for Chemical Process Safety (CCPS) (New York). The objective of the CCPS was to help prevent catastrophic chemical accidents by compiling information on the latest scientific and engineering practices, safety programs, and adininistrative procedures of the larger members of the chemical industry, so that they can be shared with other (and particularly the smaller) members of the chemical and petrochemical industries. 

Chemical Process Quantitative Risk Analysis Process Equipment Reliability Data, with Data Tables Technical Management of Chemical Process Safety (Plant)... 

Chemical Reactivity Evaluation and Application to Process Design Preventing Human Error in Process Safety... 

Investigating Chemical Process Incidents Auditing Process Safety Management Systems Making Acute Risk Decisions... 

Process Safety Eundamentals for General Plant Operations... 

Other publications include the proceedings of six international conferences and symposia three training courses and a computeri2ed bibliography of Guideline references, all available from the Center for Chemical Process Safety (1-800-242-4363). 

Plant Operations Progress, Vols. I—II, American Institute of Chemical Engineers, 1982—1992 Process Safety Progress, Vol. 12, 1993—present. 

Chemka/Process Safety Keport Sect. 900, 261, 1221, 1421, Thompson PubUshiag Group, Washington, D.C., 1994. 

Process Safety Code of Management Practices Chemical Manufacturers Association, Washington, D.C., Sept. 11,1990 M Resource Guide for the Process Safety Code of Management Practices Oct. 1990. 

Process Safety Management of Highly Hazardous Chemicals Tide 29, Subtitie B, Chapt. XVII, Part 1910, Subpart H, Paragraph 119, of the Code ofFederal Regulations (29 CER 1910.119), FederalRegisterhl >()) 6403, U.S. Department of Labor, Occupational Safety and Health Administration (Feb. 24, 1992). 

R. D. Coffee, in H. H. Fawcett and W. S. Wood, Safety and Accident Prevention in Chemical Operations, 2nd ed., Wiley-Interscience, New York, 1982, p. 305 International Symposium on Runaway Reactions, Center for Chemical Process Safety, New York, 1989, pp. 140, 144,177, 234. 

Future technology developments in paraffin alkylation will be greatly influenced by environmental considerations. The demand for alkylate product will continue to increase because alkylate is one of the most desirable components in modern low emission gasoline formulations. Increased attention will be focused on improving process safety, reducing waste disposal requirements, and limiting the environmental consequences of any process emissions. 

Accidental Release Provisions. The 1990 CAAA includes provisions similar to OSHA s process safety management standard for minimi2ing the accidental release of air toxics. Based on types and quantities of ha2ardous chemicals on-site, a faciUty is required to develop and implement... 

Eault tree analysis (ETA) is a widely used computer-aided tool for plant and process safety analysis (69). One of the primary strengths of the method is the systematic, logical development of the many contributing factors that might result ia an accident. This type of analysis requires that the analyst have a complete understanding of the system and plant operations and the various equipment failure modes. 

Table 5. Effect of Cure System on Processing Safety and Compression Set Resistance for FKM2260 ...

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