EMERGENCY RESPONSE. NorFalco Presentation Temiskaming Shores October 23, 2012

Transcription

1 EMERGENCY RESPONSE NorFalco Presentation Temiskaming Shores October 23, 2012

2 NorFALCO Agenda (1 hour) Overview of NorFalco Sulfuric Acid Properties & First Aid Transportation Equipment Emergency Response

3 NorFalco LLC North America s Largest marketer of sulfuric acid Parent company Xstrata 2006 purchase of combined Noranda and Falconbridge 4 Xstrata production facilities in North America Sudbury, Ontario & Rouyn-Noranda, QC 1.7 million tons per year production and sales in North America Xstrata global acid production over 5 Million tons per year Fully integrated network of trains, trucks, terminals, ships Offices in Cleveland and Mississauga Commitment to Responsible Care & Product Stewardship Delivering More than H 2 SO 4

4 Sulfuric Acid End Use Products Food Products Pharmaceuticals Epsom Salts Fertilizer Batteries Gasoline Paper Water Treatment

5 Volume Transport Road Shipments

6 Ontario Northland Railway Shipments

7 Sulfuric Acid Chemical Properties & First Aid Procedures

8 Sulfuric Acid Sulphuric Acid, with more than 51% acid Corrosive Label 1830 Placard ERG2012 Sample Bill of Lading entry SULFURIC ACID, 8, UN1830, PGII, RQ ERAP# and 24 Hour Number: ERG 137 GUIDE 137 SUBSTANCES WATER-REACTIVE - CORROSIVE

9 Sulfuric Acid - Guide 137

10 NorFalco LLC Sulfuric Acid Safety Seminar Chemical & Physical Properties Sulfuric Acid Strong, inorganic acid Very corrosive to skin and eyes Reacts violently with water ( or different concentrations of acid! ) Visually can look like water Can react with metals to produce hydrogen Can be corrosive to metals and many plastics Freezing and corrosive properties vary widely depending on concentration

11 NorFalco LLC Sulfuric Acid Safety Seminar Chemical & Physical Properties Properties 93%(66 Be ) 98% Strength, % H 2 SO Min 98 Min Freezing Point, F Freezing Point, C Boiling Point, F Boiling Point, C Specific Gravity, F(15.6 C) Density, lbs/gal, 60 F (15.6 C) Viscosity, cp, 68 F (20 C) Specific Heat, cal/g C Appearance Clear to slightly turbid oily Clear to slightly turbid liquid oily liquid Odor None None

12 NorFalco LLC Sulfuric Acid Safety Seminar Personal Protective Equipment For handling the following minimum PPE is required : Hard hat Goggles (chemical) Face shield In addition to goggles Acid resistant gloves, gauntlet length Acid resistant splash suit - not rainwear Acid resistant boots, steel toed recommended For a line break, an acid resistant hood is required (replaces goggles and face shield ) Respiration Protection - not generally required under normal handling operations.

13 Personal Protective Equipment

14 Why wear both chemical goggles and a face shield?? Graphic picture

15

16 NorFalco LLC Sulfuric Acid Safety Seminar First Aid For Sulfuric Acid Burns Skin Contact Immediately wash under a safety shower for a minimum of 15 minutes while removing contaminated clothing. (Nothing should replace time spent under a safety shower, this is why tepid water is so important) Call for medical help. Apply ice water compresses to affected body area. (Greatly decreases chance of scarring and keeps burn cool) Continue ice water compresses while injured is transported to a medical facility & while waiting in the medical facility. Do not apply creams or ointments in lieu of ice water compresses, unless directed by a physician

17 NorFalco LLC Sulfuric Acid Safety Seminar First Aid For Sulfuric Acid Burns Eye Contact While holding eyelids open, wash over an eyewash station for a minimum of 15 minutes. Call for medical help.

18 NorFalco LLC Sulfuric Acid Safety Seminar Some things that Sulfuric Acid is not are: Explosive Poisonous Inhalation hazard Highly Toxic Flammable Gaseous Radioactive Sulfuric Acid is relatively easy to handle and it s main danger is it s corrosive properties. That is why people tend to become complacent with it and this is when accidents occur please treat it with the utmost respect at all times and instill that respect into your fellow employees and/or subordinates.

19 Conclusion Always wear appropriate eyewear & protective clothing and follow established procedures. You may never need a safety shower or eyewash, but if you do it must be designed properly and maintained to ensure people have the equipment necessary to prevent a tragedy.

20 NorFalco LLC Sulfuric Acid Safety Seminar Other Considerations Take care in helping the injured person. It won t help anyone if you also get burned! Make sure you have your own PPE on and know what the dangers are before attempting to help.

21 NorFalco LLC Sulfuric Acid Safety Seminar Please remember that, by definition Sulfuric Acid is a liquid that causes visible destruction and irreversible alteration in human skin or eye tissue. Why would anyone take shortcuts on procedures or PPE??

22 Transportation Equipment

23 Typical Sulfuric Acid Trailer Insulated Trailer Non-Insulated Trailer

24 TC 312 or DOT 412 Truck Equipment Bottom discharge design c/w internal valve Remote shutoff located at drivers side(front) of trailer. Safety Relief Valve (to prevent overpressurizing) Spill box around top man-way Hoses to be flex hose with Teflon, per "Techquip" spec Fittings to be stainless steel suitable for acid service Gaskets to be virgin Viton B per Techquip

25 TANK CARS Sulfuric acid cars specification marking: DOT 111 A 100 W2 DOT: Approving authority 111: Non-pressure car(<100psi), also known as General Service or Low Pressure tank cars. A: Separator(means nothing in this case). 100: Tank test pressure. W2: Welded carbon steel, bottom outlet prohibited.

26 TANK CARS-NorFalco standard Tank construction material: Carbon steel A516 grade 70(normalized) 9/16 thick plate or TC128 grade B (normalized) Gasket material: Viton B All tanks are lined with baked phenolic. Reduces creation of Hydrogen gas due to corrosion of steel. Full top platform Double shelf couplers Seals applied to all fill-holes Phase-out undesirable steels in older cars

27 TANK CARS- General arrangement Length: 42 to 45 Width: 10 8 Height: 14 to 15 6 Top platform elevation: 12 Tank diameter: 98 Weight(empty) : to lbs. Loaded: 263,000 lbs

28 INCIDENT REPORTING AND EMERGENCY RESPONSE

29 Sulfuric Acid is a very common chemical

30 Norfalco Incident Response What do we have in place? Emergency Response Plan and Procedures Emergency Response Teams (Internal/External) Emergency Response Equipment Training Meets regulatory requirements

31 TRANSPORT CANADA - ER PLAN Sulfuric Acid Column 7 of Schedule I ERAP index - chemical shipped above Quantity indicated requires emergency plan filed/approved with Transport Canada French and English ER manual are reviewed annually Plan/Manual is updated by NorFalco ER Team coordinator.

32 INCIDENT REPORTING Report significant incidents immediately : In Canada and US call Falconbridge 24 Hour reporting line : or 877- ERP-ACID Minor incidents ( no injury, significant product release, damage, media or business disruption ). Report ASAP during normal business hours (above # s, or normal bus. phone number )

33 EMERGENCY RESPONSE ER Team Training Requirements: HAZARDOUS MATERIALS TECHNICIAN _ PRIVATE SECTOR SPECIALIST TRAINING STANDARDS OSHA and NFPA 472 Annual Review of ER Manual Procedures 8 Tank Car acid Transfer by Air Pressure 4 Tank Car Acid Transfer by Pump 4 Tank Car Eduction Pipe Gasket Replacement 2 Tank Truck Acid Transfer 4 Explosive Gas Measurement 2 Incident Simulation(including communication) 4 Air Breathing Apparatus (2 X 2 hour exercises) 4 TOTAL Three Years Dangerous Goods Training 8 Sulfuric Acid Basic Chemistry 8 Basic Media Training 8 Estimated Duration(hours) Tank Car Damage Assessment 4 TOTAL 28

34 NorFalco Emergency Response Network CANADA 4 NorFalco Teams USA SPSI, PA 100+ SPSI Subcontractors *approx 40 Trained NorFalco responders

35 EMERGENCY RESPONSE EQUIPMENT: (in addition to standard Hazmat) Level B splash suit (SCBA optional) Not optional if there is a risk of acid mist exposure Safety shower and dedicated water supply Decontamination area with containment and water supply Trucks and trailers with compatible containment and transfer equipment (pumps, hoses, tank car and tank truck spare parts, tools, lighting etc.) Neutralizing Materials

36 RESPONSE STRATEGIES

37 Initial Response ERG2012 ERG number 137 provides initial information Request MSDS from NorFalco Canutec

38 EMERGENCY RESPONSE Is dilution the solution?

39 Neutralization Requirements How much will I need?

40 Typical Truck Incident A typical 412 acid trailer has a capacity of 3500 gallons. If it lost 1000 gallons in an accident it would take 10,000 gallons of water to raise the ph from 0 to 1 You now have 11,000 gallons of highly acidic water to dispose of. It is always advisable to neutralize with lime, soda ash or caustic soda to minimize run off and make clean-up a little easier to manage. (be extremely careful using Caustic Soda violent reactions can occur)

41 Step #1 determine how much acid has spilled in weight Determine (or estimate) how much acid has spilled (generally in gallons) Determine specific gravity (sulfuric acid s is about 1.84) Determine concentration of acid Weight of water is 10 lbs/imp. Gallon or 8.34 lbs / U.S. Gallon be sure to use the proper units for both acid and water in this calc. Quantity of Acid Spilled X Sp.gr. X Weight of water = Weight of spill in lbs

42 Step #2 Determine amount of neutralizer required. Weight of Acid spilled X number in chart (below) = Pounds of neutralizer required. Quick lime Hydrated Lime Crushed Limestone Soda Ash CaO Ca(OH)2 CaCO3 Na2CO3 lbs of neutralizer required to neutralize 1 lb of 93% Sulfuric Acid

43 Example A truck carrying 3500 gallons (imperial) of 93% Sulfuric Acid overturns on Interstate 80. When you arrive, the driver tells you he has lost approximately ½ of his load in the ditch. How much neutralizer would you have delivered to neutralize this spill? Approximate quantity spilled = 1,750 imperial gallons Specific Gravity = for 93% acid Weight of water = 10 lbs / imp. Gallon Therefore; 1,750 X X 10 = 32,095 lbs of acid If you elect to use hydrated lime, you will require, X 0.72 = 23,108.4 lbs of lime. Remember to add a minimum 10% buffer, so: 23,108.4 X 1.10 = or round up to 25,500 lbs required.

44 EMERGENCY RESPONSE RECOMMENDATION: The use of a calcium(ca) based neutralizing agent such as hydrated lime(first choice) or limestone, is preferred compared to sodium(na) based neutralizing agent such as caustic soda, sodium carbonate(soda ash) or sodium bicarbonate(cow brand). The salt produced by the reaction of calcium base material with acid is gypsum, which is not soluble in water, thus not creating any harm to the environment. While with sodium base products, the salt produced by the reaction is soluble in water, which can affect animal and plant life by salting certain areas of lakes and rivers.

45 Things to remember! Consider the environmental and safety effects of the neutralizer selected. Identify sources of neutralizer ahead of time SOP s The calculation shown in the previous example is an approximation. It is always best to have more neutralizer available than not enough. The neutralization reaction is exothermic heat will be generated Some acid mists may be generated during neutralization/mixing. When neutralizing a spill, check the ph at several locations to monitor effectiveness.

46 Hydrogen Gas Hydrogen (H 2 ) Risk in confined spaces (tank car, truck tank, storage tank, etc.) H 2 SO 4 + Fe => FeSO 4 + H 2 Hydrogen gas may evolve if sulfuric acid is in contact with most metals Risk of explosion Explosive gas testing recommended

47 Safety Shower Safety Shower Eyewash Station

48 EMERGENCY RESPONSE Control and Contain Diking Materials Do NOT use organic material Earthen dykes recommended Plugging or patching leaking containers may be done by properly trained personnel with proper patching and PPE equipment

49 SULFURIC ACID AND VACUUM TRUCKS Ensure the Vacuum truck is clean and dry, or last contained Sulfuric Acid When using a Vacuum Truck ensure there is no mixing of water and acid, or different strengths of acid When neutralizing, be sure the reaction is complete before attempting to remove with a Vacuum truck Verify Vacuum truck construction material is compatible with the strength of acid being removed (spilled acid concentrations may have changed) After using, the Vacuum truck should be properly washed and cleaned

50 EMERGENCY RESPONSE Treatment

51 Multiple Product Incidents Be aware that other products may have spilled as a result of an incident and may be mixed with sulfuric acid, creating additional hazards

52 Transferring Sulfuric Acid Transfer is normally completed by either pump or putting air pressure onto tank car or tank truck. Important considerations include: Damage to tank car or truck. Do not use air if tank integrity or pressure rating is questionable. Transfer done via compatible chemical transfer hose The hose is the weakest link in a transfer system! Ensure risks of hose or flange leaks are properly managed to keep personnel safe NorFalco Sulfuric Acid Safety & Tech Seminar

53 Transferring If using padding air to transfer: Recommend pressure 30 psi or less Regulated air flow Monitor Pressure via gauge Emergency air release capability

54 Acid Pools Never assume this is water!!

55 Questions?