Risk Compendium for the Chemical Industry Chemical Handling and Blending Process 1
1 Receiving bulk chemicals Moving vehicles Leaking drums / containers Inhalation of fugitive chemical emissions Inhalation of hazardous products from undesirable reactions upon incompatible mixing Fire and explosions from excessive heat produced and flammable vapours Injuries or deaths from traffic accident Chemical spill, excessive inhalation / skin absorption of chemicals Ill-health from chemical Ill-health from chemical Attend and complete forklift driver training Abide by speed limit Designate loading/unloading bay Install warning alarms Install gas/vapour detection systems Place drum/containers on spill control pallets Build bund walls Install gas/vapour detection systems Install ventilation system in storage area Engage competent person in charge to manage hazardous substances Segregate incompatibles Label chemicals Obtain and use information in MSDSs Provide hazard communication training Injuries / deaths Segregate incompatibles Prohibit ignition, heat sources, smoking and open flames Label chemicals Obtain and use information in MSDSs Provide hazard communication training 2
2 Weighing of raw Fire and explosions Injuries / deaths Install local exhaust ventilation system materials Install dilution ventilation Provide well-ventilated work area Prohibit ignition, heat sources, smoking and open flames on fire and explosion safety Install local exhaust ventilation system Build enclosure around weighing scale Automate weighing system Practice good housekeeping on solvent hazards and control Excessive skin absorption of solvents dust (from raw materials in powder or solid form) Dermatitis, ill-health due to chemical Automate washing/cleaning system on solvent hazards and control Provide, use and maintain eye, body and hand protection Install local exhaust ventilation system Build enclosure around weighing scale Automate weighing system Practice good housekeeping on dust hazards and dust control Provide, use and maintain respiratory, eye, face, body and hand protection 3
3 Mixing/Blending Burnt by corrosive solutions (e.g. acids, alkalis etc) Splashes by chemicals during agitation / mixing / blending Limbs caught in moving mixer / blender Eye / skin burns Install local exhaust ventilation system Build enclosure around weighing scale Automate weighing system Provide eye wash, emergency shower Practice good housekeeping on corrosive hazards and their control Provide, use and maintain eye, face, body and hand protection Eye / skin irritation, Install covers on mixer/blender dermatitis Amputations, fractures, sprains Provide, use and maintain eye and face protection Install machine guarding Install sensors Install warning alarms on machine guarding Fire & explosions Injuries / deaths Install local exhaust ventilation Build covers on mixer/blender Prohibit ignition, heat sources and open flames on fire and explosion safety 4
4 Packing into smaller containers / drums produced by agitation, mixing or blending Excessive noise exposure from moving mixer / blender Splashed by chemicals during agitation / mixing / blending Install local exhaust ventilation Build covers on mixer/blender on solvent hazards and control Noise induced deafness Substitute noisy mechanical parts with quieter ones Build enclosures padded with noise-absorbing materials around mixer/blender Maintain mechanical parts regularly Provide and attend hearing conservation training Provide, use and maintain hearing protection Eye / skin irritation, dermatitis Install covers on mixer/blender Provide, use and maintain eye and face protection Fire & explosions Injuries / deaths Automate packing system Install local exhaust ventilation system Prohibit ignition, heat sources and open flames on fire and explosion safety 5
5 Maintenance of mixer/blender 6 Cleaning/washing of mixer/blending produced during packing Splashed by chemicals during packing Repeated lifting of packed containers / drums Eye / skin irritation, dermatitis Automate packing system Install local exhaust ventilation system Automate packing system Build enclosures around packing system Provide, use and maintain eye and face protection Back aches, strains Automate packing system Use pallets with adjustable heights that respond to weight of packed containers/drums Provide mechanical lifting aids Provide and attend ergonomics training Use proper lifting posture Provide adequate breaks Electrocution Electric shock, deaths Implement log out/tag out Limbs caught in moving mixer / blender Amputations, fractures, sprains Implement log out/tag out on machine guarding Electrocution Electric shock, deaths Implement log out/tag out 6
Limbs caught in moving mixer/blender Excessive skin absorption of solvents Amputations, fractures, sprains Implement log out/tag out on machine guarding Dermatitis Automate washing/cleaning system Provide, use and maintain eye, body and hand protection Install local exhaust ventilation on solvent hazards and control This material is not intended to be an exhaustive list of hazards and control for the above activities. Companies are to conduct risk assessment on the work activities specific to their workplaces by identifying the hazards, evaluating the risk and determining suitable control where appropriate. References should be made to the relevant regulations and code of practices when in doubt. 7