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Potential Hazards in Chemical Industries

The Most Common Potential Hazards in Chemical Industries

By Lukman Nulhakiem

 If we talk about potential hazards in chemical industries, there will be long discussion about that matter. Although one chemical plant has similar nature with one another, but each plant comes with its unique hazards.

potential hazards in chemical industriesIn this article, I will write about potential hazards in chemical industries in general which is in turn it can be used as inputs for preparing hazard identification work for your own plant site. This is very important mainly for companies which have not determined hazards list within their plant sites yet.

As a reminder, I recommend you to read my previous article about hazard identification study as well as hazard control methods if you have never experienced in making hazard list for your plant. (more…)

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12 Confined Spaces Hazards

confined-spaces1Confined space is one of the most deadly spaces in the workplaces. It is because of confined spaces contain many potential hazards and have restricted exits way.

Related to confined spaces, OSHA requires that:
a. All confined spaces in the workplaces shall be identified.
b. Confined spaces shall be treated as hazardous until proven.
c. All confined space hazards shall be identified.
d. Appropriate response should be given to these hazards before entry.

Confined space hazards can be classified into hazardous atmosphere, physical hazard, chemical contact hazard and biological hazard. The hazard list below is hazards that are commonly identified in a confined space.

  1. Oxygen rich (greater than 23.5%). This condition will introduce fire or explosion, especially when flammable vapor exists. So never use pure oxygen for ventilating a confined space. Use normal air supply only.
  2. Oxygen deficient (less than 19.5%). Oxygen deficient or lack of oxygen can cause unconsciousness to death. Oxygen concentration in a confined space can be declined due to nitrogen intrusion, welding, grinding, oxidation, sandblasting or coating.
  3. Oxygen and the existence of flammable vapors or gases can create flammable atmosphere. Chemical reaction and concentration of combustible dust may also create flammable atmosphere.
  4. Toxic atmosphere. It is introduced when a toxic chemical or gas is stored in a tank/holder, when carbon monoxide or hydrogen sulphide is produced through decomposition or work being done in the confined space.
  5. Corrosive atmosphere. Hydrochloric acid and ammonia are examples of chemicals that can build up a corrosive atmosphere.
  6. Physical configuration hazards. The use of ladder and scaffolding, wet surface, uneven bottom, bends in tunnels, narrow area or poor lighting can cause physical hazards to the workers inside confined spaces.
  7. Mechanical hazards. Mixing vessel, which is equipped with blades, can introduce mechanical hazard when workers come into the confined space (mixing vessel). Including in mechanical hazard is falling object.
  8. Surface hazard, for instance slips and falls.
  9. Noise hazards. Grinding work inside a confined space can result high level noise.
  10. Vibration hazards.
  11. Engulfment hazards. Engulfment hazard may happen when worker is entrapped by content of the confined space.
  12. Temperature hazards. Cold temperature and heat create temperature hazard inside a confined space.

Always bear in mind that hazards identification shall be finished before entering a confined space. Then, provide appropriate hazard controls to these potential hazards afterward.

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Chemical Hazard List for the Chemical Industry

chemical-hazards-listWhen we are dealing with chemicals in the workplaces, we will be exposed to the chemicals-associated potential hazards that would harm our health and safety, environment and plant facilities. Adequate information about chemical hazards will greatly help us during hazard identification study and ensure no hazards left to be identified. The list below shows hazards those are associated with chemicals preservation, loading and unloading operation, transportation, usage or maintenance work.

  • Fire. This may be caused by flammable, combustible or reactive chemicals.
  • Explosion. It comes with flammable, combustible or reactive chemicals.
  • Heat. As the result of reaction of the chemicals with another one.
  • Toxic gas. Such gas is also possible to be introduced when two or more chemicals reacting or through decomposition reaction.
  • Corrosive vapors.
  • Harmful to human health: eye irritation, corneal damage, eye burn, skin irritation, skin burn, headache, dizziness, nervous system depression, liver damage, kidney damage, heart damage, tract irritation, death, etc. Each chemical may have different health effects and this information can be extracted from the MSDS.
  • Environment contamination. Chemical spill and waste are common environment contamination factors.

The first step that has to be followed is to make a list containing hazardous chemicals used in the plant site. After that, refer to each MSDS for identifying the hazards. From MSDS, we can recognize different hazard control for each chemical. Some chemicals that are commonly found in chemical plant operation are hydrochloric acid, sodium hydroxide, hydrogen peroxide, phosphoric acid, formaldehyde, methanol, nitric acid, sulfuric acid, hydrogen and etc. Don’t forget to update the chemical hazards list regularly or when change exists. This is so important and will directly affect the hazard identification list.

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