RØADMAP TO ZERO DISCHARGE OF HAZARDOUS CHEMICALS
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1 Chemical Management Board for the Textile Meeting Industry MODULE March 25/26, 2013 RØADMAP TO ZERO DISCHARGE OF HAZARDOUS CHEMICALS IN ASSOCIATION WITH
2 DISCLAIMER PLEASE NOTE: The following presentation is being provided as an introduction to the general use of chemicals in textile manufacturing. The presentation is not intended to define applicable requirements or prescribe means or methods in accordance with those requirements, but instead to inform training participants of the potential hazards and use of chemicals in today s textile manufacturing industry. The intent of the presentation is to provide awareness to these hazards, with a focus on textile manufacturing process improvement and chemical-use reduction in the future. Country-specific regulatory requirements are not addressed in detail in this training session and each supplier is expected to become informed of these requirements for their specific operation and incorporate manufacturing practices to maintain regulatory compliance within their chemical management programs. 2
3 CHEMICAL MANAGEMENT TRAINING CONTENT All training modules can be accessed at MODULE1 INTRODUCTION TO CHEMICAL MANAGEMENT MODULE2 HAZARDS AND RISK ASSESSMENT RISK CONTROL HIERARCHY MODULE3 ZDHC MRSL FUNCTIONS AND BEST PRACTICES OF SDS CHEMICAL LABELLING CHEMICAL RISKS COMMUNICATION MODULE CHEMICAL USE AND STORAGE PPE SELECTION EMERGENCY RESPONSE MODULE5 ENVIRONMENTAL IMPACT MITIGATION MEASURES WASTEWATER TREATMENT AND MONITORING 3
4 MODULE SAFE USE OF CHEMICALS, TRANSFER AND STORAGE AT THE FACILITY PPE SELECTION EMERGENCY RESPONSE
5 CHEMICAL STORAGE Hazardous chemicals must be stored in a specialised storage area and obvious signage must be displayed. Chemicals should not be exposed to direct sunlight. The chemical storage area should be dry and well ventilated. Storage of chemicals should be based on their compatibility with other chemicals Chemical storage always requires extra consideration: Special building requirements, including room sizes, building materials, locations and more Only specific electrical devices can be used in some cases (explosion hazard) Ventilation or thermoregulation Fire suppression equipment may be required 5
6 HAZARDOUS CHEMICALS - STORAGE General Rules for Storage of Common Dangerous Chemicals (GB ) Basic requirements for hazardous chemical storage: Hazardous chemical storage should comply with relevant government regulations. Hazardous chemicals should be stored in a specialised storage area approved by the Public Security Department. Outdoor storage of hazardous chemicals should comply with fire and explosion prevention requirements. Explosives, level 1 flammable substances and poisonous substances should not be stored where exposed to the weather. Storage areas for hazardous chemicals should be managed by specialised personnel, whose personal protective equipment (PPE) are fully provided. 6
7 HAZARDOUS CHEMICALS STORAGE OF INCOMPATIBLE CHEMICALS Segregated Storage Within the same building or area, incompatible materials are separated and kept apart, typically enclosed to avoid any potential contact. Cut-off Storage Within the same building, incompatible materials are separated by wall or clapboard. Detached Storage Materials are stored in different buildings or areas. 7
8 INCOMPATIBILITY OF TEXTILE CHEMICALS Chemical Acetic acid Ammonia Calcium oxide Carbon tetrachloride Chromic acid Chlorine Incompatible Chemicals Aldehyde, bases, carbonates, hydroxides, metals, oxidisers, peroxides, phosphates, xylene Acids, aldehydes, amides, halogens, heavy metals, oxidisers, plastics, sulphur Acids, ethanol, fluorine, organic materials Benzoyl peroxide, ethylene, fluorine, metals, oxygen, plastics, silanes Acetone, alcohols, alkalis, ammonia, bases Alcohols, ammonia, benzene, combustible materials, flammable compounds (hydrazine), hydrocarbons (acetylene, ethylene, etc.), hydrogen peroxide, iodine, metals, nitrogen, oxygen, sodium hydroxide 8
9 INCOMPATIBILITY OF TEXTILE CHEMICALS Chemical Chlorine dioxide Flammable liquids Formaldehyde Incompatible Chemicals Hydrogen, mercury, organic materials, phosphorus, potassium hydroxide, sulphur Ammonium nitrate, chromic acid, hydrogen peroxide, nitric acid, sodium peroxide, halogens Strong oxidising agents, caustics, strong alkalis, isocyanates, anhydrides, oxides, and inorganic acids. Formaldehyde reacts with hydrochloric acid to form the potent carcinogen, bis-chloromethyl ether. Formaldehyde reacts with nitrogen dioxide, nitromethane, perchloric acid and aniline, or peroxyformic acid to yield explosive compounds. A violent reaction occurs when formaldehyde is mixed with strong oxidisers. 9
10 INCOMPATIBILITY OF TEXTILE CHEMICALS Chemicals Hydrogen peroxide Hydrogen sulphide Hypochlorites Oxalic acid Potassium permanganate Sulphuric acid Incompatible Chemicals Acetylaldehyde, acetic acid, acetone, alcohols, carboxylic acid, combustible materials, metals, nitric acid, organic compounds, phosphorus, sulphuric acid, sodium, aniline Acetylaldehyde, metals, oxidisers, sodium Acids, activated carbon Oxidisers, silver, sodium chlorite Benzaldehyde, ethylene glycol, glycerol, sulphuric acid Potassium chlorates, potassium perchlorate, potassium permanganate 10
11 BASIC CHEMICAL INCOMPATIBILITY CHART 11
12 INCOMPATIBLE STORAGE TABLE OF COMMON CHEMICALS ARE ALLOWED TO BE STORED TOGETHER SEPARATE PACKAGES BY AT LEAST 3M OR ONE GANGWAY WIDTH SEGREGATE THESE COMBINATIONS IN DIFFERENT BUILDING COMPARTMENTS ISOLATE DO NOT STORE TOGETHER There should not be any chemical reaction between chemicals and shelves or chemicals and containers. 12
13 HAZARDOUS CHEMICALS - STORAGE Devices for anti-explosion, anti-seep, fire protection and antistatic should be installed in chemical storage areas (if required) Chemical stock should not exceed anticipated usage before expiration; A good rule of thumb is a one month supply Stock of temporarily stored chemicals should not exceed 3 days consumption For chemicals in large containers hard to sub-package, stock should not exceed 1 shift per type In-and-out registration, first in/first out Expired chemicals must be disposed of appropriately 13
14 OXIDISING AGENTS AND ORGANIC PEROXIDES: STORAGE AND TRANSPORT 1. Oxidising agents should be stored in: Clean, dry and well ventilated warehouses Away from heat and fire sources, protected from direct sunlight Lighting equipment should be anti-explosive Special containers may be required for oxidising agents to allow pressure release Walls, floors, shelving and ventilation systems should be constructed using non-flammable materials 2. Prohibit storage with substances like: Acids (organic and inorganic), many metals or metal salts, flammable substances, organics (e.g., alcohols, acetone), combustibles 3. Different types of oxidising agents should be stored and transported differently, based on their characteristics and fire protection methods Peroxide requires specialised storage and transportation. 1
15 SAFE TRANSFER OF HAZARDOUS CHEMICALS Containers for flammable liquids should be specially constructed with springloaded caps and flame arresters. Transfer of flammable liquids should only be done in well-ventilated areas with containers earthed and bonded. Proper spill control and evacuation procedures are needed in case of chemical release and should be part of training operations. Fire suppression equipment must be available. 15
16 SAFE TRANSFER OF HAZARDOUS CHEMICALS AT A FACILITY Safety considerations for facilities that frequently transfer chemicals from storage to work areas: Chemicals may be transferred to or from work areas through pipelines or conveyors, or by using a forklift truck, trolley or other approved means. Vehicles must be in good repair to avoid damaging containers and to reduce tip over or spills Before transferring: Check labels Replace all broken, tearing or incorrectly located labels Reduce the possibility of collision and spillage of chemicals transported by a forklift truck by clearly marking passageways and making them an adequate width 16
17 SAFE TRANSFER OF HAZARDOUS CHEMICALS Do not shake chemicals. Over volatilisation can cause leaking. While transporting chemicals, even small amounts, use leakproof equipment. 17
18 HOW TO AVOID USING RESTRICTED SUBSTANCES Ask your chemical supplier for a correct and complete SDS and read it carefully. Ask your chemical supplier to confirm the Restricted Substances List and sign the declaration. Test the chemical through a third-party lab. *Note that SDS information only reports to 0.1% or 1% of chemical constituents, depending on hazard. This equates to 1000ppm or 10,000ppm, respectively. 18
19 CASE STUDY CHEMICAL STORAGE Please describe the type of systems that need to be installed in this room if it is used to store the following types of chemicals? Flammable chemicals Gas cylinders Oxidising agents 19
20 ANTI-EXPLOSION, ANTI-SEEP AND FIRE-PROTECTION EQUIPMENT Fume hood Overhead sprinklers Fire alarm Proper storage of explosives 20
21 HAZARDOUS CHEMICAL USE Read the label before using the chemical. Review SDS if unsure of any hazards. Do not use food containers for chemicals. Only mix chemicals wearing proper PPE and make sure the chemicals are correct for the purpose. Do not mix chemicals. Only create what is needed to minimise disposal. 21
22 HAZARDOUS CHEMICAL USE Do not smoke near the chemical storage area. Do not eat or prepare food in the chemical storage area. After handling chemicals, wash hands before eating. 22
23 HAZARDOUS CHEMICAL USE Use local ventilation systems to reduce inhalation of chemicals. Always wear appropriate PPE appropriate to the task. 23
24 EXPOSURE ROUTES OF HAZARDOUS CHEMICALS Chemicals can enter the body in three principal ways, through absorption, inhalation and ingestion. In the workplace the most common route of entry is inhalation, followed by skin absorption. inhalation ingestion 2
25 OCCUPATIONAL HAZARDS IN THE PRODUCTION PROCESS Hazards are present in many steps in processing textiles. The risk of these hazards can be managed with proper PPE, environmental controls, and strong chemicals management. Some examples of chemical intensive processing steps: Scouring (solvents, surfactants, acids, bases) Dyeing (dyes/pigments, surfactants, acids, bases) Other finishing processes (anti-stats, UV protectors, water repellents, hand builders) Dry cleaning (solvents) 25
26 DISCARDING CHEMICALS Discarded dangerous chemicals are part of a facility s hazardous waste. Containers or packages contaminated by discarded hazardous chemicals, should be treated as hazardous waste and shall be managed as hazardous wastes. 26
27 IDENTIFICATION OF HAZARDOUS WASTE The hazardous waste identification (HWID) process is the crucial first step in the hazardous waste management system. Correctly determining whether a waste meets the definition of hazardous waste (as may be defined by local regulations) is essential to determining how the waste must be managed. The HWID process consists of two questions: Is the waste listed in the National Catalogue of Hazardous Waste? Does the waste exhibit a characteristic of hazardous waste? 27
28 HAZARDOUS WASTE INVENTORY Identifying hazardous wastes in your company and establishing a complete and clear hazardous waste inventory is the basis of hazardous waste management. The following information should be considered for inclusion in the inventory: Waste name or waste description Waste classification and waste code Hazardous characteristics of waste Formation from which production process Storage Mass or volume of chemical Date of storage 28
29 COLLECTION AND SIGNAGE The units and individuals that collect, store, transport, utilise or dispose of solid waste shall take precautions against the spread, loss and leakage of solid waste as well as other measures for preventing the solid waste from polluting the environment. The abandonment or spread of solid waste during transportation is forbidden. 29
30 COLLECTION AND SIGNAGE For waste hazardous chemical containers and packaging, as well as equipment and areas used for gathering, storing, transporting and treating waste hazardous chemicals, shall include hazardous waste labels. Non-Hazardous Waste Hazardous Waste 30
31 COLLECTION AND SIGNAGE Signage should include: Name of hazardous waste (waste content/waste description) Hazardous characteristics and graphic Accumulation start date Emergency contacts Warning words 31
32 STORAGE OF WASTE CHEMICALS 32
33 STORAGE OF WASTE CHEMICALS NO OPEN STORAGE FOR DANGEROUS WASTE 33
34 STORAGE OF WASTE CHEMICALS NO OPEN STORAGE FOR DANGEROUS WASTE 3
35 STORAGE OF WASTE CHEMICALS SECONDARY CONTAINMENT AND BARRIER SHOULD BE SET FOR STORAGE AREA 35
36 CHEMICAL WASTE STORAGE BEST PRACTICES Appointed storage area (should construct ceiling and walls) Impermeable ground coating Secondary container Warning signs for container/package/storage area Storage separation between incompatible chemicals PPE for operators who handle waste chemicals Emergency response for chemical release (adsorbent, eye wash facility and emergency shower) Firefighting equipment Good ventilation and safe lighting Storage management regulation *Follow all local regulations on storage limits for volume or mass of chemicals 36
37 PPE SELECTION Regulation and standards Task evaluation PPE using performance Personal special requirements 37
38 PPE SELECTION Potential Health Effects of NOT using PPE EYE: irritation or eye damage SKIN: irritation and allergic contact dermatitis INGESTION: digestive tract irritation or more severe effects INHALATION: respiratory tract irritation, systemic sensitisation upon repeated exposure 38
39 RESPIRATORY PROTECTION Dust Mask Dust masks provide minimum respiratory protection against dust. Different dust masks protect against different sizes of particles. Offers no protection from toxic fumes, gas, noxious odors or an oxygen deficient atmosphere. Air Purifying Respirator Gas masks provide minimum respiratory protection for organic solvents, toxic gases (e.g., acid, smoke, ammonia). This mask is applicable for low-concentrations only. IMPORTANT: This mask is specific to a single class of chemicals. The replaceable canisters must be appropriate for the intended use and unexpired. 39
40 PROTECTIVE CLOTHING AND GLOVES Protective clothing should be worn to protect against exposure to liquid/solids and vapor and they provide a physical barrier to protect user. Types of gloves and what they protect against: Butyl Rubber Protects against peroxides, acids, bases, alcohols Not good for use with halogenated solvents or petroleum based products Nitrile Protects against oils, greases, some acids and bases, some solvents Not good for use with strong oxidising agents, strong organic solvents Neoprene Protects against gasoline, some alcohols, hydraulic fluids, organic acids and alkalines Not good for use with strong organic solvents 0
41 PROTECTIVE FOOTWEAR Protective footwear is necessary to protect feet and ankles from chemical exposure Neoprene (commonly used) Butyl rubber Other materials may not be suitable for acrylonitrile (AN) Hazards of wearing leather Readily absorbs AN and will not release it Causes skin burns 1
42 EMERGENCY RESPONSE RELATED TO HAZARDOUS CHEMICALS Examples of emergency incidents that can be caused by hazardous chemicals: Chemical release to the environment Acute poisoning Fire or explosion Others: chemical burn, frostbite, corrosion 2
43 HAZARDOUS CHEMICAL EMERGENCY RESPONSE Accident Prevention/Reduction Measures: Anti-leak equipment Gas leak detection devices Oxygen meters Spill kits/adsorption materials Emergency showers and eye washes First aid kit Fire fighting devices Appropriate PPE Response Training 3
44 LEAK PREVENTION - FACILITIES AND TOOLS
45 LEAK PREVENTION - GAS DETECTOR Types of gas detector: Portable devices Fixed-gas detectors Use of a gas detector: To detect combustible, flammable, toxic gases, oxygen depletion and transmit warning via alarms. To handle gas release accident Detect gas type and features Determine leakage sources 5
46 LEAK-ABSORPTION MATERIALS Types Examples Advantage Disadvantage Inorganic Clay, sand Chemical inertness, cheap Low absorption efficiency, incompressible, dirty, will cause secondary pollution. Organic Rice husks, rag cuttings, cotton Typical Absorption Materials Higher absorption efficiency than inorganic, cheap, light Complex Polypropylene High adsorption efficiency, chemical inertness, can be used repeatedly, compressible Low absorption rate, dirty, fire hazard, will cause secondary pollution. Expensive, some liquid residue will stay in surface. 6
47 EMERGENCY SHOWER AND EYE WASH Eye washes and showers are installed in areas where chemical exposure risk is higher, such as storage areas or preparation areas. In the event that an exposure occurs, flushing with water should be done immediately. Showers must be used for clothing/body exposures, with affected clothing removed to reduce exposure risk. Note: It is a good idea to provide a set of emergency clothes which can be used in the event of an exposure and shower. 7
48 FIRST AID KIT Kits should be: Clearly marked Easily accessible for workers Protected against dust and water Equipped with an inspection tag to document monthly checks Equipped with written first aid instructions in English and the local language Equipped with a list of the required contents of the kit (for restocking) 8
49 FIREFIGHTING DEVICES Firefighting devices include extinguishers, fire hydrants, fire alarms, fire sprinklers, temperature detectors and smoke detectors. 9
50 EMERGENCY RESPONSE TO CHEMICAL LEAKAGE Emergency report Evacuation and first aid Control of leakage Disposal of waste Only personnel trained specifically in chemical leakage should control leakage and disposal of waste. 50
51 FIRST AID FOR CHEMICAL BURNS First Aid Treatments Remove patient from accident site Wash injury liberally with tepid water Identify chemical for effective therapy Seek medical treatment Use pain medication and antibiotics as prescribed Clean and bandage wounds Follow up with compulsory care Consult with a medical specialist 51
52 CONTROL FIRE RELATED TO CHEMICALS Fires can be caused by: Compressed/liquefied gas Flammable liquid Flammable solids/spontaneous combustibles/ products that are combustible when wet Oxidant and organic peroxide Explosives Poisons and infectious substance/corrosives 52
53 NEXT TRAINING MODULE The following aspects of chemical management are reviewed in subsequent training modules available at Environmental impacts mitigation measures, wastewater treatment and monitoring 53
54 MAKE CHANGE, TOGETHER! QUESTIONS OR COMMENTS, US:
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