Lonza Inc. - Executive Summary |
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At algroup lonza, we are committed to operating and maintaining our processes in a safe and responsible manner. We use a combination of accidental release prevention programs and emergency response planning programs to help ensure the safety of our employees and the public as well as protection of the environment. This document provides a brief overview of the comprehensive risk management activities that we have designed and implemented, including: -A description of our facility and use of substances regulated by EPA's RMP regulation. -A summary of results from our assessment of the potential off site consequences from accidental chemical releases. -An overview of our accidental release prevention programs. -A five-year accident history for accidental releases of chemicals regulated by EPA's RMP rule. -An overview of our emergency response program. -An overview of planned changes for continuous safety improvement. -The detailed information (called data elements) about our risk manag ement program. Stationary Source and Regulated Substances Our facility manufactures a variety of specialty organic chemicals from batch processing operations. In our processes, we use the following chemicals that EPA has identified as having the potential to cause significant off site consequences in the event of a substantial accidental release: Toxics: Formaldehyde, Methyl Chloride, Phosphorus Trichloride Flammables: Dimethylamine, Methylamine Our accidental release prevention programs and our contigency planning efforts help us to effectively manage the hazards that are posed to our employees, the publc, and the environment by our use of these chemicals. Key Off Site Consequence Analysis Scenarios EPA's RMP rule requires that we provide information about worst-case release scenarios and alternative release scenarios for our facility. The following are brief summaries of these scenarios, including information about the key administrative controls and mitigation measures to lim it the exposure distances for each scenario: Worst-Case Scenario-Regulated Toxic Chemicals The worst-case scenario selected is a storage tank rupture that releases the entire tank contents of 135,000 pounds of Methyl Chloride. Methyl Chloride is used to produce methyl quats at the facility. This is the only storage tank for methly chloride and the release is contained within a concrete dike. This area is equipped with a deluge system and fire fighting equiment. Potential public receptors include Village of Mapleton residents, Mapleton School employees and students, Mapleton Christian School employees and students, Hollis Park District employees and patrons, Witco Corporation employees, Caterpillar employees, MG Industries employees, Consolidated Industries employees and the general public and commerce within the affected radius. The estimated distance to the toxic end point (0.82 mg/l) is 3.2 miles according to EPA's RMP*Comp (TM) model. Worst-case Scenario-Regulated Flammable C hemicals The worst-case scenario selected is a storage tank rupture that releases the entire tank contents of 149,000 pounds of anhydrous Dimethylamine (DMA). DMA is used in the production of amine products at the facility. This is the largest storage tank of Dimethylamine and the release is contained within a concrete dike. This area is equipped with a deluge system and fire fighting equipment Potential public receptors include Village of Mapleton residents, Mapleton School employees and students, and Witco Corporation employees. Assuming the released DMA results in a vapor cloud explosion, the estimated distance to 1 psi overpressure is 0.40 miles according to EPA's RMP* Comp (TM) model. (Note: MMA produced the same results). Alternate Case Release Scenario-Regulated Toxic Chemicals Alternate case scenarios were conducted for each regulated toxic chemical. The individual scenarios are identified as follows: Phosphorus Trichloride (PCl3) The alternate case scenario selected i s a 0.5 inch diameter rupture in a rail car unloading hose that releases 9,370 pounds of PCl3. The release is contained within a concrete sump. This area is equipped with fire fighting equipment. Active mitigation is employed. Potential public receptors include VIllage of Mapleton residents, Mapleton School employees and students and Witco Corporation employees. The estimated distance to the toxic end point (0.028 mg/l) is 0.40 miles according to EPA's RMP* Comp (TM) model, and the estimated duration of the release to the atmosphere is 40 minutes. Methyl Chloride The alternate case scenario selected is a 0.5 inch diameter rupture in a rail car unloaidng hose that release 6,280 pounds of methyl chloride. The release is contained within a concrete sump. This area is equipped with fire fighting equipment. Potential public receptors include Village of Mapleton residents, Mapleton School employees and students, and Witco Corporation employees. The estimated distance to the toxic end point (0.82 mg/l) is 0.20 miles according to EPA lookup tables and the estimated duration of the release to the atmosphere is 20 minutes. Formaldehyde The alternate case scenario selected is a 0.5 inch diameter rupture in a 2 inch tank truck unloading hose that releases 6,030 pounds of formaldehyde. Potential public receptors include VIllage of Mapleton residents, Mapleton School employees and students, and Witco Corporation employees. The estimated distance to the toxic end point (0.012 mg/l) is 0.10 miles according to EPA lookup tables and the estimated duration of the release to the atmosphere is 20 minutes. Alternate Case Release Scenario- Regulated Flammable Chemicals The alternate case scenario selected is a 0.5 inch diameter rupture in a 2 inch storage tank transfer line that releases 4,960 pounds of anhydrous dimethylamine (DMA). Potential public receptors include Village of Mapleton residents, Mapleton School employees and students, and Witco Corporation employees. A ssuming the released DMA results in a vapor cloud explosion, the estimated distance to 1 psi overpressure is 0.08 miles according to EPA's RMP* Comp (TM) model. (Note: MMA produced the same results). We are using this alternate case release scenario information to help us ensure that our emergency response plan and the community emergency plan address all reasonable contingency cases. General Accidental Release Prevention Program and Chemical-Specific Prevention Steps algroup lonza complies with OSHA's PSM rule and EPA's RMP rule. We also participate in CMA's Responsible Care program. We take a systematic, proactive approach to preventing accidental releases of hazardous chemicals. Our management systems address each of the key features of successful prevention programs including: -Process Safety Information -Process Hazard Analysis -Training -Mechanical Integrity -Management of Change -Pre-Startup Reviews -Compliance Audits -Incident Investigation -Employee Participation -Hot Wor k Permits -Contractor Safety These individual elements of our prevention program all work together to assist our efforts to prevent accidental chemical releases. Our facility management and our employees are committed to safe work procedures defined by the prevention program. We have specific accountablitlies and controls to ensure that we are meeting our own high standards for accident prevention. Five Year Accident History We keep records for all significant accidental chemical releases that occur at our facility. During the past five (5) years, we have not experienced an accidental chemical release from covered processes that has resulted in either deaths, injuries, or significant property damage on site or known deaths, injuries, evacuation, shelterings-in-place, property damage or environmental damage off site. Emergency Response Program Our emergency response program covered various federal, state, and local regulatory requirements for emergency response planning. We have procedures and we have conducted training for initial incident response, emergency responder contact, regulatory agency and community notifications, maintenance of emergency response equipment, and specific response management. Futhermore, we actively participate in our Peoria County LEPC, coordinating our plan with the LEPC's community emergency response plan. We have a trained emergency response team on site, and if necessary we coordinate with Timber Hollis Fire Department for handling larger emergency incidents. Our emergency response team has incident command, fire, rescue, and Hazmat training and has conducted joint training and drills with the Peoria County LEPC. Planned Changes to Improve Safety algroup lonza subscribes to the Chemical Manufacturer's Association Responsible Care initiative, which provides for continuous improvements in all aspects of our safety, health and environmental programs. In addition, the plant safety program includes safety positive (improvement r ecommendations) as well as celebrations of safety milestone achievements. |