Cytec Industries, Willow Island Plant - Executive Summary |
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Willow Island - Executive Summary (a) ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES Cytec is a leader among chemical manufacturers in its safety, health and environmental programs. Our commitment to protect our employees and the communities that are home to our operations is an integral part of Cytec's way of doing business. Cytec has established safety, health, emergency response and environmental policies and standards to meet or exceed all regulatory requirements. As a member of the Chemical Manufacturers' Association (CMA), Cytec subscribes to the codes established for Responsible Care .. (b) THE STATIONARY SOURCE AND THE REGULATED SUBSTANCES HANDLED Willow Island's Polymer Additives Department produces thiodipropionitrile which is used to make antioxidants which are used in such products as polyolefins. The regulated substance involved with this batch process is acrylonitrile. The Polymer Additives Department also produces A-1846 which is used to make antio xidants for use in such products as SPANDEX b. The regulated substance involved with this batch process is 37% hydrochloric acid. (c) WORST-CASE RELEASE SCENARIO AND ALTERNATIVE RELEASE SCENARIOS The toxic worst-case scenario is the failure of a storage tank and the release of 80,000 pounds of acrylonitrile. The mitigating effect of a dike was included in the evaluation of the possible consequences. The evaporating acrylonitrile could reach offsite endpoints and nearby public receptors. The alternative release scenario for acrylonitrile is the overflow of a storage tank due to operator error and the release of 1,250 pounds of material. The mitigating effects of a dike, the fire brigade response and the use of a foam application system were included in the evaluation of the possible consequences. The evaporating acrylonitrile could reach offsite endpoints and nearby public receptors. The alternative release scenario for 37% hydrochloric acid is the overflow of a storage tank d ue to operator error and the release of 1,000 pounds of material. The mitigating effect of a dike and the fire brigade response was included in the evaluation of the possible consequences. The evaporating hydrochloric acid could reach offsite endpoints and nearby public receptors. (d) THE GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS Cytec's general accidental release prevention program includes: 7 EPA 40 CFR 68 - Risk Management Plans 7 OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous Chemicals 7 OSHA 29 CFR 1910.120 - Hazardous Waste Operations & Emergency Response 7 Other EPA, OSHA, DOT and State regulations 7 Generally recognized & accepted engineering codes and standards, and 7 Cytec Safety, Health, Environmental and Engineering standards The following engineering and administrative controls help prevent a release of acrylonitrile - Vapor return system for acrylonitrile unloading and transfer operations - Acrylonit rile tank trucks are top-unloaded - High level interlock on acrylonitrile storage tank - Acrylonitrile storage tank is inerted with nitrogen - Acrylonitrile storage tank and piping are subject to non-destructive examination including ultrasonic thickness inspection. The following engineering and administrative controls help prevent a release of hydrochloric acid. - Vapor return system for hydrochloric acid unloading and transfer operations - Hydrochloric acid tank trucks are top-unloaded and storage tank has no side or bottom outlets - High level interlock on hydrochloric acid storage tank - Hydrochloric acid storage tank and day tanks are vented through a scrubber system - Hydrochloric acid storage tank is subject to non-destructive examination (e) 5-YEAR ACCIDENT HISTORY There have been no incidents at the Willow Island Plant that meet the criteria for reporting in the five-year accident history. (f) EMERGENCY RESPONSE PROGRAM The Willow Island Plant has an extensive emergency response program included in the "Emergency Operations Manual". This program outlines actions to be taken by operating department, maintenance, utilities, office, technical, visitors, contractors, and plant emergency response employees. The plant Fire Brigade trains and drills regularly with many exercises including local outside responders. (g) PLANNED CHANGES TO IMPROVE SAFETY CYTEC Industries is constantly striving to upgrade its processes, control technology, employee training, inspection, repair and maintenance of process equipment in order to improve safety. We are also executing a well organized plan to ensure minimum possible negative impact from Y2K. |