BASF Corporation - Freeport Site - Executive Summary |
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Commitment to the Community BASF Corporation has a long tradition of operating its facilities in the safest possible manner. BASF also believes in being a responsible corporate citizen and maintaining open, constructive dialogue with our neighbors. These principles are an integral part of our corporate vision statement and values. We believe that sharing this information with our neighbors makes good sense. By doing so, we believe the community will better understand how safe and ecologically sound BASF operations are. Policies BASF Corporation has the following Corporate Guidelines related to environmental, health and safety: 7 We produce products that are safe to manufacture, use and dispose of. 7 We assist our customers to use our products safely and in an environmentally sound manner. We provide them with information on correct handling of our products. 7 We minimize the impact on mankind and the environment during production, storage, transportation, marketing and use of o ur products. 7 Economic considerations do not take priority over environmental protection, health and safety. 7 An important contribution to "Sustainable Development" is our involvement in the "Responsible Care" initiative worldwide. This applies to our products and services in all our businesses and affiliates. 7 We are committed to making continuous improvements in safety, health and environmental protection. We do this acting on our own initiative and in consultation with recognized regulatory authorities. We take any action judged to be necessary, whether or not dictated by statutory obligation or official regulations. 7 We encourage safety, environmental and health awareness among employees. 7 We regard it as an important corporate duty to advance science and technology in order to improve safety and environmental protection. 7 We carefully weigh the potential benefits and risks of new discoveries and technologies in dialogue with scientists and society before deciding on how t o proceed. 7 We pursue an open dialogue with all relevant opinion leaders in society. Our goals are to promote and strengthen mutual understanding and deepen trust in what we do. The BASF Corporation Freeport Site implements these policies through site-specific programs and procedures. Freeport site Risk Management Plan information was presented to the community in November, 1997. Facility Description The BASF Corporation Freeport Site uses eight RMP regulated chemicals. The table below provides a summary of the units which use them and some final products which they can be found. RMP Chemical Operating Unit(s) End Uses Oleum Caprolactam I & II Nylon fibers and plastics Ammonia (Anhydrous) Caprolactam I & II Fertilizers, Nylon plastics Cyclohexanone I & II Hydroxylamine Formaldehyde Neol., railcar Water craft, appliance, and automotive coatings Epichlorohydrin Polymin. Paper recycling, Food packaging Ethyleneimine Polymin. Paper recycling, Food packaging Propylene/Propane Oxo Alcohols Plastic coatings, Paints Acrylic Acid Trimethylamine Neol. Water craft, appliance, and automotive coatings Release Scenarios Worst Case Program 1 Processes 7 Liquid spill and vaporization of ethyleneimine with no impact to off-site receptors. Administrative controls reducing vessel volume and containment in a building were considered. Liquid spill and vaporization of epichlorohydrin with no impact to off-site receptors. A containment dike was considered in the model. Program 3 Processes 7 7Liquid spill and vaporization of oleum with off-site impacts. A containment area was considered which results in a decreased rate of evaporation. Administrative controls reduced the volumes released from the storage vessel. 7 Vapor cloud explosion resulting from the release of propylene with off-site consequences. No mitigation factors were included in the model. Alternative 7 Pipe leak of oleum with off-site impacts. No active mitigation systems were taken into account. The only passive mitigation considered was a dike. 7 Rupture disk/relief venting of ammonia in the hydroxylamine unit. The scenario has off-site impacts. A deluge system, excess flow valve, and emergency shutdown system were all incorporated in the model. 7 Rupture disk/relief venting of formaldehyde with off-site receptors. The quantity of formaldehyde released was minimized by considering a deluge system. 7 Vapor cloud explosion resulting from the release of propylene with off-site consequences. No mitigation factors were considered. Accidental Release Prevention Program To prevent accidental releases, this facility is in compliance with the EPA Risk Management Program, the OSHA Process Safety Management standard, and the Chemical Manufacturer Association's Responsible Care Process Safety Code. 7 The Caprolactam plant is equipped with many safety features to minimize oleum release potential. Automatic shut-offs and relief devices accommodate fluctuations in temperature and pressure. Warning alarms, video monitoring, regular equipment inspections, and pressure monitoring in pipes and vessels provide advance notice of potential operational upsets. Specialized oil and foam spill blanket systems and a scrubber system provide a protective barrier in the event of a spill. 7 As with other chemicals of concern, ammonia vessels are equipped with automatic shut-off and relief devices to handle fluctuations in tempe rature and pressure. Warning alarms, leak detectors, regular equipment inspections, and pressure monitoring in pipes and vessels provide layers of protection for employees and the community. 7 The formaldehyde storage tank is equipped with a spill pit to contain the contents of any accidental liquid releases. The tank is also equipped with a water-fog system to control vapor releases. Automatic shut-off devices, relief valves, and safety alarms provide additional protection. Water curtains are available for railcar incidents. 7 The Polymin. plant follows stringent safety measures to prevent accidental releases. Ethyleneimine is handled only in a water solution and only inside a specially designed building. Handling the chemical in this manner reduces the volatility, reactivity, and flammability. If ethyleneimine is present in a process area, only specially trained personnel are allowed to enter. Also, automatic shut-offs, relief valves, and warning alarms are widely utilized to ensure personnel safety. 7 Chemical flammability is a great concern for BASF, and many steps are taken to prevent accidental releases. Thermal relief and automatic shut-off systems are incorporated into process designs. Systems are in place to quickly relocate or dispose of flammables in emergency situations. Continuous monitoring of pipe and vessel pressure identify potential leaks for further protection. Five Year Accident History This facility has had no accidental release(s) over the past five years which meets the reporting criteria. Emergency Response Program Emergency response programs are in place for both internal preparation and coordination with the community. The Freeport site plan is coordinated with the Brazoria County Local Emergency Planning Committee to ensure community safety. Annual drills are coordinated with the community and the community warning sirens are tested weekly. In the event of an incident, information is transmitted over a local radio station . BASF participates in the Industrial CAER program (Community Awareness and Emergency Response), which operates a hotline for communication with the community. In addition to the site plan, each operating unit has a block specific emergency plan. These plans contain information specific to chemicals within that unit. Incident commander training is conducted annually and two drills are staged each year. Information on emergency health care is incorporated into the unit emergency plans. BASF also maintains a corporate-wide Emergency Response Team that is expertly trained in emergency mitigation techniques for transportation and off-site incidents. Planned Changes to Improve Safety Facility processes are routinely changed to improve safety as a result of employee suggestions, process hazard analyses, incident investigations, etc. |