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Building a Global Centre of Excellence in Responsible Chemical Management

The Zero Discharge of Hazardous Chemicals Programme Chemical Management for the Textile Industry

Date May, 2017


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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.


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Chemical Management Training Content

MODULE2 HAZARDS AND RISK ASSESSMENT RISK CONTROL HIERARCHY

MODULE3 ZDHC MRSL FUNCTIONS AND BEST PRACTICES OF SDS CHEMICAL LABELLING CHEMICAL RISKS COMMUNICATION

MODULE5 ENVIRONMENTAL IMPACT MITIGATION MEASURES WASTEWATER TREATMENT AND MONITORING

MODULE4 CHEMICAL USE AND STORAGE PPE SELECTION EMERGENCY RESPONSE

MODULE1 INTRODUCTION TO CHEMICAL MANAGEMENT

All training modules can be accessed at www.roadmaptozero.com


Module 4 Safe use of Chemical, Transfer and Storage at

the Facility Pre Selection

Emergency Response


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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


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Hazardous Chemicals - Storage General Rules for Storage of Common Dangerous Chemicals (GB

15603-1995)

•  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.


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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.


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Incompatibility of Textile Chemicals Chemical Incompa9ble Chemicals

Ace;c acid Aldehyde, bases, carbonates, hydroxides, metals, oxidisers, peroxides, phosphates, xylene

Ammonia Acids, aldehydes, amides, halogens, heavy metals, oxidisers, plas;cs, sulphur

Calcium oxide Acids, ethanol, fluorine, organic materials Carbon tetrachloride

Benzoyl peroxide, ethylene, fluorine, metals, oxygen, plas;cs, silanes

Chromic acid Acetone, alcohols, alkalis, ammonia, bases

Chlorine

Alcohols, ammonia, benzene, combus;ble materials, flammable compounds (hydrazine), hydrocarbons (acetylene, ethylene, etc.), hydrogen peroxide, iodine, metals, nitrogen, oxygen, sodium hydroxide


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Incompatibility of Textile Chemicals Chemical Incompa9ble Chemicals

Chlorine dioxide Hydrogen, mercury, organic materials, phosphorus, potassium hydroxide, sulphur

Flammable liquids Ammonium nitrate, chromic acid, hydrogen peroxide, nitric acid, sodium peroxide, halogens

Formaldehyde

Strong oxidising agents, caus;cs, 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 reac;on occurs when formaldehyde is mixed with strong oxidisers.


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Incompatibility of Textile Chemicals Chemicals Incompa9ble Chemicals

Hydrogen peroxide

Acetylaldehyde, ace;c acid, acetone, alcohols, carboxylic acid, combus;ble materials, metals, nitric acid, organic compounds, phosphorus, sulphuric acid, sodium, aniline

Hydrogen sulphide Acetylaldehyde, metals, oxidisers, sodium

Hypochlorites Acids, ac;vated carbon

Oxalic acid Oxidisers, silver, sodium chlorite P o t a s s i u m permanganate

Benzaldehyde, ethylene glycol, glycerol, sulphuric acid

Sulphuric acid Potassium chlorates, potassium perchlorate, potassium permanganate


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Basic Chemical Incompatibility Chart


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Incompatible Storage Table of Common Chemicals

There should not be any chemical reaction between chemicals and shelves or chemicals and containers.

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

✔ tl✘


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Incompatible Storage Table of Common Chemicals •  Devices for anti-explosion, anti-seep, fire protection and anti-static

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


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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.


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Safe transfer of Hazardous Chemicals •  Containers for flammable liquids should be specially constructed with spring-

loaded 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.


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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


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Safe Transfer of Hazardous Chemicals at a Facility

•  Do not shake chemicals. Over volatilisation can cause leaking.

•  While transporting chemicals, even small amounts, use leakproof equipment.


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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.


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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


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Anti-explosion, Anti-seep and Fire-Protection Equipment

Proper storage of explosives

Fume hood

Fire alarm

Overhead sprinklers


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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.


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•  AZer handling chemicals, wash hands before ea;ng.

•  Do not smoke near the chemical storage area.

•  Do not eat or prepare food in the chemical storage area.


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•  Use local ventilation systems to reduce inhalation of chemicals.

•  Always wear appropriate PPE appropriate to the task.


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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


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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)


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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.


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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?


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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


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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.


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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.

Hazardous Waste Non-Hazardous Waste


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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


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Storage of Waste Chemicals


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No Open Storage for Dangerous Waste


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No Open Storage for Dangerous Waste


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SECONDARY containment and barrier should be set for storage area


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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


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PPE Selection

Regulation and

standardsTask

evaluation

PPE using performance

Personal special

requirements


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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


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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.


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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


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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


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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


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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


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Leak Prevention – Facilities and Tools


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Leak Prevention - Gas Detector

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

Types of gas detector: •  Portable devices •  Fixed-gas detectors


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Leak-Absorption Materials

Types Examples Advantage DisadvantageInorganic Clay, sand Chemical inertness, cheap Low absorption efficiency,

incompressible, dirty, will cause secondary pollution.

Organic Rice husks, rag cuttings, cotton

Higher absorption efficiency than inorganic, cheap, light

Low absorption rate, dirty, fire hazard, will cause secondary pollution.

Complex Polypropylene High adsorption efficiency, chemical inertness, can be used repeatedly, compressible

Expensive, some liquid residue will stay in surface.

Typical Absorption Materials

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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.


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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)


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Firefighting Devices

•  Firefighting devices include extinguishers, fire hydrants, fire alarms, fire sprinklers, temperature detectors and smoke detectors.


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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.


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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


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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


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Next Training Module

The following aspects of chemical management are reviewed in subsequent training modules available at www.roadmaptozero.com:

•  Environmental impacts mitigation measures, wastewater treatment and monitoring

the zero discharge of hazardous chemicals programme · the zero discharge of hazardous chemicals...

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