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APCBEE Procedia 9 (2014) 187 191

2013 5th International Conference on Chemical, Biological and Environmental Engineering

(ICBEE 2013)
2013 2nd International Conference on Civil Engineering (ICCEN 2013)

A Study on Handling of Hazardous Chemicals in Engineering

Industries
P. Sivaprakasha , L. M. Karthikeyanb and Sebastian josephb
a

Department of Mechanical Engineering, Karpagam Institute of Technology, Coimbatore, Tamilnadu - 641105, India
b

Department of Mechanical Engineering, Karpagam University, Coimbatore, Tamilnadu - 641021, India

Abstract
The possibility of danger in any circumference is known as Hazard. The hazardous chemicals are the substances used in
various engineering industries for production, analysis, research and other usages. Any unexpected event producing injury
or damage in engineering industries is referred as an accident. In this study, the review of literature and details of various
accidents that had happened due to hazardous chemicals in south India has been studied. Handling and environmental
preventive methods for engineering chemicals are mentioned for maintaining safe working environment of the
engineering industries.

2013P.Published
byPublished
ElsevierbyB.V.
Selection
2014
Sivaprakash.
Elsevier
B.V. and/or peer review under responsibility of Asia-Pacific
Chemical,
Environmental
Engineering
Selection andBiological
peer review&
under
responsibility of
Asia-Pacific Society
Chemical, Biological & Environmental Engineering Society
Keywords: Accident, Hazard, Risk, Safety

1. Introduction
Hazards must be identified in engineering industries using chemicals in various forms like solid, liquid and
gases to maintain safe working environment. The study of various accidents happened can be carried out for
identifying the major hazards which creates accidents in engineering industries. Most of the chemical
accidents in south India happen because of the careless mistakes and improper handling of materials. In this
study, the safe handling methods of the various chemicals are explained. The preventive methods for

Corresponding Author. Tel.: +91 9842242455; fax: +91 422 2980016.

E-mail address: drpsivaprakash@yahoo.in

2212-6708 2014 P. Sivaprakash. Published by Elsevier B.V.

Selection and peer review under responsibility of Asia-Pacific Chemical, Biological & Environmental Engineering Society
doi:10.1016/j.apcbee.2014.01.033

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chemicals from bad weather condition are studied in the last session and most of the safe handling techniques
of engineering chemicals have been discussed.
2. Handling Methods for Various Hazardous Materials
Juan et al indicated eight major causes for accidents namely mechanical failure, impact, human factors,
Instrument failure, services failure, violent reaction, External events and upset process conditions [7]. The
engineering industries are using various kinds of hazardous chemicals like flammables materials, explosive
chemicals, corrosive materials, toxic substances, heat sensitive materials, oxidizing agents, gases under high
pressure, water sensitive chemicals and radioactive materials. The petroleum and explosives safety
organization (PESO) [2] comes under department of industrial policy & promotion, government of India has
indicated the reasons and various causes for chemical accidents in their annual report 2011 12 as shown in
Fig. 1. Ren Changing et al explained that chemical accidents during transportation are main issues for a public
safety [10]. So quick response required from the accidental area to solve the problem easily and reduce human
death. Apart from the properties of chemicals, the physical state of chemical whether it is a solid, liquid or gas,
is also of greater importance in handling the chemicals. At times, it may be more advantageous to handle
chemicals as a liquid or gas even though maintaining it at a higher temperature is difficult.
2.1. Flammable and Explosive Chemicals
Rigas indicated that accidents are classified due to the hazardous substances based on three different types;
they are dispersion, fire and explosion [12]. All organic chemicals are flammable. Dust of organic materials
and dust of metals like aluminum, magnesium and sodium may be easy to ignite and explode in the air.
Flammable gases like hydrogen, acetylene, and methane are easy to ignite and may burn with explosion.
Avoid the possibility of ignition sources in the vicinity of handling such materials. Handling of flammable
solvents/liquids requires special care. Small quantities of solvents/liquids are handled through drums, carboys
and cans and large quantities through pipelines. While handling these liquids, spillage due to damage of
containers, leaking of pipe lines is to be avoided. While handling flammable solid, liquid or gas, spillage can
be restricted to a certain extent, adopting safe procedure. Kevin et al indicated in their paper that in daily life
the explosive flammable and toxic are more dangers hazards when improperly released [8]. To avoid fire
hazards ignition sources are to be eliminated by providing explosion proof electrical appliance; earthing,
bonding to the handling and storing equipment to prevent static electricity and using non-sparking tools for
maintenance jobs. A hot work permit system is to be implemented to carry out any hot work in this area. Fire
alarm and firefighting equipment are to be provided in this area as per the recommendations by Tariff
Advisory Committee. If any flammable liquid spillage or gas leak occurs the area is to be barricaded, traffic is
to be diverted till the area is free from explosive mixture. Explosive meter is an ideal instrument to check the
atmosphere and to locate the gas leak. Explosives are shock sensitive. Sivaprakasam et al indicated that in
India, fireworks manufacturer are generally carried out their work manually due to sensitive nature of the
chemical mixtures to thermal, mechanical and electrical hazards [13]. The manufacturer's instructions are the
best guide in handling of explosives. Storage and handling of explosives are controlled by the explosive
inspectorate. Metallic tools should not be used with explosives and all materials should be guarded against
rough handling.

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(a) Reasons for Chemical Accidents

15%

31%

(b) Causes for Chemical Accidents

16%

Careless
54%

1%

Friction Sensitive

Oils
Gases

Others

Soild Chemicals
83%

Fig. 1. (a) Reasons for Chemical Accidents; (b) Causes for Chemical Accidents

2.2. Corrosive Chemicals

Corrosive chemicals like acids and alkalis react vigorously with metals and organic substances according
to its concentration. While concentrated sulphuric acid can be handled through iron pipes in large quantity and
ceramic pots in less quantity, phosphoric acid can be handled through rubber lines, pipes and tanks. Dilute
sulphuric acid reacts with metals and produces hydrogen. It easily corrodes the metals and pipelines which
leads to a hidden hazard. One cannot predict when acid line leaks so periodic inspection of acid handling
equipment is necessary. While handling acid and alkali equipment like Polyvinyl Chloride (PVC) overalls,
PVC gloves, PVC gum boots, PVC hoods are to be worn. Emergency eye wash fountains, safety showers are
to be provided in the acid and alkali handling areas. Spillage of acid, if any, is to be neutralized with lime
powder and washed with water. Washable and drained liquids are to be routed to effluent pit through well
protected channels and gutters. There are limited chances for entering toxic chemicals through ingestion.
Workers may take chemicals through mouth by mistake. This can be avoided by proper label, writing the
toxic effect of the chemicals in local languages, displaying warning symbols. Other chances through mouth is
through food stuff, water which are contaminated by toxic chemicals while handling. This can be avoided by
testing food stuff and water for any contamination and adulterations, if any, when suspicion arises. Toxic
chemicals entering into the body through skin absorption is very less and can be avoided easily by adopting
safety methods of chemical handling. Proper clothing is to be worn to avoid the contact of chemical in the
body. Proper gloves are to be used while handling hazardous chemicals to protect hands. If not possible, at
least apply barrier cream in hands to resist the entry of chemicals into the body by skin absorption. PVC dress,
apron, face shields, PVC hood, PVC gloves, PVC gumboots and goggles are to be recommended materials for
chemical handling.
3. Preventive Measures from Bad Weather for Hazardous Chemicals
William noted that, in process Industries reactive chemical incidents have led to numerous losses and have
affected the society [15]. Jager stated that in a chemical industry an explosion hazard may exist when the dust
materials are produced, stored or processed and these materials are present as a mixture of air [6]. The
important preventive measures to avoid spillage or pollution of toxic chemicals are as follows:
3.1. Solid State Hazardous Chemicals
Formation of dust in hazardous chemicals must be stopped at the source itself. The dust has to be collected
by vacuum entrapped in cyclones or Scrubbers. The toxic chemicals must be treated to form non-toxic

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chemicals with other chemicals. Consider the below example.

Hydrogen Cyanide (toxic) + Sodium Thiosulphate = Sodium Thiocyanate (non-toxic)
Arsenic and its compounds are toxic, and no other method is available to change the toxic arsenic to nontoxic arsenic. Many of the chemicals undergo decomposition even at moderate temperature and evolve toxic
gases. Most of the pharmaceutical products are very sensitive to temperature. While handling and storing, low
temperature should be maintained.
3.2. Liquid State Hazardous Chemicals
Wanda et al indicated that very dangerous chemicals involved in major accidents are sulfuric acid,
hydrochloric acid, ammonia, sodium hypochlorite, and carbon monoxide [14]. Marlair explained that, in Solid
physical state, at normal temperature and pressure ammonium Nitrate is chemically stable [9]. It has a melting
point of 170oC and begins to decompose at 2100. In Ammonium Nitrate major Hazards in relation with fire
and explosion risk.
In a fusion reactor, high-level tritiated water will be generated and stored in various areas. Hayashi et al
explained that to avoid the corrosive condition the chemical contaminations in the water should be monitored
periodically [4]. Spillages are to be avoided by just draining the hazardous liquid to the ground. Draining and
washings are to be collected in proper containers. Toxic liquid should not be contaminated with drinking
water, reverse, channels, sea etc. While handling the oxidising chemicals, they come into contact with
combustible materials and thereby fires and explosives may be induced. In case of spillage, these materials
can mix with other organic materials and start fire and explosion. These chemicals are also heat sensitive and
should be kept in cool place. According to Hoppe.T et al, the preventive measures from the explosion requires
at least to meet any one of the three conditions are [5];
x To avoid the development of explosible mixtures
x To replace the atmospheric oxygen with an inert gas, working in a vacuum
x By preventing the occurrence of effective ignition sources
They react with water or moisture and produce dangerous and flammable gases and heat. In case of
spillage, these chemicals should not be washed with water. If there is any fire while handling such chemicals,
water should not be used for fire fighting. Only dry chemicals should be used to extinguish the fire. These
chemicals should be stored in a water proof shed and handled in moisture free environment.
3.3. Hazardous Gases and Vapors
Venting to open atmosphere is to be prohibited. Pressure safety relief valves should not be allowed to pop
to the atmosphere. Relief valve exit is to be connected to a common flare header. Hazardous gases and
vapours should be vented through flare system. Gas stack effluent is to be controlled by providing continuous
stack monitoring system. In Industries, gases such as hydrogen, nitrogen, oxygen, chlorine, ammonia,
acetylene, ethylene, argon etc. are used widely. These gases are supplied in cylinders in various sizes and
under varying pressures. Utmost care should be taken while handling and storing of such cylinders.
Nitrogen and carbon monoxide are the two industrial gases which may give harm to human life silently
since these are not having any characteristic odour to give warning of their existence. Rigas et al stated that
working with the organic material contents with nitration is a potentially dangerous process, because nitration
performs exothermic reactions under suitable conditions with explosive substances [11]. In gold and silver
mine, the safety precautions are essential to maintain the working environment in a safe manner. Akcil
indicated that staff members working in mines has continuously plan and provide detailed accounts of the

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management practices and initiatives being undertaken with regard to handling hazardous substances [1].
Fabiano et al noted that economical factors, technology based job design, organization of work or
environmental conditions and human factors are the several factors that can affect the occupational accidents
frequency [3]. To avoid human entrap in such atmospheres, workers should have proper knowledge about the
sources of the hazardous gases in the process and adequate precaution is to be taken by wearing breathing
apparatus.
4. Conclusion
The different types of chemicals must be stored in proper methods for safe handling. The careless mistakes
will create dangerous accidents and material losses also. This paper indicates various storage and accident
prevention methods for chemicals in industrial environment. The improper handling and storage methods
must be avoided in chemical industries for creating and maintaining a safe working environment.
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