INTRDU

LITERATURE
TOPIC BASED FINDING
Conclusion
reference
 SAFETY MEASURE IN HCl MANUFACTURING INDUSTRY
1.Introduction to Hydrochloric Acid
Manufacturing
• Hydrochloric acid, also known as muriatic acid, is an aqueous solution of hydrogen chloride gas.

• Hydrochloric acid is produced in the United States primarily by four basic methods:
the chlorination of organic chemicals;
the combination of hydrogen and chlorine;
the salt-sulfuric acid production process;
and, as a co-product in the manufacture of silica.

• Most hydrochloric acid is produced from the chlorination of organic chemicals with much smaller amounts
from the other processes.

• Hydrochloric Acid is a highly corrosive and hazardous chemical and should be handled with extreme care. Personnel
should be properly trained in the handling of hydrochloric acid and should always wear the proper protective equipment
when working around hydrochloric acid.

• All users should read the Material Safety Data Sheet (MSDS) before handling hydrochloric acid.
• Hydrochloric acid is very corrosive to the skin and mucous membranes and can cause severe burns to any part of the body.

• The corneas of the eyes are especially sensitive to hydrochloric acid and exposure to it or its vapors immediately causes
severe irritation.

• If the eyes are not quickly and thoroughly irrigated with water, partial or total visual impairment or blindness can occur.

• It is recommended that employees be provided with and required to use acid impervious clothing, gloves, boots, splash
proof goggles and other appropriate protective clothing necessary to prevent any possibility of skin contact with hydrogen
chloride mists or solutions.

• Material types which may be considered for this service include nitrile, neoprene, polyvinyl chloride (PVC), butyl rubber,
Responder, Trellchem, and Tychem.

• Face shields should also be provided when there is a chance of splashing liquid hydrochloric acid. Face shields can augment
protection provided by splash-proof goggles and safety glasses, but are not intended to replace these safety appliances.
• Hydrochloric acid has excellent warning properties.

• Concentrations of 0.3 parts per million (ppm) can be detected by smell, and concentrations above five parts per million will
cause discomfort.

• OSHA has established a ceiling value of five parts per million (5 ppm) for hydrochloric acid.
This means that an employee's exposure to hydrogen chloride should at no time exceed five parts per million.
Effective in 2003, the ACGIH TLV for hydrogen chloride is a ceiling value of 2 ppm.
Safety & First Aid
Safety precautions

• Since hydrochloric acid is highly corrosive, operators must always

wear protective gear when handling hydrochloric acid. Take a shower
or bath after the operations, and wash their face and hands, and
gargle immediately before taking a meal.

• If the place where the hydrochloric acid mist is produced, and the
place cannot be naturally ventilated, discharge the contaminated air
using an exhaust system.

• When a sealed acid-resistant bottle is opened, the slightly higher

pressure in the bottle than the ambient pressure may eject the
contents;

• therefore, keep the face or hands away from the cap of the bottle. ・
When hydrochloric acid is being taken out of an acid-resistant bottle,
do not use air pressure, but use a bottle holder that can be safely
tilted, and a siphon.

• When hydrochloric acid is sampled by suction, use a safe pipette,

vacuum pipe, or the equivalent.
• If an operator needs to enter a storage tank, tank car, tanker, tank truck or equipment using hydrochloric acid, fill the tank
with water to clean it beforehand, and sufficiently ventilate the tank after flushing.

• Disconnect any hydrochloric acid pipes connected to the storage tank, or insert a blanking plate to prevent any hydrochloric
acid from flowing in, and the operator must enter the tank wearing a ventilation mask (air aspirator) and safety rope and
have an observer standing outside the tank.

• Care must be taken so that the hydrochloric acid to be used does not mix and react with an oxide (especially nitric acid and
chlorate), cyanide, or sulfide which generates toxic gases.

• Water should always be easily accessible whenever hydrochloric acid is stored or used.

• Safety showers and eye wash fountains should be located in the immediate work area and clearly marked.

• These units should be tested on a regular basis. Portable or temporary systems are available.

• Every precaution should be taken to ensure that a suitable system is in place and operational before handling hydrochloric
acid.

• Only trained and properly protected personnel should be allowed to enter areas where hydrochloric acid is present.

• ANSI Standard 2358.1 contains placement and performance criteria for emergency eyewash and shower equipment.
Fire Precautions

• Although hydrochloric acid itself is not combustible, it corrodes various metals to generate hydrogen. Therefore, isolate
any flames during the operation of the pipelines and the tank.
• If the pipes or the tank must be welded or cut using a torch or any tool using a flame, it is necessary to check whether the
hydrochloric acid has been discharged and whether the pipes and the tank have been sufficiently cleaned and ventilated by
introducing air before starting the operations.

Treatment of Empty Containers and Waste

• As a rule, sufficiently clean up empty containers with water to remove any remaining hydrochloric acid after emptying the
contents. However, when the containers are to be exclusively used for hydrochloric acid, and the remaining mist or acid
cannot leak out, cleaning with water is not required.
• When hydrochloric acid is being disposed of, neutralize it by adding lime milk or a soda ash solution while slowly stirring it,
and then dilute it with a large quantity of water.

• Before entering tanks or opening pipelines that have contained hydrochloric acid, they should be drained or pumped out
and thoroughly flushed with water.
• Contact with the liquid draining from the equipment should be avoided.
• Do not enter a confined space (which includes tanks or pits) without following proper entry procedures such as 29 CFR
1910.146.
• Good housekeeping practices are important where hydrochloric acid is used.
• All spills should be contained and immediately recovered or flushed with water into a chemical sewer or a segregated
holding basin which is provided for the specific purpose of neutralization.
• Hydrochloric acid must never be flushed to a sanitary sewer or other outlet which connects to waterways or uncontrolled
runoff streams.
• Contact local and federal authorities for applicable regulations.

First Aid

• Eye Contact - The eyes should be immediately flushed with large amounts of water continuously for at least 15 minutes. Get
immediate medical attention. It is necessary to hold the eyelids apart while flushing to ensure complete irrigation of the eye.
Washing eyes within several seconds is essential to achieve maximum effectiveness. A delay of a few moments or incomplete
washing can result in partial or permanent blindness. Never attempt to neutralize hydrochloric acid in the eyes with
chemicals. Do not apply oils or ointments unless specifically prescribed by a physician.

• Skin Contact - Flush the area of contact with large amounts of water. Contaminated clothing should be removed while
underneath a safety shower. Get immediate medical attention. Do not attempt to neutralize the acid with alkaline solutions.
No oils or ointments should be applied unless specified by a physician.

• Inhalation – Remove individual to fresh air and get immediate medical attention. In cases of severe exposure, humidified
oxygen should be administered by someone medically trained to administer oxygen. If respiration or pulse has stopped, have
a trained person administer Basic Life Support (Cardio-Pulmonary Resuscitation and/or Automatic External Defibrillator) and
CALL FOR EMERGENCY SERVICES IMMEDIATELY.
Ingestion - Get immediate medical attention. If individual is a fully conscious, give large amount of water. Do not use sodium
bicarbonate in an attempt to neutralize the acid. Do not induce vomiting. Never give anything by mouth to an unconscious
person.

Traumatic Shock - Whenever injured persons are being cared for, the person administering first aid should watch for signs of
traumatic shock. Traumatic shock may follow serious injury and is a depressed condition of many body functions due to
inadequate blood circulation throughout most of the body. Signs of shock are pale, moist, cool skin; shallow and irregular
breathing; and weak pulse. Beads of perspiration may be noted about the lips, forehead, palms, and armpits. The patient may
become nauseated. To treat shock, keep the patient lying down and as warm and comfortable as possible. Raise the patient's
feet eight to twelve inches unless there is head injury, breathing difficulty, or if the patient complains of added pain.

Respiratory Protection
Basically there are 3 types of respirators
1. Escape
2. Air Purifying Respirators
3. Self-contained Breathing Apparatus

ESCAPE
In areas where the unexpected release of hydrogen chloride vapors may lead to potentially dangerous exposure, appropriate
escape respirators should be carried by or be readily accessible to each employee. The most common respirator used for this
purpose is the mouthpiece respirator. This respirator contains a single cartridge with a mouthpiece and nose clip. Employees
should only use this respirator when escape times are short and airborne concentrations of hydrogen chloride vapors are low.
AIR PURIFYING RESPIRATORS

• Air purifying respirators contain cartridges or canisters of absorbent or reactive

material to remove harmful gases from breathing air.
• These respirators are available as either half face or full-face units
• For hydrochloric acid service, use a cartridge or canister designed for hydrogen chloride
service.
• Where vapor concentration exceeds or is likely to exceed 5 ppm, a cartridge or canister
respirator should be used.
• When working in environments where airborne concentrations are irritating to the
eyes, full- face piece respirators should be used.
• Cartridge or canister respirators are strictly air-purifying devices and must never be
used in an oxygen deficient atmosphere (less than 19.5% oxygen by volume), in
environments immediately dangerous to life or health (IDLH), or areas containing
unknown concentrations of hydrochloric acid.
• It is important to remember that cartridges and canisters have a limited service life.
• Conditions such as humidity, chemical concentrations in the workplace, other
chemicals in the workplace, and frequency of use will affect cartridge and canister
service life.
• Therefore, an evaluation of workplace conditions should be made to determine the
appropriate cartridge/canister replacement schedule.
AIR PURIFYING RESPIRATORS

• Air purifying respirators contain cartridges or canisters of absorbent or reactive

material to remove harmful gases from breathing air.
• These respirators are available as either half face or full-face units
• For hydrochloric acid service, use a cartridge or canister designed for hydrogen chloride
service.
• Where vapor concentration exceeds or is likely to exceed 5 ppm, a cartridge or canister
respirator should be used.
• When working in environments where airborne concentrations are irritating to the
eyes, full- face piece respirators should be used.
• Cartridge or canister respirators are strictly air-purifying devices and must never be
used in an oxygen deficient atmosphere (less than 19.5% oxygen by volume), in
environments immediately dangerous to life or health (IDLH), or areas containing
unknown concentrations of hydrochloric acid.
• It is important to remember that cartridges and canisters have a limited service life.
• Conditions such as humidity, chemical concentrations in the workplace, other
chemicals in the workplace, and frequency of use will affect cartridge and canister
service life.
• Therefore, an evaluation of workplace conditions should be made to determine the
appropriate cartridge/canister replacement schedule.
SELF CONTAMINATED APPARATUS

• Self-contained breathing apparatus (SCBA) can provide respiratory protection in an oxygen-deficient environment and in
situations where unknown concentrations of hydrogen chloride vapors are present. The SCBA can also provide protection in
emergency situations.

• The SCBA is an atmosphere-supplying respirator for which the breathing air source is designed to be carried by the user
(OSHA )(Occupational Safety and Health Administration).

• A full-face mask is always used with this type apparatus.

• OSHA requires that when wearing the SCBA in an Immediately Dangerous to Life and Health
(IDLH) atmosphere (i.e. oxygen deficient or unknown concentrations of hydrogen chloride, as
could be expected in an emergency situation), the SCBA be operated in the pressure demand
mode and be certified by NIOSH for a minimum service life of thirty minutes.

• Escape SCBA devices are commonly used with full face pieces or hoods and, depending on
the supply of air, are usually rated as 3 to 60 minute units.

• OSHA requires that all respirators must be NIOSH approved and shall use breathing gas
containers marked in accordance with the NIOSH respirator certification standard,
42 CFR part 84.
Methods of Handling and Storage

Storage

• Hydrochloric acid is most commonly stored

either in rubber-lined steel storage tanks or
in fiberglass-reinforced plastic storage tanks.

• The rubber-lined steel tanks are usually more

expensive to install and are generally used
when larger volumes of acid are stored and
the chance of tank damage (puncture, tear, etc.)
is greater due to external physical stress in a
high density work or traffic area.

• A storage tank should have a concrete

containment dike coated with an acid-resistance
coating to confine any spilled product.

• Storage tanks should be equipped with instrumentation to accurately measure tank inventory and provide notification if
the storage tank is approaching an over-filled condition.
Storage Tank Venting
• To prevent possible tank failure, all hydrochloric acid storage tanks should be vented so that the pressure or vacuum ratings of
the tank are not exceeded.
• Exceeding the design limits of the storage tank could lead to possible failure of the storage tank.
• A properly designed vent system will maintain the tank at or near atmospheric pressure and within the tank design
parameters.
• A pressure/vacuum relief device should be in place in addition to the tank vent. Significant increases in pressure occur when
storage tanks are being filled.
• As acid is transferred into the tank and displaces air in the tank, the pressure tends to increase unless the vent system has the
capability to relieve the pressure.
• When liquid is withdrawn from the tank, an equal volume of outside air must enter the tank through a vent system or a partial
vacuum will be created inside the tank.
• This vacuum could cause cracking or collapse of the tank. Smaller changes in pressure occur during static storage conditions
due to changes in ambient temperature.
• A properly designed vent is especially important when acid is unloaded into the storage tank from a tank car or trailer utilizing
air pressure because of the sudden surge of air through the unloading hose and into the storage tank at the end of unloading.
The vent system must be designed to handle this air surge condition.
• The use of a larger diameter unloading line, longer vent line or vent line tied into a scrubber, etc. will require an even larger size
vent line.
• The scrubber back-pressure can make a large difference in the pressure in the storage tank during and immediately after
unloading.
• A typical packed column scrubber or re-circulating scrubber exerts very little back pressure; however, venting into the bottom of
a vessel below a liquid head may exert a back-pressure above the tank design in routine venting operations.
• The potential for over-pressuring FRP and other low pressure design tanks when using air pressure unloading is especially high.
• The air surge at the end of unloading will cause a rapid pressure rise in the tank and can exceed the tank design pressure unless
the vent system is sized properly.
• Catastrophic failures of FRP tanks have occurred due to over-pressurization. Professional engineering services should be
employed to design and size the vent system.
• Facilities are encouraged to frequently inspect scrubber systems for evidence of obstructions and proper operation to minimize
back pressure buildups.
• To prevent health hazards caused by hydrochloric acid mist, and to avoid the danger that the room will be filled with hydrogen
generated by the corrosion of metals, the building should be of an open structure and well ventilated.
• Use electrical facilities that are as airtight and corrosion resistant as possible. For the wiring, use plastic-coated wire, or use
airtight metal conduits protected by acid-resistant paint or plastic conduits.
• Store hydrochloric acid apart from oxidants (in particular, nitric acid or chlorates) and combustibles, as well as cyanides or
sulfides.
• Avoid direct sunlight and close proximity to a heat source. In addition, avoid passageways and places where there is a risk of
something falling.
• The containers must be mechanically strong and corrosion resistant, and should not allow the contents to leak out. The
containers must be tightly sealed, and an appropriate head space (5% by volume or greater) must be left when the container is
filled with hydrochloric acid.
• When hydrochloric acid is stored in a tank, always check the quantity of the remaining hydrochloric acid to prevent any danger
of its overflowing. Install a ventilation hole in the tank and connect the hole to a hazard prevention facility.
• Fiberglass-Reinforced Plastic (FRP) Tanks
 A fiberglass-reinforced plastic (FRP) tank is constructed in layers of fiberglass and each layer is mixed with resin. The selection
of the resin is extremely important, and the tank manufacturer should specify how each layer will be constructed and specify
the correct type of resin for the specific application.
 Fiberglass tanks are not always designed to withstand pressure or vacuum so proper venting is critical, especially if the
product is to be loaded into the tank with air pressure. The tank manufacturer should be consulted for a recommendation on
proper vent openings and pressure/vacuum relief systems.
 Fiberglass storage tanks should also be equipped with two 24-inch man ways, 3-inch flanged nozzles and 3-inch flanged
product inlet line. The tank manufacturer should be consulted for a recommendation on proper vent openings and
pressure/vacuum relief systems.
Structure
 When hydrochloric acid is transported, shipped,
or received using a tank truck, tank car, or
tanker, it is important to have an accurate
knowledge of the structure and materials of
the valves and pipes, as well as the interior and
exterior of the storage tanks related to the
transport, receiving, and shipping operations
on the basis of correct and accurate drawings;
and to keep everyone informed about these.
SPILLS AND NEUTRALISATION

• Containment of a spill or leak is of primary importance.

• The storage tank should have an impervious containment dike and the entire hydrochloric acid unloading area should be
designed to properly contain any spills.
• All persons working around the spill area should wear the full set of protective equipment as recommended in the Safety and
First Aid Section,. Rubber boots are absolutely necessary when working around a spill.
• Personnel should keep upwind of the spill, and if it is necessary to enter the spill area, a self-contained breathing apparatus
should be worn. People who are not involved with the leak or spill should be kept away.
• The hydrochloric acid can be neutralized with an alkaline material but the reaction between concentrated hydrochloric acid and
an alkali gives off heat and can be quite violent.
• Therefore, the acid should first be diluted by using a water spray and then neutralized. The spray will also reduce the fuming of
the hydrochloric acid. Alkaline materials to be used and quantities necessary for neutralization.

Equipment

• Hydrochloric acid is extremely corrosive to metals including the following: carbon steel, stainless steel, nickel, Monel,
bronze, brass, copper, Incone, and aluminum. These are commonly used industrial materials. Great care should be taken
to avoid contact of these materials with hydrochloric acid.

• Piping – All piping systems should be well supported. The coldest ambient temperature that may be encountered should
be considered in the selection of piping
• Lined steel is often used in piping system for hydrochloric acid because it is the most structurally rigid and is less likely to be
adversely affected by physical abuse. Lined steel systems also do not require gaskets at flanged connections.

• The liner itself acts as the gasket mating material. Common lining materials are polypropylene (PP), polyvinylidene fluoride
(PVDF) and polytetrafluoroethylene (PTFE). Pipes are typically carbon steel manufactured to ASTM F-1545 specifications.

• Hoses - Acid resistant hoses can be used to handle hydrochloric acid for both suction and discharge applications. Viton , natural
rubber, neoprene, butyl rubber and Hypalon are some of the materials that offer good chemical resistance to hydrochloric acid.

• Pumps – Composite and lined-steel pumps in hydrochloric acid service are mostly constructed of one of the following: PVDF
(polyvinylidene fluoride) ETFE (ethylene tetrafluoroethylene) FRP (fiberglass reinforced plastic) PFA (perfluoroalkoxy) PP
(polypropylene) Centrifugal pumps are commonly used when pumping hydrochloric acid.

• Magnetic drive centrifugal pumps have an advantage in that no seal is required which eliminates the possibility of leakage
through a seal. A double mechanical seal should be considered if sealed pumps are used. The gland area of the pump should be
shielded for personnel protection.

• Hydrochloric acid transfer or offloading pumps should be equipped with instrumentation to prevent continued operation when
the pump is dead-headed or running dry. A minimum flow recycle line will also help to prevent pump damage from dead-
heading.

• Suction lift is required in order to unload tank cars and tank trailers with top outlets. Self-priming centrifugal pumps are often
used for this application.
• Standard centrifugal pumps will require priming if used in these applications. Diaphragm and other positive displacement
pumps do not require priming and may find use in these applications. If a diaphragm pump is used, however, and the
diaphragm ruptures, fumes may be worse because of compressed air used to operate the pump.

• Valves - Depending upon the type of valve employed, a number of chemically resistant polymers may be suitable for valve
lining.
Examples are: PFA (perfluoroalkoxy), PTFE (polytetrafluoroethylene), PVDF (polyvinylidene fluoride) and PP (polypropylene).
Composite body ball valves have bodies, balls, and handles made of a fiberglass reinforced epoxy resin.

• Gaskets - Suitable materials for gaskets are Teflon envelope, Hycar rubber, ethylene-propylene rubber, or vinyl materials.

• Pressure Gauges - Pressure gauges need to be protected by a diaphragm from direct contact with hydrochloric acid.

Safety Facilities

• In order to prevent leaked hydrochloric acid from flowing out of the area of the storage facilities, it is preferable to install
facilities for the safe storage of hydrochloric acid or facilities for recovering it and preventing it from causing harm.

• Provide protection using banks to contain liquids, tank beds, and pit-like structures using acid-resistant paint, acid-resistant
mortar, concrete lined with asphalt, acid-resistant blocks, or facilities treated with sodium silicate.
CONCLUSION

• Operating rules
It is important to establish rules for the proper use of facilities for handling
hydrochloric acid or any associated facilities, and to operate them in
accordance with the rules.

• Voluntary inspection
Hydrochloric acid is a highly corrosive substance. It is important to
periodically inspect equipment that is used for handling hydrochloric
acid and to retain the inspection records.

• Supervision by qualified persons

When laws stipulate certain requirements, operations must be carried out
in accordance with these requirements.

• Prevent of erroneous operations

For the piping of facilities for handling hydrochloric acid, it is important to
take measures such as the indication of the name and the direction of flow
of the liquid, as well as color coding and indication of the opening and
closing direction of major valves and cocks. Furthermore, for the inspection
of the operating procedures or facilities, the utilization of a checklist is
effective.
Education and training First of all, make sure that the operators handling hydrochloric acid observe the operating standards for
safe operations. For this, it is necessary to provide education and training concerning:

• The location of protectors, showers, eye washers, sodium bicarbonate solution for gargling, water taps, cleaning hoses, and
first aid facilities
• Proper methods for the use of protectors and first aid facilities
• First aid measures to be taken in case of an emergency
• For operators filling tanks, measures for preventing a lack of oxygen deficiency.

It is also important to train supervisors concerning the following, and regularly carry out training drills for dealing with
disasters:

• Proper usage of the first aid facilities

• Measures to be taken in case of chemical injury

REFERENCES

• Hydrochloric Acid Storage and Piping Systems, Pamphlet 163, The Chlorine Institute, 2001 .

• 49 CFR, Code of Federal Regulation Title 49 – Transportation, Hazardous Materials Regulations, U.S. Government Printing
Office.

• NIOSH Respirator Decision Logic, DHHS (NIOSH) Publication No. 87-108, May, 1987 .
• 2007 TLVs and BEIs, Threshold Limit Values for Chemical Substances and Physical Agents.

• Safety Science Volume 121January 2020 Alex Garcia de Almeida, Jan Erik Vinnem.

• Journal of Loss Prevention in the Process Industries Volume 65May 2020Article 104092 Xiaoming Gao, Abdul
Aziz Abdul Raman, Hanee F. Hizaddin, Mustapha Mohammed Bello.

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