5. Improving safety performance

While chlorine-based products provide great benefit to society, the industry acknowledges the safety hazards of some aspects of its chemistry. Elemental chlorine is a poisonous gas that can irritate the respiratory system, mucous membranes, eyes and skin. As a liquid, chlorine causes skin and eye burns on contact. hydrochloric acid and hypochlorous acid, both corrosive and potentially dangerous if mishandled, can be formed when chlorine gas reacts with moisture. Through the WCC safety program, the industry works to achieve continuous improvements in global safety performance, both at facilities and during transportation. Key initiatives include:

• Incident Reporting Program, initiated by the WCC Global Safety Team in 2002, is intended to improve safety incident record-keeping globally. This program documents chlorine related-incidents (including accidental emissions and near misses) at both fixed facilities and in transportation. The information is compiled and reported to WCC members to provide lessons that may help prevent future incidents. Currently, most of the data reported is from Europe and North America. Human error and corrosion of equipment were the two most common factors reported in the database. A challenge for WCC is to improve reporting from other regions and make this a truly global database of incidents.
• Designation of Chlorine Safety Stewards at major chlorine-producing companies. Using information and tools developed by WCC, these Safety Stewards help promote safety improvements within their own company facilities. This includes distribution of posters and manuals for the safe operation of equipment and handling of chlorine products. Materials, such as the WCC Safety Poster, have been translated into multiple languages for global use.
• Sharing safety guidelines across national and regional associations, dissemination of safety information through the WCC Global Network, and promotion of safety to endusers through the ICCA Responsible Care® program. An example of this type of initiative was the conference in Beijing in April 2006 (see Chapter 6).

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Safety at production facilities

Within chlor-alkali plants and downstream production facilities, management of chlorine is especially important to protect employees, the local community and the environment. Facilities continuously work to improve equipment design, process control procedures and employee training. As a result, the chlor-alkali industry is one of the safest of all manufacturing sectors. In 2004, U.S. chlorine producers had a workplace injury and illness incidents rate that was 67% lower than the average for U.S. workers, and 76% lower than for other manufacturing industries.

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Transportation safety

Safe transportation of chlorine continues to be a high priority. In the U.S., the Chlorine Institute has worked in partnership with the railroads and government since 1924 to help improve transportation safety. Voluntary safety guidelines and strict government regulations cover all aspects of chlorine transportation by rail. Numerous safeguards—such as enhanced mechanical integrity, employee training and additional inspections—aim to help prevent accidental releases.

CHLOREP: A model for emergency response

For more than 30 years, the Chlorine Institute has helped emergency responders prepare for and respond to chlorine emergencies in the U.S. and Canada through its Chlorine Emergency Response Plan (CHLOREP). This program has been studied and benchmarked against the chlorine industries of many countries around the world. CHLOREP quickly mobilizes industry expertise to an accident site involving chlorine. Trained emergency teams from chlorine producing, packaging and consuming plants are on alert on a 24-hour basis to handle chlorine emergencies. Any carrier, customer, or civil authority can obtain basic emergency information and be put in contact with the closest CHLOREP regional team by phoning emergency dispatch agencies—CHEMTREC in the U.S. or CANUTEC in Canada.

In Europe, bulk chlorine has been shipped for almost 60 years without a single fatality. More than 90% is used at the site of manufacture, and is not transported at all. However, since chlorine has so many essential uses, it is inevitable that some must be transported. Railways are the main method of transport, accounting for 77% of chlorine movements in Europe (excluding pipeline). Road transport for bulk supply is used only in the UK and, to a limited extent, in Spain. Stringent safety measures are implemented during transport. Chlorine is carried in specially designed steel containers, ranging from cylinders carrying a few kilograms of chlorine to road and rail tank cars containing 20-60 metric tonnes. The industry will continue to build on its strong safety record with continuous improvements in transport and distribution. The chlor-alkali industry will continue to work with governments and railways to explore ways to improve the safety and security of rail shipments and to address the causes of any incidents. It will also continue to cooperate with researchers and tank car manufacturers to improve the structural integrity of chlorine tank cars.

Latin American congress on transportation

In 2005, Clorosur organized a latin American congress of chlor-alkali and derivatives transportation aimed at sharing best practices from several countries. The event also aimed to foster closer relationships between the various parties involved in the chlor-alkali production chain in Latin America, by promoting a broad debate between producers and their marketing and distribution partners.

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Extending safety to the end-user

The chlorine industry is committed to promoting safety at all stages of product lifecycles, from production to end-use and disposal. This includes helping to educate end-users on safe handling practices. An example is the Charters of Co-operation program between the European Chlorinated Solvent Association (a part of Euro Chlor) and national groups representing chlorinated solvent users. Fourteen charters are in place in six countries with the aim of supporting Responsible Care® and use of best practices throughout the industry. In dry cleaning and industrial degreasing, improved practices and increased recycling mean that volumes of solvents sold have fallen markedly while usage has risen.

OxyChem tackles safety in Chile

Occidental Chemical Corp (OxyChem) health, environment and safety (HES) programs aim to reduce and manage risks and promote safe production, distribution, use and disposal of products. Product risk assessment is based on the internationally recognized Global Chemicals Management Policy (GCMP) framework. A case in Chile exemplifies GCMP’s effectiveness. Chilean authorities had a problem with street vendors selling a compromised version of bleach in discarded soft drink containers, which created a serious public safety hazard. OxyChile worked together with distributors to improve packaging and labeling standards for household bleach. Also, OxyChile funded the development and distribution of information on the safe handling and use of bleach that accompanied all product shipments, and worked with others to establish a voluntary self-verification process for proper product use. The improved practices helped reduce emergency incidents relating to accidental ingestions by 50% in the first year.

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