RISK ASSESSMENT USING POOL FIRE AND HEALTH INDEX ANALYSIS AT BIOENERGY PLANT

JULIZA BT MOHD FUAD NGO

A report submitted in partial fulfilment of the requirements for the award of the degree of Master of Engineering (Civil Environmental Management)

Department of Environmental Engineering Faculty of Civil Engineering Universiti Teknologi Malaysia

NOVEMBER, 2008

iii

To my beloved parents, friends, course mates & lecturers, Thanks for your patience, support, guidance & confidence in me.

iv

ACKNOWLEDGEMENT

I would like to express my sincere appreciation to my supervisor Dr Mohd Fadhil Md Din for his dedicated guidance, valuable ideas. Tireless efforts ad ongoing support troughout this project

Special appreciation to my parents; Mohd Fuad Ngo Abdullah and Hisah Omar and my family for their understanding, support and love.

Further more, I would like also grateful to all lab assistants, including Pn. Ros, En Yusuf, En Suhaimi and others for helping me in collection of samples, equipment preparation and share their opinion. Words of thank would never be enough. This project would not be able to be completed in time without their endless cooperation and guidance.

Last but not least, I would like to thank all my fellow friends for their support and motivations in completing this research study.

ABSTRACT

Risk assessment is recognized as a complete process of identifying a hazard and evaluating the risk either in absolute or relative terms. Risks at Vance Bioenergy Sdn Bhd are measured by identifying the most hazardous and flammability of raw material used in methyl ester and refined glycerin plant. As a result, methanol is the most flammability; hence the study focuses at the methanol storage tank. The area affected is determining using pool fire analysis. Besides that, the study also

identifies the air emission from the stack sampling based on the secondary data obtained from preliminary environmental impact assessment study. The health

effects from the air quality within Vance Bioenergy Sdn Bhd. and their surrounding areas are determined constantly to verify whether it could affect to human or not. Overall, the health index at three sampling point showed averagely 0.7, which is less than 1 and presume it could not give any significant impact to health. Beside that, the air quality also complied with the Malaysian Recommended Environmental Air Quality Guidelines. An Emergency Response Plans (ERP) is proposed to mitigate and prevent any risk or accident during the plant operations.

vi

ABSTRAK

Penilaian risiko merupakan proses lengkap dalam mengenalpasti bahaya dan menilai risiko kemalangan sama ada secara keseluruhan atau fokus kepada sesuatu bahagian. Risiko di Vance Bioenergy Sdn Bhd dilakukan dengan mengenalpasti bahan mentah yang paling merbahaya dan mudah terbakar. Daripada kajian yang dijalankan, metanol merupakan bahan yang sangat mudah terbakar. Untuk itu kajian ini dijalankan di tangki simpanan methanol. Kawasan yang terjejas dikenalpasti menggunakan analisis pool fire. Selain itu, kajian ini juga mengenalpasti kualiti udara yang dilepaskan oleh cerombong dandang di Vance Bioenergy Sdn Bhd berdasarkan kajian lepas. Kesan terhadap kesihatan dari kualiti udara di Vance Bioenergy Sdn Bhd dan kawasan sekitarnya ditentukan untuk memastikan sama ada udara yang dilepaskan dari cerombong member kesan dar segi kesihatan kepada manusia atau tidak. Secara keseluruhan, index kesihatan yang diperoleh adalah 0.7 iaitu kurang dari 1 dan tidak memberi sebarang kesan kepada kesihatan manusia. Selain itu, kualiti udara juga memenuhi Standard Kualiti Udara Malaysia. Seterusnya, Emergency Response Plans (ERP) dicadangkan untuk mecegah dan menghindar sebarang risiko atau kemalangan semasa loji beroperasi.

vii

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

TITLE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF SYMBOLS/ ABBREVIATIONS LIST OF TABLES LIST OF FIGURES LIST OF APPENDICES

i ii iii iv v vi vii x xi xii xiv

INTRODUCTION 1.1 1.2 1.3 1.4 1.5 Introduction Problem Statement Objectives of the Study Scope of the Study Background of the Company 1 3 4 4 4

LITERATURE REVIEW

2.1 2.2

Introduction Purpose of Risk Assessment

6 8

viii 2.3 Process of Risk Assessment 2.3.1 2.3.2 2.3.3 2.3.4 2.4 Hazard Identification Exposure Assessment Dose-Response Assessment Risk Characterisation 8 8 9 10 11 12 12 13 13 14 15 15 16 17 17 18 19 21

Types of Risk Assessment 2.4.1 Qualitative Risk Assessment 2.4.2 Quantitative Risk Assessment

2.5 2.6 2.7

Pool Fire Failure Rates for Tankage Types of Air Pollutants 2.7.1 2.7.2 2.7.3 2.7.4 Sulphur Dioxide (SO2) Nitrogen dioxide (NO2) Carbon Monoxide (CO) Total Suspended Particulates (TSP)

2.8 2.9

Methanol Glycerin

2.10 Production Process of Glycerin Distillation and Refining Plant 2.11 Emergency Response Plan

24

METHODOLOGY

3.1 Introduction 3.2 3.3 3.4 3.5 Data and Information Collection Hazard Identification Pool Fire Air Quality 3.5.1 3.5.2 3.6 Equipment Sampling Location

26 26 27 27 29 29 30 34

Exposure Assessment

ix 4 RESULT AND DISCUSSION 4.1 4.2 4.3 4.4 4.5 Introduction Hazard Identification Pool Fire Failure Rate for Tank Exposure Assessment 4.5.1 4.5.2 4.6 Air Emission Air Ambient 36 36 40 41 44 44 50 51 54 55 55 60 64 66

Emergency Response Plan (ERP) 4.6.1 4.6.2 Declaration of Emergency Emergency Procedure 4.6.2.1 4.6.2.2 4.6.2.3 Plant Emergency Transportation Emergency Injured Person

4.7

Evacuation Plan

CONCLUSIONS AND RECOMMENDATIONS

5.1 5.2

Conclusions Recommendations

69 70

REFERENCES

71

APPENDICES

75

LIST OF SYMBOLS/ ABBREVIATIONS

Q m Hc, k D Af q Q R xr EDair C IR EF ED BW NIOSH DOSH OSH ERP

Heat release rate (kW) Mass burning heat (kg/m2-sec) Heat of combustion (kJ/kg) Empirical Constant (m-1) Diameter of pool fire (m) Surface area of pool fire (m2) Radian heat flux (kW/m2) Heat release rate (kW) Distance from center of the pool fire to edge of the target (m) Radiative fraction Estimate dose (mg/kg/day) Concentration Inhalation rate (m3/day) Exposure factor (days/year) Exposure Duration years (kg) Body weight (days) National Institute of Occupational Safety and Health The Department of Occupational Safety and Health Occupational Safety & Health Emergency Response Plan

xi

LIST OF TABLES

TABLE NO

TITLE

PAGE

2.1 3.1 3.2 4.1

Failure rates for the tankage Burning rate data for fuel Standard value for IR, EF, ED, BW and AT Hazard identification for raw material used in Methylester and Refined Glycerine process

15 28 35 38

4.2 4.3 4.4 4.5 4.6 4.7

Effect of Thermal Radiation Specification of boiler The stack air quality emission Health Index for A1, A2 and A3 Type of pollutants and effect to health Definition of term used in ERP

40 44 45 50 51 52

xii

LIST OF FIGURES

FIGURE NO

TITLE

PAGE

1.1 2.1 2.2 2.3 2.4 2.5

Location of Vance Bioenergy Sdn Bhd. Element of risk analysis Process of health risk assessment Methanol chemical formula Glycerin chemical formula Process of Palm Oil conversion into Methyl Ester and Refine Glycerin Material

5 6 11 18 20 23

3.1: 3.2 3.3 3.4 (a) 3.4 (b) 3.4 (c) 3.5 (a) 3.5 (b) 3.5 (c) 3.6 (a) 3.6 (b) 3.6 (c) 4.1 4.2 4.3

GrayWolf DirectSense Tox PPC Kit Mini Vol. Portable Air Sampler Sampling location for A1, A2 and A3 Sampling for TSP at Station A1 Sampling for CO, NO2 and SO2 at Station A1 Station A1 at Jalan Keluli 5 Sampling for TSP at Station A2 Sampling for CO, NO2 and SO2 at Station A2 Station A2 at Jalan Keluli 4 Sampling for TSP at Station A3 Sampling for CO, NO2 and SO2 at Station A3 Station A3 at the Taman Pasir Putih Methanol Storage Tank Small pool fire at Methanol Storage Tank Large pool fire at Methanol Storage Tank

29 29 30 31 31 31 32 32 32 33 33 33 37 42 43

xiii TITLE PAGE

FIGURE NO 4.4

Predicted TSP dispersion GLC within 3km radius from the factory.

46

4.5

Predicted NO2 dispersion GLC within 3km radius from the factory. Predicted SO2 dispersion GLC within 3km radius from the factory Predicted CO dispersion GLC within 3km radius from the factory

47

4.6

48

4.7

49

4.8 4.9 4.10 4.11 4.12 4.13

Assembly Point Emergency procedure for fire Emergency procedure for hazardous chemical spill Emergency procedure for toxic gas released Emergency procedure for fire during transportation Emergency procedure for chemical spill during transportation

56 57 58 59 62 63

4.14 4.15

Emergency procedure for Injured Person Evacuation Procedure

65 68

xiv

LIST OF APPENDICES

APPENDIX

TITLE

PAGE

A B C D E F G H I J K

MSDS Acid Citric MSDS Sodium Hydroxide MSDS Methanol MSDS Glycerin MSDS Palm Oil MSDS Acid Phosphorus MSDS Sodium Methylate 30% Example of Calculation for Pool Fire Result for Air Sampling Example of Calculation for Health Index Recommended Malaysian Air Quality Guidelines

75 81 88 95 102 108 114 123 125 126 127

CHAPTER 1

INTRODUCTION

1.1

Introduction

Risk can be defined as a dangerous or unpleasant occurrence that possibly creates a dangerous situation. Risk assessment is a proper measurement at workplace that could cause harm to people, seriousness of the hazard level and to propose a mitigation procedure that could reduce the risk to the acceptable level. It is very important to ensure nobody gets hurt and free from contamination environment (USEPA, 2008).

Risk characterization is an integral component of the risk assessment process for both ecological and health risks (Fowle, 2000). A human health risk assessment is the process to estimate the nature and probability of adverse health effects in humans that may be exposed to chemicals in contaminated environmental media, either current or the future situation. An ecological risk assessment however is the process in evaluating the environmental impact from an exposure to of or more environmental stressors such as chemicals, land change, disease, invasive species and climate changes (USEPA, 2008).

2 In Malaysia, National Institute of Occupational Safety and Health (NIOSH) and The Department of Occupational Safety and Health (DOSH) are two organizations that responsible in enhancing occupational safety and health. DOSH is a department under the Ministry of Human Resources. This department is

responsible for ensuring the occupational safety, health and welfare of people at work as well as protecting other people from the safety and health hazards arising from the activities of various sectors such as manufacturing, mining and quarrying, construction, hotels and restaurants (DOSH, 2007).

The role of occupational safety and health has been in existence since 120 years ago, in the late 19th century. It started with steam boiler safety and then followed by machinery safety. After that, it was continued with industrial safety, industrial safety and hygiene and lastly occupational safety and health that cover every work sector. Factories and Machinery Act 1967 (Revised - 1974),

Occupational Safety and Health Act 1994 (Act 514) and Petroleum Act (Safety Measures) 1984 (Act 302) are three acts that being forced by DOSH (DOSH, 2007).

NIOSH was launch on December 1, 1992 as an intention to improve the safety and health of workers at the workplace in Malaysia. Training is an integral part of Occupational Safety & Health (OSH). To ensure the success of any OSH programme at the workplace, adequate and effective training must be adapted at all level associated with OSH. Training enables managers, supervisors and workers to understand the workings of safety management systems and the legal compliance required. They will also understand their own responsibilities and the necessary actions to be taken towards upgrading safety and health at their respective workplaces. Many training provide by NIOSH for example, Occupational Safety & Health Act 1994, Safety & Health Officer Examination Workshop and Safety in the Use of Chemicals (NIOSH, 2008).

3 1.2 Problem Statement

The requirements of risk assessment have become more important particularly after the fatal explosions at Petronas oil terminal at Pasir Gudang Industrial Estate. The incidents occurred when two storage tanks containing petrol and a natural gas tank caught fire by lightning strike during a thunderstorm on 28 April 2006 (Bernama, 2006). Even though no injuries reported, this incident

increases awareness among the people about the importance and purpose of risk assessment. Besides that, two incidents are also reported at methanol plant in

Seberang Perai, Penang (The Star, 2004) and Labuan (The Star, 2007) on 2004 and 2007. The latest incident is at Tanjung Langsat on 24 August 2008 where a fire broke out at one of the eight oil storage tanks (Bernama, 2008).

Pasir Gudang Industrial Estate have various types of industry such as chemical, plastic, oil and gas, food and others. Most of them are involving with hazardous and dangerous materials. Vance Bioenergy Sdn. Bhd. is one of the

industries at Pasir Gudang Industrial Estate that handling with contaminated and hazardous materials. Nearby Vance Bioenergy located heavy industry such as Chye Hup Heng Sdn Bhd (metal recycling), Panagawa Sdn Bhd (plastic manufacturing), White Horse Ceramic Industries Sdn Bhd (tile manufacturing) and Mox Gases Sdn Bhd (gas). Risk assessment should be carried out to ensure the possible and

dangerous accident which can be minimized.

Air is one of the major problems in Malaysia. Beside incident from fire or explosion, another risky problem that may occur at Vance Bioenergy Sdn Bhd is from air. Air emission from stack will disperse to the surrounding and may pollute the air. Health index analysis is carried out to determine either the concentration of air pollutants may cause an impact to human health or not.

4 1.3 Objectives of the Study

The objectives of this study are as follows:

a) To determine the quantitative risk assessment on potential risk at methanol storage tank and health risk from air pollutant within the Vance Bioenergy Sdn Bhd. b) To propose a standard procedure of emergency response plan (ERP) during any emergency events.

1.4

Scopes of the Study

The scopes of this study are as follows:

a) Identified the potential quantified risk within the Vance Bioenergy Sdn Bhd boundary using pool fire analysis. b) Identified the health effect of air quality at Vance Bioenergy Sdn Bhd by calculating using an airborne health index equation. c) Propose the emergency response plan (ERP) to be followed by workers, contractors or visitor at the industry in case of any accident occurs.

1.5

Background of the Company

Vance Bioenergy is a leading biodiesel production, marketing and trading company based in South East Asia. Vance Bioenergys corporate headquarters is in Singapore and its production based in Malaysia. Vance Bioenergy is located at PLO

5 668 and 669 of Jalan Keluli 5, Pasir Gudang Industrial Estate, Mukim Plentong, Johor Bahru, Johor.

Currently,

Vance

Bioenergy

is

an

established

industrial

biofuel

manufacturing since 2006. Palm based Methyl Ester is the main product of Vance Bioenergy Sdn Bhd, while crude Glycerin and fatty acids solution is the by products of Methyl Ester facility. The existing Glycerin plant is producing at 24000 tons/yr or 78 tons/d. Now, Vance Bioenergy Sdn Bhd intended to increase their existing Glycerin facility to raise their production from 78 tons/d to 156 tons/d.

The main process in Vance Bioenergy is converted the crude palm oil into Methyl Ester, which identified as biofuel raw material. However during the

separation process, the glycerin material could be extracted too. The main processes for the production of Methyl Ester and refined glycerin from palm oil are discussed on Chapter Two (2).

Figure 1.1: Location of Vance Bioenergy Sdn Bhd.

CHAPTER 2

LITERATURE REVIEW

2.1

Introduction

National Research Council defines risk analysis as having three core elements of risk assessment, risk management and risk communication. Interaction and overlap between the three elements are depicted in Figure 2.1.

Risk Assessment

Risk Management

Risk Communication

Figure 2.1: Element of risk analysis.

7 The first core element of risk analysis is risk assessment. Risk assessment is a process through which the probability of loss by or to an engineering system is estimated and the magnitude of the loss is also measured or estimated the aim of the risk assessment process is to remove a hazard or reduce the level of its risk by adding precautions or control measures, as necessary. This would create a safer and healthier workplace (Modarres, 2006). In general, risk assessment process includes:
a)

Identify hazards, Consider normal operational situations as well as non-standard events such as shutdowns, power outages, emergencies, etc.,

b) Evaluate the likelihood of an injury or illness occurring, and its severity, c)

d) Review all available heath and safety information about the hazard such

as manufacturers literature, information from reputable organizations, results of testing, etc.,

e) f)

Identify actions necessary to eliminate or control the risk, Monitor and evaluate to confirm the risk is controlled, any documentation or records that may be necessary. Documentation may include detailing the process used to assess the risk, outlining any evaluations, or detailing how conclusions were made.

g) Keep

Assessments should be done by an experienced team of individuals who have a good working knowledge of the workplace. Staff should be involved always include supervisors and workers who work with the process under review as they are the most familiar with the operation (California EPA, 2001).

Risk management is the process through which potential of magnitude and contributors to risk are estimated, evaluated, minimized and controlled. Risk communication is the process through which information about the nature of risk and consequences, risk assessment approach and risk management option are exchange, shared and discussed between the decision makers and other stakeholders (Modarres, 2006).

8 2.2 Purpose of Risk Assessment

The main purposes of risk assessment are: a) To identify all possible hazards b) To identify measures that will prevent or minimize all possible hazards. c) To recommend further appropriate control measures to prevent or reduce risks.

2.3

Process of Risk Assessment

The risk assessment process is typically described as consisting of four basic steps. There are Hazard Identification, Exposure Assessment, Dose-Response Assessment and Risk Characterisation.

2.3.1

Hazard Identification

In Hazard Identification is all about to determine the types of health problems a chemical could cause by reviewing study of its effects in humans and laboratory animals. Depending on the chemical, these health effects may include short term ailments, such as headaches, nausea and eye, nose and throat irritation or chronic diseases, such as cancer. An important step in Hazard identification is the selection of key research studies that can provide accurate, timely information on the hazard posed to humans by a particular chemical (California EPA, 2001).

9 2.3.2 Exposure Assessment

Exposure assessment is the process of measuring or estimating the intensity, frequency and duration of exposure of the human population to risk agents. The primary routes of exposures to environmental risk agents for human beings are through the inhalation of gases, vapours and dusts, through ingestion of foods, water or unintentionally of other materials including dust, soil and via skin contact (Ball, 2006).

The most accurate way assessing exposure is by measuring the concentration of the agent of concern in relation to the presence and activities of affected persons. Measurement, however is often expensive and maybe in practical. It is therefore common to rely upon mathematical models that estimate concentrations to which persons are exposed. Exposure assessment often depends on factors that are hard to estimate and for which there are few data (Ball, 2006).

A major source of complexity in exposure assessment is the strong influence that individual personal habits can have on human exposure. If exposure occurs through air or water, exposure assessment must consider how the risk agent moves from its source and if it is altered over time. Chemical agents are generally diluted in the environment and may degrade after release. The aim of exposure assessment in this case is to determine the concentration of toxic materials where they interface with target population (Ball, 2006).

Another important aspect of exposure assessment is determining which group in the population may be exposed to a risk agent. Some group may be especially susceptible to adverse health effects. These include pregnant women, very young and vey old people and people with impaired health. Exposure to multiple risk agents often results in portions of the population becoming more sensitive to single agents. Exposure to risk agents that act synergistically greatly complicates risk

10 assessment. Exposure to both cigarettes smoke and asbestos results in a rate of cancer incidence much greater than that indicated by the dose-response data for the individual substances. An individual can be exposed to a single risk agent from several distinct sources. Exposure to lead, for example can come from breathing air, eating food and drinking water (Ball, 2006).

2.3.3

Dose-Response Assessment

Dose-response assessment evaluates the information obtained during the hazard identification step to estimate the amount of a chemical that is likely to result in particular health effect in humans. An establish principle in toxicology is that the dose makes the poison. For example, a commonplace chemical like table salt is harmless in small quantities, but it can cause illness in large doses. be quite harmful if taken in large doses (California EPA, 2001). Similarly hydrochloric acid, a hazardous chemical produced naturally in our stomachs but can

This is the process of characterizing the relationship between the dose of an agent administered or received and the incidence of an adverse health effect in exposed populations. The process considers important factors such as intensity of exposure, the age distribution of those exposed and possibly the other variables that might affect response, such as gender and lifestyle (Ball, 2006)

Dose-response assessment estimates how different level of exposure to a chemical can impact the likelihood and severity of health effects. The dose-response relationship is often different for many chemicals that cause cancer than it is for those that cause other kinds of health problems (California EPA, 2001).

11 2.3.4 Risk Characterisation

The last step in risk assessment brings together the information developed in the previous three steps to estimate the risk of health effect in an exposed population. Risk characterisation analyzes the information developed during the exposure and dose-response assessments to describe the resulting health risks that are expected to occur in the exposed population (California EPA, 2001).

Figure 2.2: Process of health risk assessment (California EPA, 2001).

12 2.4 Types of Risk Assessment

2.4.1

Qualitative Risk assessment

The level of risk can be described either qualitatively (i.e. by putting risks into categories such as high, medium or low) or quantitatively (with a numerical estimate). Current risk assessment methods do not enable accurate quantitative estimates of risk for low levels of exposure to environmental hazards. Numerical estimates of risk will rarely be feasible because of variability in the agent and population and limitations in toxicological and exposure data which will be reflected in the uncertainty assessment, but a degree of quantification may be possible for some components such as data collection and exposure assessment (Modarres, 2006).

Qualitative risk analysis requires that the probability and consequences of the risks be evaluated using established qualitative-analysis methods and tools. Trends in the results when qualitative analysis is repeated can indicate the need for more or less risk-management action (Modarres, 2006).

It is easier to perform a qualitative risk analysis because it does not required gathering precise data. In this approach, rank ordered approximations of probability and consequence are often quickly estimated (Modarres, 2006).

13 2.4.2 Quantitative Risk assessment

The quantitative risk assessment provides numerical scales for input and output values, such as a number expressing a probability that there will be an outbreak in a defined period of time or per unit of commodity (Modarres, 2006). It may involve:
a)

Asking precise questions about activity and outcome; Obtaining evidence pertaining to the model; Calculating outcomes; Submitting for peer review.

b) Developing mathematical model linking activity and outcome; c)

d) Assigning quantitative values to the model; e) f)

Quantitative risk analysis generally follows qualitative risk analysis. It requires risk identification. The qualitative and quantitative risk analysis processes can be used separately or together. Considerations of time and budget availability and the need for qualitative or quantitative statements about risk and impacts will determine which method(s) to use. Trends in the results when quantitative analysis is repeated can indicate the need for more or less risk management action (Modarres, 2006).

2.5

Pool fire

Pool fire occurs when release of flammable material from a system in an establishment. If the material is stored below its normal boiling point, the liquid will collect in a pool. A pool fire occurs when the liquid is ignited. The damaging impact of a pool fire is thermal effects, primarily through the thermal radiation from

14 the flame surface. The damage are depends on the type of fuel, geometry of the pool, duration of the fire and distance from the fire. The pool size or diameter is an important consideration in the modeling of a pool fire (DOE, 2004).

2.6

Failure Rates for Tankage

The failure rates for the atmospheric pressure storage tanks were based largely on a hazard analysis study carried out by Energy Anaysis Inc in the United States. The failure rates have been modified slightly (Alara, 1997).

In postulating failure scenarios involving tangkage, fully developed major fires in both the tanks and the bunded areas were considered. These are fires where significant quantities of material have been exposed either through loss of a roof or leakage into bund and ignition. The fire is considered to have progressed such that standard correlations for flame size are applicable. The scenario considered is a fire burning within a tank that has lost its roof (tank fire). Loss of roof can occur via internal explosion within the tank. In the case of floating roof tanks, structural failure or excessive external loads can cause the tank roof to sin (Alara, 1997).

The effect of the loss of roof scenario, such as the projectile motion and impact of the roof fragments upon surrounding areas or tanks has not been known t induce failures in the other tanks as well as easily travel in excess of 50 m but less than 100 m before impact (Alara, 1997).

15

Table 2.1: Failure rates for the tankage

Failure Rate Tank fire Cone roof Floating deck Sub dike fire Dike fire Tank explosion Tank Flash Fire Sub Dike Flash Fire Dike Flash Fire Source: Alara, 1997 2.6 x 10-4 /yr 1.3 x 10-4 /yr 6.0 x 10-5 /tank in sub dike/yr 1.2 x 10-5 /tank in full dike/yr 2.0 x 10-5 /yr 1.4 x 10-5 .yr 1.1 x 10-5 /yr 4.5 x 10-6 /yr

2.7

Types of Air Pollutants.

2.7.1

Sulphur Dioxide (SO2)

Sulfur dioxide is a colourless, pungent, irritating, water-soluble reactive gas. This gas is formed during the combustion process of fuel containing sulphur (e.g. oil and coal) mainly from industrial activities. High concentrations of SO2 in the atmosphere increase the risk of adverse symptoms in asthmatic patients and irritate the respiratory system. Other effects associated with long-term exposure to high concentrations of SO2 include respiratory illnesses, alterations in lung function and aggravation of existing cardiovascular diseases (Imran, 2007).

There are also environmental concerns associated with high concentrations of SO2. Sulfur dioxide along with NOX is a major precursor to acidic deposition, which contributes to the acidification of soils, lakes and streams resulting in adverse impact

16 on the ecosystem. Sulfur dioxide can also be harmful to plant life and accelerates the corrosion of buildings and monuments (Imran, 2007).

2.7.2

Nitrogen dioxide (NO2)

Nitrogen dioxide (NO2) is a reddish brown, highly reactive gas that is formed in the ambient air through the oxidation of nitrogen monoxide (NO). Nitrogen oxide (NOX) is the term used to describe the total sum of NO, NO2 and other oxides of nitrogen. The major sources of man-made NOX emissions are high-temperature combustion processes, such as those occurring in automobiles and power plants. Most of the NOX (95%) from combustion processes are emitted as NO and the rest as NO2. Nitrogen monoxide (NO) is readily converted to NO2 in the environment (Siti Noorshafarina, 2007).

Short term exposure to NO2 may lead to changes in airway responsiveness and lung function in individuals with preexisting respiratory illnesses and increases respiratory illness in children. Long term exposure may increase susceptibility to respiratory infection and cause alteration in lung function. Nitrogen oxides also react in the air to form ground-level ozone and fine particle pollution, both of which are associated with adverse health impacts (Siti Noorshafarina, 2007).

Nitrogen oxides contribute to a wide range of environmental effects, including the formation of acid rain and potential changes in the composition and competition of some species of vegetation in wetland and terrestrial systems, visibility impairment, acidification of freshwater bodies, eutrophication of estuarine and coastal waters and increase in levels of toxins harmful to aquatic life (Siti Noorshafarina, 2007).

17 2.7.3 Carbon Monoxide (CO)

Carbon monoxide is a colourless, odourless and at high concentration, a poisonous gas. Carbon monoxide is formed when the carbon present in fuel is not burnt completely. CO is emitted mainly from motor vehicle exhaust. Other sources of CO emission include industrial processes and open burning activities (Imran, 2007).

Carbon monoxide enters the bloodstream through the lungs and reduces oxygen delivery to organs and tissues. The health threat from exposure to CO is most serious to those who suffer from cardiovascular diseases. At high levels of exposure, CO can be poisonous even to healthy people. Visual impairment, reduced work capability and poor learning ability are among the health effects associated with exposure to elevated CO levels (Imran, 2007).

2.7.4

Total Suspended Particulates (TSP)

Total suspended particulates (TSP) are solid matter or liquid droplets from smoke, dust, fuel ash, or condensing vapours that can be suspended in the air. They either come from natural sources such as soil, bacteria and viruses, fungi, molds and yeast, pollen, salt particles from evaporating sea water or from man-made sources such as motor vehicle use, combustion products from space heating, industrial processes and power generation. TSPs include a range of different sized particles. The coarser particles are 50-100 micrometres and finer particles are smaller than 10 micrometres in diameter (Siti Noorshafarina, 2007).

18 They represent a broad class of chemical particles and may include inorganic fibres, trace metals (such as lead) and a variety of organic materials. TSP may originate from combustion, forming hydrocarbons, or from sulphates and nitrates formed during sulphur dioxide or nitrogen dioxide emissions. Particulates can be inhaled but larger particulates can be filtered by the upper respiratory tract. Smaller particulates (respiratory suspended particulates) can enter deeper into the lungs (Siti Noorshafarina, 2007).

2.8

Methanol

Methanol also known as methyl alcohol, carbinol, wood alcohol, wood naphtha or wood spirits, is a chemical compound with chemical formula CH3OH. Methanol is a clear, colorless liquid with a faint odor like alcohol. The smell is not very strong and is considered a poor indicator of vapor concentration (Canada Safety Council, 2005). Methanol burns in air forming carbon dioxide and water: 2 CH3OH + 3 O2 2 CO2 + 4 H2O

Figure 2.3: Methanol chemical formula

Methanol is used as a solvent for lacquers, paints, varnishes, cements, inks, dyes, plastics and various industrial coatings. It is also used in the production of

19 pharmaceuticals, formaldehyde and other chemical products. Methanol appears as an ingredient in many products, from industrial solvents to windshield-washer fluid and nail-polish remover. It is also used as a fuel (Canada Safety Council, 2005). Inhalation of methanol vapor is the most common route of occupational exposure. Poisonings have also resulted from absorption through the skin; although it is only a mild skin irritant, it can be absorbed through the skin in toxic amounts. Accidental swallowing is also possible. beverages (Canada Safety Council, 2005). Methanol tastes and smells much like common alcohol (ethanol) and has been used as a substitute in illegal alcoholic

Methanol is a flammable liquid and can pose a serious fire risk. It burns with a pale blue flame not usually visible in normal light. Its flash point is 12 c. above this temperature enough vapor is produced to create a flammable mixture with air. The vapor is heavier than air and can travel along the ground to a distant source of ignition and flashback. Containers may explode in the heat of a fire. Although methanol is normally stable, contact with strong oxidizing agents increases the risk of a fire or explosion (Canada Safety Council, 2005).

2.9

Glycerin

Glycerin is a commercial product which principal component is glycerol. The pure chemical element is called Glycerol, which indicates that it is an alcohol. The impure commercial product is called glycerin (Bonnardeaux, 2006).

Glycerol, the main component of glycerin, has the chemical formula C3H5(OH)3. It is a trihydric alcohol, possessing two primary and one secondary hydroxyl groups, which are its potential reaction sites and the basis for glycerins versatility as a chemical raw material (Bonnardeaux, 2006).

20

Figure 2.4: Glycerin chemical formula

Glycerin is one of the most versatile and valuable chemical substances. It possesses a unique combination of physical and chemical properties that are utilized in numerous products. Glycerin has over 1,500 known end uses, including many applications as an ingredient or processing aid in cosmetics, toiletries, personal care, drugs, and food products. In addition, glycerin is highly stable under typical storage conditions, compatible with many other chemical materials, virtually non-toxic and non-irritating in its varied uses, and has no known negative environmental effects (Bonnardeaux, 2006).

A water clear, odourless, viscous liquid with a sweet taste, glycerin is derived from both natural and petrochemical feedstock. It occurs in combined form in all animal fats and vegetable oils and constitutes, on average, about 10 per cent of these materials. Natural glycerin is obtained from fats and oils during soap and fatty acid production and by transesterification (an interchange of fatty acid groups with another alcohol) during biodiesel production. Crude glycerin is 70 to 80 per cent pure (Bonnardeaux, 2006).

Crude glycerin is usually designated for plastics and alkyd resins markets (lacquers, varnishes, inks, adhesives, and synthetic plastics). Crude glycerin is often concentrated and purified prior to commercial sale. Glycerin with purities up to 95.5 per cent and 99 per cent pure are used by the food, cosmetic and pharmaceutical

21 industries. Synthetic glycerin is produced from petrochemical building blocks via several processing steps designed to achieve the desired concentration and high product quality required for certain drug and pharmaceutical applications (Bonnardeaux, 2006).

2.10

Production Process of Glycerin Distillation and Refining Plant

The main processes for the production of Methyl esters and refined glycerin from palm oil are presented in Figure 2.5. First step in Glycerin Refining process is the pH correction carried out in line by means of the dosing pump and static mixer. Crude glycerin is then fed to the deaerator-predrying loop composed of a recirculation pump, which also feeds the product to the distillation column, a heater recovering energy from the pump around stream and a deaeration vessel (V-I) where air and part of the water are removed (Vance Bioenergy, 2008).

The deaerated glycerin is fed, under the flow control to the distillation column, on the discharge side of the reboiler recirculation pump. The distillation column is composed of various sections that starting from the bottom are: a. Bottom section, where the glycerin and water are evaporated, by means of an external reboiler with forced circulation realized by means of the pump. At the bottom section heavier product is taken by the pump and fed to wiped film evaporator. The residue is discharged batch wise in a solid form. The evaporated glycerin is condensed and recycled to the bottom section of the column. b. First packing layer is washing stages where the rising vapours are countercurrently washed by a partial recycle of condensed glycerin. In this section,

22 all heavy components which can be carried over in distillation, are scrubbed from the vapours. c. The second packing layer is the rectification section where the glycerin is condensed; in the third packing layer it is dried by counter-current washing of the vapours. A total draw-off plate extracts the liquid dried glycerin at the bottom of this section. The glycerin flows to a deodorizer with structured packing where the odoriferous compounds are steam stripped. The vapours are returned to the tower, under the scrubber while the distilled glycerin is pumped by the bleaching section. d. The third packing layer is the condensation stage where most of the glycerin condenses by means of an external pump-around. The liquid glycerin is extracted at the bottom of the layer by means of a total draw-off plate and collected in the receiver. From there the glycerin is pumped partly to the second packing layer for drying of the vapours and partly is cooled and recirculated to the third packing layer of the column for condensation of the rising vapours. e. The vapours are then sent to the scrubber with the fourth packing layer (of smaller section). This is the final condensation stage where the second grade glycerin is condensed by means of another external pump-around. In the scrubber, the condensation temperature is much lower and consequently the glycerin concentration will be lower since also part of the steam will condense. The liquid glycerin is extracted at the bottom of the scrubber from where it is pumped, cooled and partly recycled as pump-around to the scrubber and partly discharged to battery limits as second grade glycerin. f. The vacuum system is connected to the top of the scrubber and it is composed of two boosters, two surface condensers and two ejectors g. The bleaching section is composed of a three-bed system of activate carbon; first grade glycerin is cooled to bleaching temperature and then passed in series through two of the three bleachers. When the first bed of activate

23 carbon is exhausted, this bleacher is by-passed and carbon replaced, while the glycerin flows through the second and third bleacher. The glycerin is then passed through a polishing bag filter and finally cooled down to storage temperature.

Figure 2.5: Process of Palm Oil Conversion into Methyl Ester and Refine Glycerin Material

24 2.11 Emergency Response Plan

Environmental emergencies are incidents or events that threaten public safety, health, and welfare and include hurricanes, floods, wildfires, industrial plant explosions, chemical spills, acts of terrorism, and others. While these events range in size, location, causes, and effect, most have an environmental component. Emergency response is the organizing, coordinating, and directing of available resources in order to respond to the event and bring the emergency under control. The goal of this coordinated response is to protect public health by minimizing the impact of the event on the community and the environment (NIESH, 2007)

An emergency response plan must provide the resources and information needed to evaluate the human and environmental health impact. incident as list below. a) Fire. b) Explosion. c) Leakage from deteriorated or damage containers. d) Spillage during handling or transportation. e) Splash involving worker injury. f) Spillage or leakage producing toxic vapours or fumes. Emergency Response Plan is concise information necessary to respond effectively to any of the

According to the American Society for Industrial Securitys Emergency Planning Handbook, effective emergency planning begins with the following (Vendrell, 2001):
a)

Defining an emergency in terms relevant to the organization doing the planning

b) Establishing an organization with specific tasks to function immediately

before, during, and after an emergency

25
c)

Establishing a method for utilizing resources and for obtaining additional resources during the emergency

d) Providing a recognizable means of moving from normal operations into and

out of the emergency mode of operation

CHAPTER 3

METHODOLOGY

3.1

Introduction

This chapter explained thoroughly the procedure of works to achieve the objectives as stated in Chapter 1. This chapter illustrates the mechanism, process and method of analysis as conducted in similar research. The discussions also focus on sampling station and equipment used for air quality, data collection and methods on calculation for pool fire and health index.

3.2

Data and Information Collection

This study begins with data and information collected for standard analysis of risk assessment. Informations are gathered from books, journals, EIA reports,

guidelines from DOE and internet. Beside that, information on background and process involved in Vance Bioenergy Sdn. Bhd. are also obtained.

27 3.3 Hazard Identification

All information about production process of glycerine refining plant and raw material used are collected for analysis. Then, the data are classified by referring National Fire Agency Protection (NFPA) based on flammability, health and reactivity. The study will focus on the most flammable raw material used for the plant operations. Then, the analyses are continued by determining the area affected if any explosion occurred at the raw material storage tank using pool fire analysis.

3.4

Pool Fire

The heat release rate, Q of pool fire may be estimated from equation 1. The example values of , mand for common liquid is as shown in table 2.1.

(1)

Where:

= =

Heat release rate (kW) Mass burning heat (kg/m2-sec) Heat of combustion (kJ/kg) Empirical Constant (m-1) Diameter of pool fire (m) Surface area of pool fire (m2)

Hc, k D Af

= = = =

28

Table 3.1: Burning rate data for fuel

Mass Burning Fuel Rate m" (kg/m2-sec) Methanol Ethanol Butane Benzene Acetone Dioxane Gasoline Kerosene Diesel 0.017 0.015 0.078 0.085 0.041 0.018 0.055 0.039 0.045 Heat of Combustion Hc (kJ/kg) 20000 26800 45700 40100 25800 26200 43700 43200 44400 Empirical Constant k (m-1) 100 100 2.7 2.7 1.9 5.4 2.1 3.5 2.1

Source: USNRC Version 1805.0

To estimate the radian heat flux, the following equation has been used,

(2)

Where: Radian heat flux (kW/m2) Heat release rate (kW) Distance from center of the pool fire to edge of the target (m) xr = Radiative fraction = 0.3

q Q R

= = =

29 3.5 Air quality

3.5.1

Equipment

The main parameters of air quality indicators are Carbon Monoxide (CO), Total Suspended Particulate (TSP), Nitrogen Dioxide (NO2) and Sulphur Oxide (SO2). For the purpose of this study, GrayWolf DirectSense TOX PPC Kit as shown in Figure 2.1 is used to measure the air quality parameters such as CO, NO2, and SO2 as well as the temperature. The measurement unit for all the gases using this equipment will be in parts per million (ppm), whereas, temperature will be measured in C. Mini Vol. Portable Air Sampler as shows in Figure 2.2 is used for measuring TSP.

Figure 3.1: GrayWolf DirectSense Tox PPC Kit

Figure 3.2: Mini Vol. Portable Air Sampler

30 3.5.2 Sampling Location

An early visited to sampling area must be conducted for identified the right sampling location. Sampling location must be at open area. There are three

sampling location for air quality. The sampling location are selected at the boundary of the factory and the nearby residential area. Every station name as A1, A2 and A3. A1 and A2 is at the factory boundary while A3 is at Taman Pasir Putih located about 700m from the factory. The location is as shown in Figure 2.3. The sampling location were chosen include the areas with impact potentials. Figure 2.2, 2.3 and 2.4 shows the air quality measurement at site.

Figure 3.3: Sampling location for A1, A2 and A3

31

Figure 3.4 (a): Sampling for TSP at Station A1

Figure 3.4 (b): Sampling for CO, NO2 and SO2 at Station A1

Figure 3.4 (c): Station A1 at Jalan Keluli 5

32

Figure 3.5 (a): Sampling for TSP at Station A2

Figure 3.5 (b): Sampling for CO, NO2 and SO2 at Station A2

Figure 3.5 (c): Station A2 at Jalan Keluli 4

33

Figure 3.6 (a): Sampling for TSP at Station A3

Figure 3.6 (b): Sampling for CO, NO2 and SO2 at Station A3

Figure 3.6 (c): Station A3 at the Taman Pasir Putih

34 3.6 Exposure Assessment

Air is an important pathway for contaminants and inhalation is the major route of exposure to contaminants that exist in atmospheric gases or attached to airborne particles. Data from air quality will be used for the exposure assessment. Using equation as states below, health index for CO, NO2, SO2 and TSP are determined. Beside that, the health effect for every parameter is also defined. In calculating the inhalation dose, it is assumed that 100% of the contaminant is absorbed after inhalation. The amount of a contaminant absorbed into the body through inhalation (EDair) can be estimated as follows:

(3)

Where:

EDair

Estimate dose trough air inhalation: the air inhalation dose is expressed as milligrams of the contaminant inhaled per kilogram of body weight per day.

Concentration of the contaminant in the air, in milligrams per cubic meter of air (mg/m3).

IR

Inhalation rate: The amount of air person breathes in a day in cubic meters (m3/day). If contaminated air is breathed for only part of a day, then inhalation rate is adjusted accordingly.

EF

Exposure factor: Indicates how often the individual has been exposed to the contaminant over a lifetime (unitless)

ED

Exposure Duration: Duration for the individual exposed to the contaminant (years)

BW

Body weight: The average body weight in (kg) based on an individuals age group

35
AT = Average time: Average time for the individual exposed to the contaminant (days)

The standard value of IR, EF, ED, BW and AT is obtain from EPA 1991b and as tabulate in Table 2.2.

Table 3.2: Standard value for IR, EF, ED, BW and AT

Inhalation Rate (IR) m3/day 20 Exposure Frequency (EF) days/year 250 Exposure Duration (ED) years 25 Body Weight (BW) kg 70 Averaging Time (AT) days 6250

Source: EPA 1991b,1991

Health Index (HI) is the ratio of the estimated intake dose from exposure to the response dose. Reference dose are dependent on the route of exposure and may only be used with exposure data for the same route. The health index is calculated using the formula below. If the acceptable level of intake is deemed to equal the reference dose, then by definition, a health index of less than 1.0 is acceptable.

(4)

Where: HI ED(predicted) ED(allowable) = = Health index (dimensionless) The predicted estimated dose per day through air inhalation (mg/kg/day) = The allowable or permissible estimated dose per day through air inhalation (mg/kg/day)

CHAPTER 4

RESULT AND DISCUSSION

4.1

Introduction

This chapter will discuss on the result that obtain from the study. All the data and information gathered are analyzed and the results are presented in table and figure to make it easier to understand.

4.2

Hazard Identification

The main risks that may have potential impact to the environment arising from the factory are mostly related to fire hazards within the proposed facility itself and externally to the surrounding area. Data tabulated in Table 4.1 are summarized from Material Safety Data Sheet (refer Appendix A-G). From the table shows that all the raw materials and finished products are low risks in nature except for Methanol and Sodium Methylate 30% solution. Based on National Fire Protection Agency (NFPA), both materials are very flammable. This study will focus only on

37 the major fire due to the failure of the methanol storage tank. When proper

preventive measures are in place, there will be no significant impact to these materials on site. Assessment is to evaluate and minimize the likelihood and

consequences of an accident leading to fires that can cause damage to property and human life.

In Vance Bioenergy Sdn. Bhd., there are three storage tanks of methanol. Two of the tank with the capacity of 720 m3 located at PLO 669 while the other one with 276 m3 capacity located at PLO 668. This study will focus on the storage tank at PLO 669 which has the bigger capacity. The location of tanks is as shown in Figure 4.1.

Methanol Storage Tank

Figure 4.1: Methanol Storage Tank

Table 4.1: Hazard identification for raw material used in Methylester and Refined Glycerine process Raw material/Finished Product Acid Citric Hazard Identification Eye contact (irritant) can result in corneal damage or blindness Skin contact produce inflammation and blistering Severe over-exposure can produce lung damage, choking, unconsciousness or death Very hazardous in case of skin contact (corrosive, irritant, burn) eye contact (irritant, corrosive), ingestion Slightly hazardous in case of inhalation (lung sensitizer). Liquid or spray mist may produce tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract. Inhalation of the spray mist may produce severe irritation of respiratory tract, characterized by coughing, choking, or shortness of breath. Severe over-exposure can result in death. Highly flammable. Hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (permeator). Severe over-exposure can result in death. NFPA Classification Health:2 Flammability: 1 Reactivity: 0 Other names 2-Hydroxy-1,2,3propanetricarboxylic acid

Sodium Hydroxide 50% Solution

Health:3 Flammability: 0 Reactivity: 1

Sodium Hydroxide, 50%

Methanol

Health:2 Flammability: 3 Reactivity: 0

Wood alcohol Methylol Wood Spirit Carbinol Methyl alcohol 38

Table 4.1: Hazard identification for raw material used in Methylester and Refined Glycerine process (contd) Raw material/Finished Product Glycerine Hazard Identification Slightly hazardous in case of Skin contact (irritant, permeator), Eye contact (irritant), Ingestion Inhalation. Hazardous in case of ingestion. Slightly hazardous in case of Eye contact (irritant) Inhalation Corrosive to eyes and skin. The amount of tissue damage depends on length of contact. Eye contact can result in corneal damage or blindness. Skin contact can produce inflammation and blistering. Inhalation of dust will produce irritation to gastrointestinal or respiratory tract, characterized by burning, sneezing and coughing. Severe over-exposure can produce lung damage, choking, unconsciousness or death. Skin contact can produce severe burns and ulceration of the skin. Eye contact will result in eye corrosion or corneal or conjunctival ulceration. Contact may result in permanent damage to the eyes and even blindness. Inhalation of concentrated mists, spray, or vapor may cause severe damage to the upper respiratory tract. NFPA Classification Health:1 Flammability: 1 Reactivity: 0 Other names 1,2,3-Propanetriol Glycerol

Palm Oil

Health: 0 Flammability: 1 Reactivity: 0 Health: 3 Flammability: 0 Reactivity: 0

Acid Phosphorous

Sodium Methylate, 30%

Health: 3 Flammability: 2 Reactivity: 2

Sodium Methoxide

39

40 4.3 Pool Fire

The ignitions at methanol storage tank are typically cause by several factors such as lightning, frictional heat and sparks, hot surface and electrostatic discharge. The size of the spillage pool depends critically on the size of pool fire and radian flux. For this study, size of spillage pool computed from two difference sizes of pool fire which are 5m and 10 m. While the hazard distances specified for pool fires are determine based on three levels of thermal radiation.

The maximum flux is 37.5kW/m2 which can severely damage the unprotected tanks and other process equipment. Another one is 12.5 kW/m2 which causes wood and other cellulosic material to ignite after prolonged time. The minimum radian flux is 4.0kW/m2 which roughly corresponds to the threshold of pain for human. The others approximate radian flux level and corresponding damage conditions are as shown in Table 4.2.

Table 4.2: Effect of thermal radiation Radian Flux (kW/m2) 37.5 25.0 Damage Conditions Sufficient to cause damage to process equipment Minimum energy required to ignite wood at definitely long exposure (non-piloted) Minimum energy required for piloted ignition of wood, melting of plastic tubing Pain threshold reached after 8 sec, second degree burns after 20 sec Sufficient to cause pain to personnel if unable to reach cover 4.0 within 20 sec, however blistering of the skin (second degree burns) is likely 0% lethality 1.6 Will cause no discomfort for long exposure

12.5

9.5

Source: EIA Guidelines for Risk Assessment (2004)

41 Figure 4.2 shows the pool fire with diameter of 5 m. The explosion at methanol storage tank may hit the target in circular area of 6.31 m radius for 4kW/m2 radian flux. While for 12.5kW/m2 and 37.5kW/m2 the radius is in 3.57 m and 6.31 m. When the fire at the methanol storage tank is sustained for more than five minutes, the huge explosion may be expected.

Figure 4.3 shows the large pool fire with diameter of 10 m. for the large size of pool fire the effected area are larger. The distances from the pool fire centre for 4 kW/m2, 12.5 kW/m2 and 37.5 kW/m2 radian flux are respectively 12.62 m, 7.14 m and 4.12 m.

4.4

Failure Rate for Tank

The failure rate for fire and explosion phenomena at methanol storage tank were typically 4.07 x 10-4 /yr. This included tank and sub dike fire (90-95%), full dike fire (2-5%) and tank explosions (3-5%). The failure rate for tank fires is increased to 65% of the total failure rate or 2.64 x 10-4 /tank/ yr.

4kW/m2 (6.31 m)

12.5kW/m2 (3.57 m) 37.5kW/m2 (2.06 m)

Figure 4.2: Small pool fire at Methanol Storage Tank 42

4kW/m2 (12.62 m)

12.5kW/m2 (7.14 m)

37.5kW/m2 (4.12 m)

Figure 4.3: Large pool fire at Methanol Storage Tank 43

44 4.5 Exposure Assessment

4.5.1

Air Emission

The types of activities that cause air pollution are those related to air emission of Refined Glycerin plants. The potential of air pollution will be from the existing boiler from chemical process of the existing Methyl Ester Plant. With the proper control the plant operation will not have much impact on the air quality. The air emission from the existing boiler using Light Fuel Oils (LFO) at Vance Bioenergy Sdn Bhd is obtained from the preliminary environmental impact assessment for Refine Glycerin Plant, 2008. The specification of boiler is as tabulate in table 4.3

Table 4.3: Specification of boiler

Types Model Types of fuel Usage rate of fuel (kg/hr) MB3000/250 Diesel/Natural gaseous 811.6 (Diesel) 713( Natural gaseous) Limit Content of Sulfur (%) 3.5 (Diesel) 0 ( Natural gaseous) Stack Height (m) Exit velocity (m/s) 30.48 12.42 (Diesel) 14.14 ( Natural gaseous) Capability (kg.wap/hr) Type of feeding 13608 Pressure Jet Modulating Boiler

Source: Dept of Environmental Engineering, 2008

Two sampling have been carried out by Envilab Sdn. Bhd. and Lotus laboratory Services (M) Sdn. Bhd. for air emission from chimney of boiler. The results are as tabulated in table 4.4.

45

Table 4.4: The stack air quality emission

Parameter Particulate Matter Sulphur Oxide (SOx) Nitrogen oxides (NOx) 2 Nov 2007 g/Nm3 0.019 0.013 0.3 21 Feb 2008 g/Nm3 0.08 0.02 0.31

Source: Dept of Environmental Engineering, 2008

The air dispersion within Pasir Gudang Industrial Estate is shown in Figure 4.4, 4.5 and 4.6. It based on the worst case scenario independent of wind direction of boiler using LFO. The result shows that the maximum concentration at the factory site it self are 0.032 g/m3 for TSP, 0.0016 for NO2, 0.0026 ppm for SO2 and 0.039 ppm for CO. The concentration of the air pollutants are decreasing through the distance. The emission from the chimney of boiler also within the acceptable limits of Environmental Quality (Clean Air) Regulations 1978.

0.0090 mg/Nm3 (3km)

0.0184 mg/Nm3 (2km)

0.0325 mg/Nm3 (0.8km)

Vance Bioenergy Sdn Bhd

Figure 4.4: Predicted TSP dispersion GLC within 3km radius from the factory (Dept of Environmental Engineering, 2008)

46

0.0005 g/Nm3 (3km)

0.0009 g/Nm3 (2km)

0.0016 g/Nm3 (0.8km)

Vance Bioenergy Sdn Bhd

Figure 4.5: Predicted NO2 dispersion GLC within 3km radius from the factory (Dept of Environmental Engineering, 2008). 47

0.00072 g/Nm3 (3km)

0.00147 g/Nm3 (2km)

0.0026 g/Nm3 (0.8km)

Vance Bioenergy Sdn Bhd

Figure 4.6: Predicted SO2 dispersion GLC within 3km radius from the factory (Dept of Environmental Engineering, 2008).

48

0.0108 g/Nm3 (3km)

0.0221 g/Nm3 (2km)

0.0389 g/Nm3 (0.8km)

Vance Bioenergy Sdn Bhd

Figure 4.7: Predicted CO dispersion GLC within 3km radius from the factory (Dept of Environmental Engineering, 2008)

49

50 4.5.2 Air Ambient

The air quality sampling is done to identify either the emission from boiler give an impact to the air ambient at the surrounding area and risk to people or not. Overall the concentration of SO2, NO2, CO and TSP at all station are low and complied with Recommended Malaysian Air Quality Standards. The amount of a contaminant absorbed into the body through inhalation are calculate as equation 1 (refer Chapter 3) and the result for sampling station A1, A2 and A3 are as shown in Appendix I

The computed health index for the individual air pollutants for A1, A2 and A3 have been shown to be well less than 1 with the value below than 0.5 (Table 4.5). The results of the analysis shows that air pollutants emitted from the factory plant are not expected to have any significant impact on health of the workers and people surrounding. Health effect of SO2, NO2, CO and TSP on human is tabulated in Table 4.6

Table 4.5: Health Index for A1, A2 and A3 Health Index A1 SO2 NO2 CO TSP 0.023 0.176 0.082 0.238 A2 0.031 0.176 0.075 0.419 A3 0.085 0.147 0.082 0.283

51

52 Table 4.6: Type of pollutants and effect to health Type of pollutants SO2 Health effect Affect the respiratory system and the functions of the lungs. Causes irritation of the eyes. Inflammation of the respiratory tract causes coughing, mucus secretion, aggravation of asthma and chronic bronchitis and makes people more prone to infections of the respiratory tract. CO TSP Source: USEPA, 2008 Irritate the lungs and lower resistance to respiratory infections such as influenza. NO2 High concentration in ambient may cause increased incidence of acute respiratory illness in children. Long-term exposure to NO2 may cause adverse health effects. CO enters the bloodstream and reduces oxygen delivery to the body's organs. The health threat from CO is most serious for those who suffer from cardiovascular disease. The most frequent health problems occur within the respiratory system. Bronchitis and lung damage can also occur.

4.6

Emergency Response Plan (ERP)

This Emergency Response Plan outlines the guidelines to be followed by the employees, contractors and visitors to Vance Bioenergy Sdn Bhd. The scope of this plan includes the necessary details covering organization, communications,

53 responsibilities and plan of action which shall be used by all personnel involved in emergency response. The objective of this plan is to provide overall plan of action to be followed in an emergency situation with specific aim of

a) Ensuring the safety of all personnel b) Minimizing damage to property c) Ensuring safety of neighbouring plants, residential and public

Section Heads shall be responsible for regular reviewing and updating of those sections in the plan which are relevant to his section's activities. The revision shall be submitted to Safety, Health and Environment Section to be incorporated as changes into the plan, after approved by the Vance Bioenergy Sdn Bhd Safety Committee Chairman. The reviewing and updating shall be carried out at least annually. The ERP will be amended when important components become outdated or business and regulatory changes occur. Whenever changes are made, a revision date and appendix number shall be noted. The updated revision will be issued to all relevant personnel. At least one copy should be in every building including in the guardhouse. In table 4.7 described the definition of some term used in ERP.

Table 4.7: Definition of term used in ERP Definition Emergency Controller Defined as the fully responsible person for the entire emergency operation. Emergency Controller shall be the Technical Director. In the case of any emergency occurring during night time, week-end or holiday, the Duty Supervisor will act as Emergency Controller until the arrival of the Technical Director, Production General Manager or other managers. During his absence, Production General Manager, Production Manager / Sr. Officer or other managers will take over. Emergency Commander Defined as the Production General Manager who will assist Emergency Controller giving instructions in controlling the

54 emergency at the site.

Table 4.7: Definition of term used in ERP (contd) Definition Fire Fighting Team Defined to be all Vance Bioenergy Sdn Bhd personnel who have been assigned a duty / duties during emergency, to fight fire or control emergency under the command of Fire Fighting Chief or Emergency Commander. First call-out is Defined as calling up the key personnel i.e. Technical Director, Production General Manager, Fire Fighting Chief, Safety Health and Environment Officer, Senior Production Officers and Engineers. For outside assistance call - out for government and neighbourhood plants information, the calling must with the consent by the Technical Director / Production General Manager. Second call-out Defined as calling up the off duty personnel and outside assistance in case of emergency become worsened. Plant Area Defined to be the entire process plant and its facilities including tank yard area. Vance Bioenergy Defined to be all employees who have been employed, Sdn Bhd employee Contractors permanently or temporarily and to whom have been issued with Vance Bioenergy Sdn Bhd Identification Badge. Defined to be all workers, employed by third parties, which are called in by Vance Bioenergy Sdn Bhd to perform a job at Vance Bioenergy Sdn Bhd's premises. Visitors All other persons who are legally authorized and want to visit or enter Vance Bioenergy Sdn Bhd's premises.

55

4.6.1

Declaration of Emergency

The first response to all fires, explosions or condition that creates a potential for injury or destruction shall be announced through the speaker system plant wide. Announcement through the speaker system plant wide shall initiate the Emergency Response Plan (ERP). Other form of communication such as hot line, walkie-talkie and telephone can also be used to initiate the emergency. When notifying the emergency provide information such as name of person that make announcement, the exact location of the emergency and the type of emergency; fire, leak, explosion and etc.

On the announcement of an emergency, the personnel at the affected area which are not involved in the Fire Fighting Team shall proceed immediately to the Assembly Point in front of the main office building. The Fire Fighting Team shall proceed to the scene of the emergency fire.

The Emergency Controller or Commander shall assess the emergency situation and declare an emergency where appropriate. He shall announce through speaker system the type and condition of emergency. The Emergency controller shall declare an emergency in the plant area. When the emergency is beyond control and the Emergency Controller announced plant evacuation, all personnel not involved in Emergency Response Plan in the plant area shall proceed to the Assembly Point (Figure 4.8). Once an emergency is declared, the Emergency

Controller shall direct the Assistant Supervisor to activate First and Second Call-out for the key personnel.

All Vance Bioenergy Sdn Bhd employees who are called out should report immediately to the Assembly Point and assume their respective assignment as laid

56 down in the Emergency Response Plan. Those not involved in emergency Response Plan shall report to their Section Leader appointed by the Section Head for further instructions and standby as back-up emergency supports.

4.6.2

Emergency Procedure

For Vance Bioenergy Sdn Bhd the emergency response plan categorized into three (3) types. There are Plant Emergency, Person Emergency and Transportation Emergency.

4.6.2.1 Plant Emergency

If any personnel observe any emergency incidents at plant area, it should alert on-site personnel of possible dangers and provides for an orderly stop of operations in the affected area or evacuation if necessary. It shall also signal the emergency response team (ERT) to take necessary action.

When a major emergency is declared, all personnel in the plant area have to follow emergency procedure and discontinue all the operations. When the

emergency is beyond control and the Emergency Controller announced plant evacuation, all personnel not involved in Emergency Response Plan in the plant area shall proceed to the assembly point as shown in Figure 4.8. If the situation is out of control, the emergency response team should call for assistance from external sources like Fire Department (Bomba), Ambulance or Police. Figure 4.9, 4.10 and 4.11 show the emergency procedure for various situations.

57

Assembly point

Fi 56

gure 4.8: Assembly Point

57

Fire

Fight fire

Fight fire only if it is safe enough to do so

Raise alarm

Raise alarm to notify ET and alert others to evacuate and stay away from area Assess situation. Any causality? Shut down electricity and gas supplies

ERT response

Identify hazards

Refer MSDS if necessary. Any risk of fire escalating quickly/explosion? Any structural collapse Proceed with fire fighting, contain fire or withdraw? Fight fire with fire extinguisher or hose reel. Remove flammable substance from vicinity. Need to carry out rescue operation Work in pairs. Be prepared to withdraw if situation gets out of control.

Prepare action plan

Action

Hand to Bomba and report to DOE

Hand over to Bomba on their arrival. Report to DOE. Update them on the situation. Standby to offer any help if required.

Figure 4.9: Emergency procedure for fire

58

Chemical Move away a safe distance on discovering a hazardous spill and put on PPE Inform direct supervisor or committee members to raise alarm to notify ERT and alert others to evacuate and stay away from area Try to recall details of spilled chemical but do not go back for a second look (label on container, foaming, fuming, fire, smell colour, etc). Immediately inform the DOE. Determine whether to inform Bomba Assess situation. Any causality? Switch of electricity Seal off area to prevent others from entering area and all other areas where spill can spread Refer MDMS. Any risk of fire/explosion? Any danger of absorption through skin? Decide how to handle spill (close leaking valve, neutralize spill) Wear full protection with encapsulating and breathing apparatus, if unsure. Control spread of spill. Prevent spill entering open drains. Work in pairs. Contain used adsorbents in bag/drum and label it properly for disposal. Flush area with water Hand over to Bomba. Update them on the situation. Standby to offer any help that is required.

Get away Raise alarm

Identify spill if possible

ERT response Cordon of area

Identify hazards Prepare action plan Wear PPE Control and clean

Hand over to Bomba

Report to DOE Decontaminate

Submit report of the occurrence to DOE

Flush contaminated clothing with water. Remove PPE to down

Figure 4.10: Emergency procedure for hazardous chemical spill

59

Toxic gas release Move away a safe distance on discovering a hazardous spill and put on PPE Inform direct supervisor or committee members to raise alarm to notify ERT and alert others to evacuate and stay away from area Try to recall details of spilled chemical but do not go back for a second look (label on container, foaming, fuming, fire, smell colour, etc). Immediately inform the DOE. Determine whether to inform Bomba Assess situation. Any causality? Switch of electricity Seal off area to prevent others from entering area and all other areas where spill can spread Refer MDMS. Any risk of fire/explosion? Any danger of absorption through skin? Decide how to handle spill (close leaking valve, neutralize spill) Wear full protection with encapsulating and breathing apparatus, if unsure. Work in pair

Get away Raise alarm

Identify toxic release

ERT response Cordon of area

Identify hazards Prepare action plan Wear PPE Rectify up spill

Hand over to Bomba

Hand over to Bomba. Update them on the situation. Standby to offer any help that is required.

Decontaminate

Flush contaminated clothing with water. Remove PPE to down

Figure 4.11: Emergency procedure for toxic gas released

60 4.6.2.2 Transportation Emergency

The potential impacts due to the methanol storage tank will arise if accidents occur and cause spillage or release of such waste into the environment. The

methanol storage tank discharged or spilled may cause hazard to plants or animals due to the toxicity of the waste. In the worst scenario, accidents could result in fire or explosion. The following rules will be followed while transporting:

a) Use highways, trunk roads and other main roads. b) Avoid damaged/ uneven roads, congested roads and roads passing through dense populated areas or other environmentally sensitive areas. c) Follow the speed limit. d) Minimize the transit time from the waste generator to the proposed site. e) The methanol storage tank will be sent to project proponent directly without transit.

The lorries should be equipped with the following safety equipment:

a) Fire extinguisher b) Safety gear like masks, goggles and gloves c) First aid kits d) Sawdust e) Scoop f) Plastic bag

The lorry driver will carry the necessary information which has all the necessary information such as type of waste, its physical and chemical properties, first aid, spill control procedures and the necessary precaution needed to be taken while handling the waste. The lorry driver will be trained on how to use the safety equipment and the emergency response methods. Should there be fire, explosion or major leak, the wastes will be moved or transferred to a safer, place. All spills will be considered hazardous. No one will approach the spills until the identity of spill is

61 known. In all cases, the personnel at the accident site should wear protective clothing. The safety precautions will be as follows:

a) Always approach a spill from upwind b) Do not touch the waste materials c) Remove all possible ignition sources (e.g. running engine) d) Do not smoke e) Restrict access to the area

The most effective way to control a spill resulted from transport related accident is to contain it. This act can facilitate on-site clean-up operations and prevent of contamination of water sources. In case of spill on land, earthen dikes will be built with the help of shovels or bulldozer; or the land is excavated to pond the waste. Pumps will be used to recover the spillage of methanol from truck and storage tank. For the part too little to be pumped up, saw dust or clay powder will be used to adsorb the spilled waste. If the situation is out of control, the lorry driver should summon assistance from sources like office, Fire Department (Bomba), Ambulance or Police. Personnel not actively involved will be evacuated from the area.

Action will be taken to return the environment to its conditions before accident. Actions that might be taken under this phase will be replacement of contaminated earth and replanting of vegetation. Figure 4.12 and 4.13 are the ERP for various situations during transportation.

62

Control room

Stop vehicle

Switch of engine

Evacuation

Identify hazard

Prepare plan of action

Fight fire

Contact Office/ Bomba/ DOE

Is situation in control?

Clean up

Hand over to Bomba

Report

Figure 4.12: Emergency procedure for fire during transportation

63

Chemical spill on road

Stop vehicle

Evacuation

Turn on hazard light

Display hazard sign

Wear PPE

Identify spill

No Contact Office/ Bomba/ DOE Refer to waste card Wear appropriate PPE Stop spill from containers and contain spill Wait for help Is situation in control?

Yes Refer to waste card Wear all appropriate PPE Contain spill Clean up Report

Figure 4.13: Emergency procedure for chemical spill during transportation

64 4.6.2.3 Injured Person

The safe removal and care of injured persons is of utmost importance. The On-Scene-Commander is responsible for assuring that care is provided for injured persons.

If an injured person is in an area of immediate danger, that person must be removed as carefully and as quickly as possible, to the safe area. The On-SceneCommander shall be notified immediately of all injuries occurring as a result of the emergency. If necessary, the On-Scene-Commander or designated technician shall request assistance from the Plant First Aid to provide care and/or transportation of the injured person to the hospital.

When an ambulance is coming for transportation of the injured, contact Security Guardhouse at main entrance so that, an ambulance is on route. In the event of transporting a victim or injured person, using the plant ambulance, the red emergency light may be utilized, but all traffic signs and signals must be obeyed. Drive defensively and get the victim to the hospital quickly and safely. emergency procedure for injured person is described briefly in figure 4.14. The

65

Control room

Production General Manager & Section Manager of the Area Technical Director

Fire Fighting Team for rescue operation

To the scene emergency Fatality Apply first aid treatment

Police Report Call for ambulance (If own ambulance inadequate)

Describe the injuries and the number of affected personnel

Transport the injured or fatal case to hospital

Figure 4.14: Emergency procedure for Injured Person

66 4.7 Evacuation Plan

An evacuation shall take place when the health and safety of plant personnel, contract personnel, and visitors are endangered by fire, explosion or release of toxic gas and vapors. The On-Scene-Commander or a designated technician shall contact the guardhouse and the main entrance and inform them that there will be an evacuation. The Security Supervisor or designated security personnel shall actuate the alarm for Evacuation (See figure 4.15).

Evaluation plan for facility personnel need to be prepared where there is a possibility that evacuation could be necessary. It will describe the signals to be used to begin evacuation, the evacuation routes and alternate evacuation routes if there is a possibility that the primary routes could be blocked by fires or releases of hazardous wastes. The potential types of incident will have appropriate response laid out. This will be the essence of the contingency plan. For each incident, a series of steps will be devised to adequately respond. Also, the equipment, materials and personnel protection e.g. respirators and protective clothing necessary to respond to each incident must be identified.

The response strategy should specify when or invoke the arrangements with state and local authorities and decisions criteria for evacuation. As the contingency plan is not a static document, it must be reviewed and amended, if necessary, whenever:

a) Applicable regulations are revised b) The plan fails in an emergency c) The facility changes in a way that materially increases the potential for incidents or changes the response necessary to emergencies d) The list of emergency coordinators changes; and e) The list of emergency equipment changes.

67

Copies of the contingency plan and all revisions must be maintained at the plant. In addition, the plan and all revisions can be submitted to the following organizations that may be called on to provide emergency services:

a) Police departments b) Fire departments c) Hospitals d) State and local emergency response teams.

The head of department or plant supervisor have to ensure that the head count of their personnel is completed. Evacuation shall be made to the safest and closest assembly point which has been assigned in the Assembly Point Area (Figure 4.4) of this plan or as directed by the Emergency Controller. Evacuation for operating areas should as far as possible avoid having to travel through or under vessel, pipe structures, process areas etc. to the assembly point. Plant personnel shall stay at the assembly point for further instructions and do not leave the assembly point without, proper clearance from the department head or supervisor;

All plant personnel shall remain at their designated assembly area until it has been determined that it is safe to return to the plant. To avoid delaying evacuation to the assembly point, maximize the occupancy of each vehicle or plant truck within safe limits and obey all traffic rules and signs out of the plant.

68

Alarm activation

Activation of fire alarm

Stop work

Stop work / telephone calls / meetings immediately Supervisors evacuate their staff through the nearest safe exit. All visitors / contractors to be Walk brisk but do not run. Proceed straight to Assembly area. If the front exit is blocked, Emergency Director should decide to use the back exit and proceed to External Assembly area. Announcement should be made to inform all evacuees to proceed to External Assembly area. Do not collect personal belongings or stop Assemble according to assembly stands laid out. Stay in line and do not move about Evacuation Officer conducts headcount of their staff. Report any suspected missing personnel

Evacuation

Process to assembly area

Assembly

Head count

Standby

Remain in Assembly Area until further instruction. Do not return to work until ALL

Figure 4.15: Evacuation Procedure

CHAPTER 5

CONCLUSIONS AND RECOMMENDATIONS

5.1

Conclusions

The followings are the conclusion obtained from the study.

1)

Methanol is the most hazardous and flammability material used at Vance Bioenergy Sdn. Bhd. Large explosion at one of the methanol storage tank would affect 12.62 m in radius from the fire. The failure rate for explosion happened at methanol storage tank is 4.07 x 10 /year
-4

2)

Air quality within Vance Bioenergy Sdn. Bhd. is in good condition because the Health Index (HI) recorded is less than one.

3)

Emergency Response Plan for Plant, Injured Person and Transportation emergency had been proposed as evacuation if any incident happened. The plan must be posted at or near raw material storage, treatment area and inside the plant itself. ERP consist the information necessary to respond effectively to any incident occurred. Thus it can minimize hazards to human health or environment.

70 With proper management as proposed in emergency response plan, the activity within Vance Bioenergy Sdn Bhd wil not cause any catastrophic or failure events.

5.2

Recommendations

Following recommendation should be carried out in order to improve the study.

1)

Beside determine the radius of affected area, this study can be improved by calculate the height of flame and burning duration.

2)

Use other analysis such as BLEVE model to get more result on the risk that may occur.

3)

Beside focus on methanol storage tank only, Sodium Methylate 30% solution also very flammability at Vance Bioenergy Sdn Bhd. The analysis should be carried out to identify risk from Sodium Methylate 30% solution storage tank.

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75 APPENDIX A

76

77

78

79

80

81 APPENDIX B

82

83

84

85

86

87

88 APPENDIX C

89

90

91

92

93

94

95 APPENDIX D

96

97

98

99

100

101

102 APPENDIX E

103

104

105

106

107

108 APPENDIX F

109

110

111

112

113

114 APPENDIX G

115

116

117

118

119

120

121

122

123 APPENDIX H Example of Calculation for Pool Fire

Size of pool fire = 5m

r : m" : H : k : 0.3 0.017 kg/m2.sec 20000 kJ/kg 100 m-1

For q = 37.5 kW/m2

Area of pool fire

Heat release rate

124

kW

Radius of area affected

APPENDIX I

Result for Air Sampling

CA (mg/m3) Normal Operation *Standard A1 SO2 NO2 CO TSP 3 3 2450 0.062 A2 4 3 2240 0.109 A3 11 25 2450 0.0735 130 170 30000 0.26 A1 0.587 5.871 479.452 0.012

EDair (mg/kg.days) Normal Operation *Standard A2 0.783 5.871 438.356 0.021 A3 2.153 4.892 479.452 0.014 25.440 33.268 5870.84 0.051

*Based on Recommended Malaysian Air Quality Standards

125

126 APPENDIX J Example of Calculation for Health Index

For normal operation of SO2,

mg/m3

For standard of SO2,

mg/m3

Health index for SO2

127 APPENDIX K Recommended Malaysian Air Quality Guidelines

Pollutant Ozone (O3) Carbon Monoxide (CO) Nitrogen Dioxide (NO2) Sulfur Dioxide (SO2) Particulate Matter (PM10) Total Suspended Particulate (TSP) Lead (Pb)
Note: * mg/m3

Averaging Time 1 Hour 8 Hour 1 Hour 8 Hour 1 Hour 24 Hour 1 Hour 24 Hour 24 Hour 12 Month 1 Hour 8 Hour 3 Month

Malaysia Guidelines ppm (g/m3) 0.10 200 0.06 120 30.0 35* 9.0 10* 0.17 320 0.04 10 0.13 350 0.04 105 150 50 0.1-0 260 0.60 90 1.5