INDUSTRIAL AND ENGINEERING
NEWS EDITION VOL. 14, No. 3
CHEMISTRY
FEBRUARY
10, 1936
Vol. 28, Consecutive N o . 6
Published by the American Chemical Society Harrison E. Howe, Editor Publieattoa Offioe: Easton, Pa. Cable: Jteohem (Washington)
Editorial Offioe: Room 706, Mills Building, Washington, D. C. Advertising Department: 332 West 42nd 8treet. New York, N. Y.
Telephone: National 0848 Telephone: Bryant 9-4430
Safety Measures at Dyestuffs Plants C. H . S . T U P H O L M E , 6, H a m i l t o n Gardens, N. W. 8, L o n d o n , E n g l a n d NTERESTING details of the elaborate Istuffs safety precautions adopted at the dyeplant of Imperial Chemical Indus-
tries, Ltd., were described recently by W. C. Hiscock in a paper before a joint meeting of the Institute of Chemistry and the Society of Chemical Industry. Dr. Hiscock dealt primarily with the Grangemouth plant of Scottish Dyes, Ltd., though the methods employed there are typical of the dyestuffs plants of the I. C. I. group. The I. C. I. plant at Grangemouth manufactures various dyestuffs based on the anthraquinone molecule and used in dyeing and printing cotton, wool, viscose, and acetate rayon. The principles involved are similar to general dyestuff manufacture, in that the final dyestuff molecule is built up through a chain of processes involving the preparation of series of intermediates. The problem consists of the preparation of 137 intermediates, 99 parent dyestuffs, and 900 brands. Each process employs such chemical equipment as agitated pans, vats, stills, filtering plants of various types, agitated high-pressure autoclaves, and so on. The processes are grouped together in sheds, which are filled with shafting, a multitude of pipe lines carrying steam, compressed air, vacuum, hot oil, acids, solvents, and so on. There are also cables carrying electric power for lighting and isolated power units. In general, the reactions involve chemicals dangerous to the human system, their danger from toxicity or other reasons varying in degree only. In some reactions high temperatures are necessary; in others noxious gases or vapors are produced; while in still others the reactants are corrosive. Dr. Hiscock pointed out that the policy of the I. C. I. is based fundamentally on the principle that the people in charge of manufacturing processes are just as responsible for carrying through their processes without accident or ailment as they are for carrying them out with good yields, on time schedule, and at an economic cost. Safe working is placed higher in connection with the carrying out of an operation than any other consideration. Yields and output are sometimes sacrificed at the altar of safe and hygienic working. Processes have been shut down completely when the possibility of danger has been discovered. All safety and prophylactic measures are
carried through primarily by the production chain of command. Whatever measures are employed, assistance or advice given through service sections, nothing is done to divorce the responsibility from the plant superintendents, foremen, etc., directly engaged in controlling works operations. It is, of course, unreasonable to expect the satisfactory working of this principle by just making a statement to this effect; the higher management must do its share of providing instruction and the necessary service. With this end in view, the higher command insists on the reporting of every accident or ailment, however small, so that the superintendents, foremen, etc., can put forward definite suggestions as to how a recurrence can be prevented. Although these occurrences are reported from a compensation point of view, the forms used are followed up to see whether there is a weakness in the company armor, and whether the weakness can be remedied. Naturally, all accidents cannot be foreseen or a solution found to prevent a recurrence, but subsequent investigations keep the subject before those in charge and make them think in the right direction. All workers starting in I. C. I. factories are supplied with a copy of the I. C. I. Safety Handbook for retention. Processes have all been considered carefully to eliminate unhealthy operations—e. g., material is charged into cold nitrobenzene and detailed operating instructions are posted in the sheds for each process. In addition, a process record sheet is kept for each batch. It may appear that this is over-elaborate, but lit is not. Both the process worker and the material being produced are very valuable, and their ultimate well-being most important. Operating instructions are also posted on machinery. A thorough investigation of all the chemicals used or produced in the works has been made. This is, of course, followed up when new processes are introduced. In collaboration with the Works Medical Officer, all the available literature has been examined. In the case of all these materials an instructional sheet has been drawn up giving details of their action, precautions to be taken, symptoms to be looked for, and first-aid treatment. All the plant at Grangemouth has been 33
constructed or reviewed from time to time from a point of view of the possibility of danger. Systematic inspection by a fulltime plant inspector, appointed by the Engineering Department, is continually being applied. Unexpected happenings are reviewed and the possibility of a recurrence ruled out as far as possible. The chief endeavor is to keep the shed atmosphere clear of any harmful gases or vapors. This is done primarily by covering and drafting of all vessels to the open air. Unfortunately the procedure is not successful in all cases, especially where the vessels have to be opened for charging, inspecting, and so on. It is sometimes possible to employ devices in which a strong draft of air by a fan is drawing air over the charging hole. Where such devices fail, the whole plant or part of it is placed in the open air. In one case the plant concerned employs a process in which the solvent used is hot aniline. Here drafting cannot be relied upon, so there is no alternative but to place the offending plant in the open air, against the wall of a shed in which other parts of the plant are located, communicating doors being kept closed. Many of the Grangemouth processes employ nitrobenzene as solvent. Formerly, these processes were scattered throughout practically every shed in the works. Workers from all sheds were affected and the position became serious, particularly during hot weather. The problem was solved by grouping these processes into one shed in a suitable plant, and removing as much of the shed walls as possible. The most undesirable operations are now actually conducted outside the shed. By this arrangement the number of workers exposed is limited, and they can be suitably clothed to face the more rigorous conditions. In plant designing for chemical processes a verv important essential is to cut down handling of chemicals as much as possible. Corrosive liquids and solvents should be stoied in closed vessels ventilated suitably outside; they should be conveyed in closed pipe lines, subsequently measured in suitable vessels, and delivered t o the reaction vessels through closed pipes. Sight glasses should be introduced instead of funnels. Acid handling has always caused a large number of minor accidents, and a complete set of regula-
34
INDUSTRIAL AND ENGINEERING CHEMISTRY
tions covering all phases of acid handling has now been introduced. T h e "bucketing" of acids is forbidden, except in the experimental plant, where speciallydesigned buckets are used. In the designing of a plant for a new product, or t h e rebuilding of a n old plant, t h e works appoints a plant design committee, who studies a n d advises from every aspect on the design of the plant. T h e protection of the worker gets first t h o u g h t , not only for protection against gassing, splashing*, and so on, but also from t h e point of view of comfort in working a n d t h e expending of energy. For example, t h e maximum height of charging manholes must not be greater than 2 feet 3 inches. The protection of the worker against the unexpected is, of course, of paramount importance. As already stated, unfortunately chemical operations d o not a l ways go according t o plan. From this point of view every operation in t h e factory has been studied a n d scheduled for protect ive clothing a n d appliances. These schedules are approved, a n d copies are in the possession of t h e labor D e p a t m e n t and the shed superintendents. By constant education a n d discipline n o difficulty is found in persuading t h e workers that instructions must be obeyed. A complete change of clothing, including underwear, is supplied for certain processes; overalls for o t h e r s ; while rublier boots a r e provided for most process workers. Goggles are scheduled for many operations involving t h e use of such reagents a s acids and caustic alkalies. Gloves a n d sleeves are also scheduled for many processes. For general process work the. h a n d s a r e given a treatment of a lanoline preparation a n d then covered with stockinette gloves, followed b y r u b ber gloves a n d sleeves. Rubber gloves alone are not allowed, because they induce sweating a n d modern rubber contains chemicals of a doubtful action on t h e skin. For certain processes, such a s handling phthalic anhydride, cotton stockinette gauntlets a r e scheduled. In some of t h e heavv engineering jobs, such as welding steel plate, special gloves are provided. Masks a n d respirators of standard types are scheduled. For gases a n d vapors a mask is used in which compressed a i r from a clean source is distributed over t h e face. This mask gives complete protection in case of spills, sudden evolution of gas, a n d so on. In another mask, air is inhaled through a pipe from outside the shed. F o r closed vessels a n d general rescue work oxygen-breathing a p p a r a t u s is used. C a n ister gas masks a r e not allowed, as their effective life, even when recharged, is doubtful in concentrated atmospheres; after storage t h e effectiveness of a canister is also an unknown q u a n t i t y , even in d i lute concentrations. Electrieal equipment a t Grangemouth has been installed from t h e point of view of suitability for a chemical factory. Points which have been given serious a t tention a r e : installation of cables of safe current carrying capacity and switehgear of adequate r u p t u r i n g capacity; planning of power distribution networks with control and overload protection for all circuits; provision of isolating links for safety when working o n t h e line; provision of overload a n d no-volt trips on all motors; balancing of lighting load on t h e three phases; e a r t h i n g for static discharging; earthing of all metal p a r t s which could possibly become "live" through breakdown of insulation; and emergency s t o p pushes for line shafting. T h e electrical equipment is, moreover, under constant inspection.
All workers are emcouraged t o t a k e firstaid classes, outside working hours, u n d e r t h e works medical officer. I. C . I. h a v e socialized in this subject, and encouraged t h e men by monetary grants for a t t e n d ance a n d efficiency. In each I. C. I. works a safety officer is apfiointcd. He is usually t h e works labor manager. His functions d o not conflict with the operation of t h e principles of responsibility down t h e line of management, as his duties are to inspcct a n d give a d vice. H e is conversant with all I. C . I. methods and is expected to see t h a t t h e y are operating properly. All I. C. I. works have also a works council, consisting of equal numbers of t h e staff appointcd from t h e management a n d workers elected annually by t h e workers only. T h e labor manager acts as its secretary, and the medical officer a t t e n d s . From this works council is appointed a safety subcommittee, which has powers t o coopt other workers when necessary. Again, t h e labor manager acts as secretary, a n d the medical officer a t t e n d s all meetings. This committee holds regular meetings and tours of inspection of t h e works. In the case of the former it discusses all matters pertaining t o safety of immediate interest, all recent works accidents, statistics, publications on safety matters, and advises t h e management of its views. In the case of t h e last mentioned, t h e committee raises points which have been missed or suggests improvements t o the management. The views submitted by t h e safety s u b committee are transmitted t o t h e d e p a r t ments concerned for consideration a n d possible adoption. Since t h e suggestions represent carefully considered views of both workers a n d staff they are usually adopted. Occasionally, after department consideration, t h e pros a n d cons are put forward t o t h e higher management for derision. T h e fact that these discussions are held conjointly with the workers stimulates interest all round. Experience has shown at Grangemouth that t h e workers' representatives on t h e safety subcommittee have been each year e x t r e n v l y useful preachers of t h e "Gospel of Safety" a m o n g their fellow workers. They have taken an intelligent interest in t h e subject from every angle, a n d have not been afraiel t o assist the management in the spreading of propaganda and maintaining enthusiasm.
First
Commercial Chemical
Synthetie
NTEREST has arisen in what was t h e Iinelustrial first instance in t h e United States of synthetie production b y purely chemical means of a n organic substance occurring in nature. We a r e indebted t o C. A. Browne, who is always interested in things historical, a n d t o t h e cooperation of F. G. Zinsser, for what we publish here. Information at hand points t o t h e production of salicylie acid by the U . S . Salieylie Acid Works as the first. About 1871, August Zinsser, father of F . (J. Zinsser, while in Europe, bought t h e United States patent rights from P r o fessor Kolbe lor t h e manufacture of salicylic aciel according to what was known as the Kolbe process. T h e new company, the U . S . Salicylic Acid Works, was begun as a subsidiary of Win. Zinsser a n d Co. and t h e business was in full swing in l876. T h e products, consisting of the acid itself, a mouth wash, and a dusting powder, were exhibited at t h e Centennial Exposition where t h e salicylic acid received a n award a t t h e hands of a dis-
VOL. 14, NO. 3
tinguished committee. The committer included such chemists a s F . A . Genth, long a professor of chemistry a t t h e University of Pennsylvania and a former president
of
the
AMERICAN
CHEMICAL S O -
CIETY, w h o signed as the judge. This had t h e further approval of t h e group judges, among whom we find Charles J . J o y , w h o for a long while was connected with t h e chemical department of Columbia I n i v e r s i t y , a n d J . W. Mallott, a former president of our SOCIETY and prominently connected with t h e chemical department erf t h e University of Virginia when he served for many years. T h e process then in use consisted of drying sodium phenolate i n open furnaces a n d packing this dry powder in an iron cylinder provided with wire screen trays. This cylinder was heated with a coal fire, and carbonic acid, generated from limestone and acid, was passed through this mass spread o n t h e trays. Half of t h e phenol was distilled off as such and t h e remainder was the crude salicylate of soda, a dark powder which was acidified a n d decolorized with t i n alts a n d then crystallized. T h e bulk of t h e acid was shipped in these d a y s to California for t h e preservation of canned fruits a n d wine, a n d a lot of it was used in t h e brewing industry for t h e preservation of hottled beer before t h e era of pasteurization. These uses were later prohibited under the pure food laws. If t h e r e is a n earlier instance in t h e United States of t h e manufacture of a synthetic organic chemical compound occurring in nature, t h e N e w s EDITION would b e happy t o have the information for publication.
Motion Picture of InternalCombustion E n g i n e THE construction, operation, a n d care of t h e internal-combustion engine is pictured interestingly in a newly revised two-reel silent educational motion picture film, entitled " T h e Power Within," prepared under t h e supervision of t h e Bureau erf Mines, United States Department of t h e Interior, in cooperation with one erf t h e country's large automobile manufacturers. T h e story opens with various episodes showing t h e uses of power produced by t h e internal-combustion engine in lighting homes, pumping water, plowing fields, a n d in t h e operation of automobiles, boats, a n d airplanes. Animated drawings explain in detail t h e name, location, a n d operation erf each part of t h e motor; show how firing takes place in cylinders; illustrate changing erfgears, how power is transmitted through gears t o rear wheels, a n d the ill effects t o gears and cylinder walls brought about by improper lubrication; and show how this difficulty may be avoided. T h e picture describes the action of the carburetor in atomizing and mixing fuel with air before it enters t h e cylinders; improper firing a n d waste of gasoline due to fouled spark plugs; knocking caused by accumulation of carbon; and t h e proper use of t h e choke. Waste of gasoline and of power are also shown b y animated drawings. Copies of this film in 16-mm. or 35-mm. sizes a r e loaned for exhibition purposes t o schools, churches, clubs, civic a n d business organizations, a n d others, upon application t o t h e Pittsburgh Experiment Station erf t h e Bureau erf Mines, Pittsburgh, P a . No charge is made for the use of t h e film, but t h e exhibitor is asked to pay t r a n s portation charges.
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