Table A-4.

1: Potential Hazards
Process / Conditions

Potential Hazards

Fire

Explosion

Reactor

High pressure process

Toluene gas piping

High Temperature
Process

Leakage

Explosion

Failure of cooling system

Fire

Leakage

Explosion

Failure of safety relief valve

Fire

Ruptured tubes

Explosion

Structural and mechanical failures of equipments

Burns

Failure of critical devices

Process / Conditions
Toluene gas piping

Sources

Potential Hazards

Poses a fire and/or explosion risk as a result of its flammability

Leakage might happen anywhere along the supply line thus creating a high possibility of fire and/or explosion hazard towards
people and also the plant itself

Failure of the reactor

cooling system

The worst safety problem that can occur with reactors is through runaway reactions usually caused by coolant failure perhaps
for a brief period or reduced cooling capacity. Rate of temperature rise becomes progressively rapid once the heat generation
exceeds available cooling capacity. It can lead to overpressurization of the reactor which eventually leads to explosion

High pressure process

Use of high pressures mainly in the sections of benzoic acid production greatly increases stored energy in the plant

Problem of leaks becomes much more serious with high pressure operation since this increases the mass flow rate of fluid
which can leak out through a given hole

High temperature process

The use of high temperatures in combination with high pressure greatly increases stored energy in the plant

Possible rupture of the tubes carrying the process fluid and explosions in the radiant zone

Mechanical failures of structures or devices due to high temperature operations which are mainly associated with creep which
is the gradual extension of a material which is under steady tensile stress over a prolonged period of time

Failure of critical devices like safety relief valves, control valves etc. pose a serious threat to employees and the overall plant
itself

Other potential hazard from this type of process is the possibility of direct skin contact to hot materials or hot structures

Excessive heat on the employees, either as the result of high ambient temperature or of excessive radiant heat

Table A-4.3: Health complications of the enlisted hazardous materials

Material
Toluene

Health Complications

Toluene is a central nervous system depressant. Exposure to very high levels (15,000 to 30,000 ppm) for a short
time may cause mental confusion, loss of coordination, and unconsciousness.

Exposures to 200 ppm for 8 hours caused mild fatigue, weakness, confusion, lacrimation, and paresthesias
(sensation of pricking, tingling, or creeping) of the skin.

Exposures to 600 ppm for 8 hours produced additional effects including euphoria, headache, dizziness, dilated
pupils, and nausea.

While at 800 ppm for 8 hours the symptoms were more pronounced and also included nervousness, muscular
fatigue, and insomnia that persisted for days.

exposure to 100 ppm for 6 hours resulted in eye and nose irritation, and in some cases, headaches, dizziness, and a
feeling of intoxication.

Repeated or prolonged skin exposure to toluene causes skin drying, fissuring, and dermatitis. Liquid splashed in the

eyes of two workers caused transient corneal damage and conjunctival irritation with complete recovery within 48
hours.

Benzoic acid

Eye: Causes eye irritation.

Skin: May cause skin irritation. May be harmful if absorbed through the skin. May be absorbed through the
skin in harmful amounts. Absorption throug h the skin has produced labored breathing in humans.

Ingestion: Harmful if swallowed. May cause irritation of the digestive tract.

Inhalation: May cause respiratory tract irritation. May be harmful if inhaled. Intermittent breathing of dust
over a 4-week period produced interstit ial fibrosis in the lungs of rats. Benzoic acid begins to sublime at 1
00C.

Benzene

Benzaldehyde

Skin: Causes skin irritation. It can be absorbed through intact skin and affect the liver, blood, metabolism, and urinary system.
Eyes: Causes eye irritation.
Inhalation: Causes respiratory tract and mucous membrane irritation. Can be absorbed through the lungs. May affect
behavior/Central and Peripheral nervous systems (somnolence, muscle weakness, general anesthetic, and other symptoms
similar to ingestion), gastrointestinal tract (nausea), blood metabolism, urinary system.
Ingestion: May be harmful if swallowed. May cause gastrointestinal tract irritation including vomiting.
May affect behavior/ Central and Peripheral nervous systems (convulsions, seizures, tremor, irritability, initial CNS stimulation
followed by depression, loss of coordination, dizziness, headache, weakness, pallor, flushing), respiration (breathlessness and
chest constriction), cardiovascular system, (shallow/rapid pulse), and blood.
May cause adverse reproductive effects (female fertility, Embryotoxic and/or foetotoxic in animal) and birth
defects.
May affect genetic material (mutagenic).
May cause cancer (tumorigenic, leukemia)
The substance can be absorbed into the body by inhalation of its vapour, through the skin and by ingestion, cause cough, sore throat, skin
redness, eye redness and pain

Carbon monoxide

Acute exposure: The signs and symptoms of acute exposure to carbon monoxide may include headache, flushing, nausea, vertigo,
weakness, irritability, unconsciousness, and in persons with pre-existing heart disease and atherosclerosis, chest pain and leg pain.

Chronic exposure: Repeated bouts of carbon monoxide poisoning may cause persistent signs and symptoms, such as anorexia,

headache, lassitude, dizziness, and ataxia.

Carbon dioxide

It can cause asphyxiation, chemical anoxia

May cause headaches, dizziness, restlessness, paresthesis; dyspnea; sweating; malaise; increased heart rate, elevated blood pressure,
pulse pressure; coma; asphyxia; convulsions; frostbite (dry ice)