METHANOL INSTITUTE Methanol Safe Handling Manual Prepared by: Alliance Consulting International San Diego, California, USA Prepared for: Methanol Institute Arlington, Virginia, USA Edition: 1.0 Date: October 2008 Table of Contents 1 Introduction to the Manual .......................................................... 1 1.1 Purpose of the Manual ......................................................................................... 1 1.2 The Methanol Value Chain................................................................................... 2 1.3 Methanol Institute Product Stewardship Policy .................................................... 2 1.4 Methanol Institute Contact Information................................................................. 3 1.5 About the Authors................................................................................................. 3 2 Methanol General Information .................................................... 5 2.1 What Is Methanol?................................................................................................ 5 2.2 The Methanol Life Cycle (Value Chain)................................................................ 7 2.2.1 Methanol Manufacture.................................................................................... 7 2.2.2 Sustainable Production................................................................................... 8 2.2.2.1 Recycling............................................................................................... 8 2.2.2.2 Reuse.................................................................................................... 8 2.2.2.3 Waste Management.............................................................................. 8 2.3 Uses of Methanol.................................................................................................. 9 2.3.1 Chemical Intermediates................................................................................ 10 2.3.2 Fuel Applications .......................................................................................... 10 2.3.3 Biodiesel Fuel Production............................................................................. 12 2.3.4 Wastewater Denitrification............................................................................ 14 2.3.5 Emerging and Miscellaneous Uses .............................................................. 14 2.3.5.1 Direct Methanol Fuel Cell.................................................................... 14 2.3.5.2 Methanol to Hydrogen Fuel Cell ......................................................... 14 2.3.5.3 Turbine Engines .................................................................................. 15 3 Transportation and Storage of Methanol .................................. 17 3.1 Methanol Transportation..................................................................................... 17 Table of Contents i METHANOLSAFEHANDLI NGMANUAL 3.1.1 Ocean-Going Transport................................................................................ 17 3.1.2 Rail Transport ............................................................................................... 17 3.1.3 Tanker Truck Transport ................................................................................ 18 3.2 Methanol Storage ............................................................................................... 18 3.2.1 Docks and Marine Terminals........................................................................ 18 3.2.2 Tank Farms................................................................................................... 19 3.2.3 Portable Containers (Totes and Drums)....................................................... 19 3.2.4 Electrical Classification................................................................................. 20 3.2.5 Grounding and Bonding................................................................................ 20 4 Health and Safety...................................................................... 23 4.1 Exposure to Methanol......................................................................................... 23 4.1.1 Routine Sources of Exposure....................................................................... 23 4.1.2 Accidental Sources of Exposure................................................................... 24 4.1.3 Routes of Exposure ...................................................................................... 25 4.1.4 Methanol Metabolism ................................................................................... 25 4.1.5 Effects of Exposure ...................................................................................... 26 4.1.5.1 General Symptoms ............................................................................. 26 4.1.5.2 Acute Effects....................................................................................... 26 4.1.5.3 Chronic Effects.................................................................................... 26 4.2 Exposure Control................................................................................................ 27 4.2.1 Engineering Controls .................................................................................... 27 4.2.1.1 Ventilation ........................................................................................... 27 4.2.2 Personal Protective Equipment .................................................................... 27 4.2.3 Respiratory Protection .................................................................................. 28 4.2.4 Chemical-Resistant Clothing/Materials ........................................................ 28 4.3 Safety Precautions ............................................................................................. 29 4.3.1 Routine Operations....................................................................................... 29 4.3.2 Special or High Hazard Operations.............................................................. 29 4.3.2.1 Confined Space Entry ......................................................................... 29 4.3.2.2 Hot Work ............................................................................................. 30 4.3.3 Exposure Monitoring..................................................................................... 31 4.4 First Aid Measures.............................................................................................. 32 4.4.1 Inhalation ...................................................................................................... 33 ii Table of Contents 4.4.2 Skin Contact ................................................................................................. 33 4.4.3 Eye Contact .................................................................................................. 33 4.4.4 Accidental Ingestion ..................................................................................... 33 5 Managing Methanol Safely: Process Safety............................. 35 5.1 Employee Participation....................................................................................... 37 5.2 Process Safety Information ................................................................................ 37 5.3 Process Hazard Analysis.................................................................................... 38 5.4 Operating Procedures ........................................................................................ 38 5.5 Training............................................................................................................... 38 5.6 Contractors ......................................................................................................... 39 5.7 Pre-Startup Safety Review ................................................................................. 39 5.8 Mechanical Integrity............................................................................................ 39 5.9 Hazardous Work Permits.................................................................................... 40 5.10 Management of Change..................................................................................... 40 5.11 Emergency Planning and Response .................................................................. 41 5.12 Incident Investigation.......................................................................................... 41 5.13 Process Safety Audits ........................................................................................ 42 5.14 Trade Secrets ..................................................................................................... 43 5.15 Implementing Process Safety............................................................................. 43 5.15.1 What Is a “Hazard”? ................................................................................... 43 5.15.2 What Is a “Risk”? ........................................................................................ 44 5.15.3 Hazard Identification and Risk Assessment Methods ................................ 44 5.15.4 Process Hazard Assessment Documentation ............................................ 44 6 Fire Safety................................................................................. 45 6.1 Fire Detection and Protection............................................................................. 45 6.1.1 Vapor Control...............................................................................................