houstonlogo rjilogo

The Right-to-Know Network

Back to search

Solvay USA Inc., Baton Rouge Facility

Parent Companies:
Solvay Holding Inc.
EPA Facility ID:
100000125884
Other ID:
70821STFFRAIRLI
Facility DUNS:
8161234
Parent Company DUNS:
874748937

Location:

Address:
1275 Airline Highway
Baton Rouge, LA 70805
County:
EAST BATON ROUGE
Lat / Long:
30.509, -91.188 (Get map)
Method:
Interpolation - Photo
Description:
Plant Entrance (General)
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Solvay USA Inc.
Phone:
(609) 860-4000
Address:
504 Carnegie Center
Princeton, NJ 08540
Foreign Address:

Person responsible for RMP implementation:

Name:
Tom Horvath
Title:
Plant Manager

Emergency contact:

Name:
Dewana Evans
Title:
HSE Manager
Phone:
(225) 359-3682
24-hour phone:
(225) 359-3888
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
East Baton Rouge Parish LEPC
Full-Time Equivalent Employees:
125
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
2184-V3
OSHA Star/Merit Ranking
Yes
Last Safety Inspection Date:
Feb. 2, 2017
Inspecting Agency:
State environmental agency
Using Predictive Filing:
Yes

Processes:

Diphenols
RMP ID:
1000059081
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ethyl chloride [Ethane, chloro-]
75-00-3
106,500
No
Methyl chloride [Methane, chloro-]
74-87-3
107,800
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Dec. 19, 2014
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000047346

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Diphenols)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Diphenols)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Deluge systems
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers

4. Flammables: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Diphenols)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls

5. Flammables: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Diphenols)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • Dikes
not considered:
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Diphenols, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000049177
Safety Review Date
Oct. 31, 2014, since latest RMP submission
PHA Update Date
Nov. 11, 2011, since latest RMP submission
PHA Techniques
  • None
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Oct. 22, 2014, since latest RMP submission
Training Review Date
Feb. 2, 2012, since latest RMP submission
Maintenance Review Date
Aug. 25, 2014, since latest RMP submission
Maintenance Inspection Date
July 10, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Aug. 7, 2012
Management of Change Review Date
Jan. 6, 2014
Pre-startup Review Date
Aug. 7, 2012
Compliance Audit Date
Sept. 27, 2012
Compliance Audit Change Completion Date
Dec. 30, 2015
Incident Investigation Date
Sept. 25, 2014
Incident Invest. Change Completion Date
June 30, 2015
Participation Plan Review Date
July 9, 2014
Hot Work Review Date
April 1, 2013
Contractor Safety Review Date
Sept. 24, 2014, since latest RMP submission
Contractor Safety Eval. Date
Sept. 25, 2014, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
Aug. 28, 2014
Local Response Agency:
Local Response Agency Phone:
(225) 389-2055
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

General Executive Summary for the Risk Management Plan at the Solvay USA Inc., Baton Rouge facility

EPA facility ID # 1000 0012 5884

LDEQ facility ID # 193924



Date of summary: 12/15/2014



1. Our Accidental Release Prevention and Emergency Response Policies



We at Solvay USA Inc., Baton Rouge, LA, are strongly committed to employee, public and environmental safety. This commitment is demonstrated by our comprehensive accidental release prevention program that covers areas such as design, hazard analysis, installation, operating procedures, mechanical integrity, management of change, incident investigation and employee training associated with the processes at our Baton Rouge facility. It is our policy to implement appropriate controls to prevent possible releases of regulated substances. The Solvay Baton Rouge site has also established an Emergency Response Team, consisting of plant personnel, that is well trained and prepared to respond to emergency situations.



2. Our Facility and the Regulated Substances handled



Our Baton Rouge facility produces Hydroquinone, Catechol, Vanillin and Ethyl Vanillin. Our facility's manufacturing activities encompass Diphenols Ethers Production. The RMP-covered process at our facility stores & handles the following regulated chemicals: Methyl Chloride, and Ethyl Chloride.





3. Our General Accidental Release Prevention Program and the Chemical-Specific Prevention Steps



The Solvay Baton Rouge facility has taken all the necessary steps to comply with the accidental release prevention requirements set out under 40 CFR 68 Subpart D of the EPA RMP regulations. The following sections briefly describe the elements of the release prevention program that is in place at our facility.



Process Safety Information



Solvay USA Inc., Baton Rouge Facility maintains detailed records of safety information that describes the properties and hazards of the chemicals used in our manufacturing units, the process technology emplo
yed, safe operating parameters and safety instrumented systems, and equipment specifications and design basis associated with all processes.



Process Hazard Analysis



Our facility conducts comprehensive analytical studies to ensure that hazards associated with our processes are identified and controlled efficiently. The methodologies used to carry out these analyses are Process Hazard Review (or PHR, equivalent to What-If) and Safety Review on Diagrams (or SRD, equivalent to HazOp), incorporating Layers-of-Protection Analysis (LOPA). The studies are undertaken by a cross-functional team of qualified personnel with expertise in PHA methodology, process engineering, process operations, and equipment maintenance, and are reviewed & revalidated every five years. Recommendations, if any, related to the hazard analysis are addressed in a timely manner.



Operating Procedures



For the purposes of safely operating our covered processes, Solvay USA Inc., Baton Rouge Facility maintains written operating procedures that address step-wise the various modes of operation. The information is periodically reviewed and maintained current, and accordingly certified annually. Written Operating Procedures are readily accessible to employees involved in operating the processes.



Training



Solvay USA Inc., Baton Rouge Facility has a comprehensive training program in place to ensure that employees who are operating the processes are trained and competent in the operating procedures associated with these processes.



Mechanical Integrity



Solvay USA Inc., Baton Rouge Facility carries out documented maintenance inspections on process equipment to ensure proper operations. Process equipment examined by these inspections includes, among others, pressure vessels, storage tanks, heat exchangers, piping systems, relief and vent systems, emergency shutdown systems, controls and pumps. Process equipment that are in contact with the hazardous RMP-listed chemicals receive priorit
y for inspections. Maintenance functions are carried out by qualified personnel with previous training in maintenance practices. Furthermore, these personnel are offered specialized training as needed. Any equipment deficiencies identified by the maintenance inspections are corrected in a safe and timely manner.



Management of Change



Written procedures are in place at Solvay USA Inc., Baton Rouge Facility to manage changes in process chemicals, technology, equipment and procedures. Proposed changes are implemented after they have been justified and reviewed for potential hazards that are addressed prior to implementing the change. Process operators, maintenance personnel or any other employee whose job tasks are affected by a modification in process conditions are promptly made aware of the change and why it is necessary, and offered training to understand and work with the modification.



Pre-startup Safety Reviews



Pre-start up safety reviews related to new processes and to significant modifications in established processes are conducted as a regular practice at the Solvay USA Inc., Baton Rouge Facility. The extent of review is based on the complexity of the modification. These reviews are conducted by a cross-functional team to confirm that construction, equipment, instrumentation, operating and maintenance procedures are suitable for safe startup, and that all action-items from the safety review for the change have been addressed, prior to placing equipment into operation.



Compliance Audits



Solvay USA Inc., Baton Rouge Facility conducts internal compliance audits on a regular basis to determine whether the provisions set out under the RMP regulations are being implemented. These audits are carried out at least every 3 years, and any corrective actions required as a result of the audits are prioritized and undertaken in a safe and timely manner.



Incident Investigation



Solvay USA Inc., Baton Rouge Facility promptly investigates any incid
ent that has resulted in, or could reasonably result in a catastrophic release of a regulated chemical. These investigations are undertaken by cross-functional teams to identify the root cause(s) leading to the incident as well as any corrective actions to prevent the release from reoccurring.



Employee Participation



Solvay USA Inc., Baton Rouge Facility truly believes that process safety management and accident prevention is a team effort. The site has a written program as well as an employee-driven HS&E team leading the effort to attain 100% employee participation in HS&E improvement efforts. Company employees are strongly encouraged to express their views concerning accident prevention issues and to recommend improvements. In addition, our employees have access to all information created as part of the facility's implementation of the RMP regulations, including information resulting from process hazard analyses in particular.



Contractors



On occasion, our facility hires contractors to perform specialized maintenance and construction activities. Prior to selecting a contractor, a thorough evaluation of safety record of the contractor is conducted. Only those contractors who satisfy Solvay's selection criteria are approved for being hired. Solvay USA Inc., Baton Rouge Facility has a strict policy of informing the contractors of known potential hazards related the contractor's work and the processes. Contractors are also informed of all the procedures for emergency response should an accidental release of a regulated chemical occur.





4. Our Five-year Accident History



Solvay USA Inc., Baton Rouge Facility has had an excellent record of preventing accidental releases over the last 5 years. Due to our stringent accidental release prevention program and policies, there has been no RMP-reportable release of regulated chemicals from our covered processes during this period. Our record reflects our safety culture and commitment to preventing accid
ental releases.





5. Our Emergency Response Program



Solvay USA Inc., Baton Rouge Facility has a written emergency response plan to deal with accidental releases of hazardous chemicals. The plan includes all aspects of emergency response including incident command system of response management, adequate first aid and medical treatment, shelter-in-place and evacuations, notification of local emergency response agencies and the public, as well as post-incident decontamination of affected areas and critique of the response. The site has established an Emergency Response team consisting of plant personnel well trained and prepared to respond to emergency situations.



To ensure proper functioning, our emergency response equipment is regularly inspected, tested and serviced. Site-wide emergency preparedness drills are conducted periodically and response critiqued for improvement opportunities. In addition, the plan is promptly updated to reflect any pertinent changes taking place within our processes that would require a modified emergency response.



East Baton Rouge Parish LEPC is the Local Emergency Planning Committee (LEPC) with which our emergency plan has been coordinated and verified.





6. Planned Changes to Improve Safety



The Solvay USA Inc. Baton Rouge facility is committed to maintaining and operating our manufacturing units in a safe and environmentally responsible manner. Our site is committed to achieving HS&E excellence through continuous improvement of our HS&E processes. Ongoing changes to improve safety include Implementation of Responsible Care Management System (SCMS), Total Productive Maintenance (TPM), wider implementation of Safety Instrumented Systems (SIS), a Behavior-based Safety Program (SafeStart), enhanced employee awareness of safety through improved training and education, and creating an accountability culture for safety performance.