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Mexichem Fluor Inc. - St. Gabriel Site

Parent Companies:
Mexichem Fluor SA de CV
EPA Facility ID:
100000141438
Other ID:
70776CMRCS4990
Facility DUNS:
805624178
Parent Company DUNS:
812865046

Location:

Address:
4990B ICI Road
St. Gabriel, LA 70776
County:
IBERVILLE
Lat / Long:
30.236, -91.096 (Get map)
Method:
Interpolation - Photo
Description:
Center of Facility
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Mexichem Fluor Inc.
Phone:
(225) 642-0094
Address:
P.O. Box 30
St. Gabriel, LA 70776
Foreign Address:

Person responsible for RMP implementation:

Name:
John Pacillo
Title:
Operations Director
Email:

Emergency contact:

Name:
James Hathcock
Title:
Regulatory Affairs Manager
Phone:
(225) 642-6348
24-hour phone:
(225) 642-6316
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Iberville Parish LEPC
Full-Time Equivalent Employees:
68
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
No
CAA Permit ID#:
OSHA Star/Merit Ranking
Yes
Last Safety Inspection Date:
Jan. 27, 2015
Inspecting Agency:
EPA
Using Predictive Filing:
Yes

Processes:

Fluorocarbon gas mfg.
RMP ID:
1000079163
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
4,008,770
No
Hydrogen chloride (anhydrous) [Hydrochloric acid]
7647-01-0
5,956
No
Hydrochloric acid (conc 37% or greater)
7647-01-0
6,531,397
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
May 3, 2017
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000063086

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 Fluorocarbon gas mfg.)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
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:
  • None
not considered:
  • Dikes
  • 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 Fluorocarbon gas mfg.)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
Public OCA Chemical (in Fluorocarbon gas mfg.)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
Public OCA Chemical (in Fluorocarbon gas mfg.)
CBI claimed:
No
Percent weight:
38.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Fluorocarbon gas mfg., Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000066519
Safety Review Date
May 2, 2017, since latest RMP submission
PHA Update Date
March 30, 2016, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Quench System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
April 28, 2017, since latest RMP submission
Training Review Date
June 16, 2015, since latest RMP submission
Maintenance Review Date
March 31, 2017, since latest RMP submission
Maintenance Inspection Date
March 28, 2017, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 16, 2017
Management of Change Review Date
March 6, 2014
Pre-startup Review Date
March 28, 2017
Compliance Audit Date
Sept. 22, 2016
Compliance Audit Change Completion Date
July 31, 2017
Incident Investigation Date
April 4, 2017
Incident Invest. Change Completion Date
June 30, 2017
Participation Plan Review Date
July 1, 2015
Hot Work Review Date
July 1, 2015
Contractor Safety Review Date
Feb. 8, 2017, since latest RMP submission
Contractor Safety Eval. Date
April 26, 2017, 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:
Feb. 28, 2017
Local Response Agency:
Local Response Agency Phone:
(225) 687-5140
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

14535 LDEQ Facility ID Number



The Mexichem Fluor Inc. St. Gabriel facility is located on approximately 83 acres one mile south of St. Gabriel, on Louisiana Highway 75. The facility manufactures the refrigerant gas 1,1,1,2-tetrafluoroethane (KLEA 134a). The facility has been in operation since December 1992 and currently employes 94 people (including contract workers). Although KLEA 134a is the primary product, the facility also produces hydrochloric acid as a process by-product.



KLEA 134a is the ozone friendly replacement refrigerant for CFC12. It is used in automotive air conditioners, refrigerators, freezers, appliances (both home and commercial), and has many other consumer uses. It is also purified to a medical-grade for use as a propellant in inhalers.



Under EPA's RMP rule, 1,1,1,2-tetrafluoroethane (KLEA 134a) is not regulated. However, hydrogen fluoride (a raw material used in the process) and hydrochloric acid (a process by-product) are both regulated under the rule. Flammable chemicals are not present at the facility in quantities regulated under the RMP rule.



This RMP involves predictive filing for hydrochloric acid. The facility produces 36% nominal strength hydrochloric acid. However, it has the capability to produce hydrochloric acid at strengths up to 38%. Since the threshold concentration for hydrochloric acid in the RMP rule is 37% and the facility is capable of producing acid at strengths up to 38%, the predictive filing option is used for 38% hydrochloric acid.



The quantities of hydrogen fluoride and hydrochloric acid (conc. 37% or greater) provided in Section 1.17.c.3 include not only the maximum intended quantities found in the manufacturing process, but also the maximum intended quantities found in railcars located on-site. Only a small fraction of that shown is in the manufacturing process and of that a significant fraction is in storage (i.e., the bulk of the quantities provided are in storage either in storage tanks
or in railcars). Hydrogen chloride (anhydrous) is found only in the manufacturing process.



The facility has been recognized by the National Safety Council for its outstanding safety performance and has been awarded the Chemical Manufacturers Association (CMA) Award of Excellence for achieving zero lost workday cases among both employees and contractors. The facility was also awarded the 2009 Louisiana Chemical Association's "Best in Class" Serious About Fostering Excellence (SAFE) Award.



The facility has not, in the past 5 years, had an accident that meets the criteria for inclusion in the 5-year accident history.



The facility employs several measures to prevent a catastrophic release from occurring:



Design: design reviews; process hazard analyses; adherence to national, industry, and company design standards; experienced designers; and management of change;



Construction: positive material identification; quality assurance inspection; quality assurance testing; and pre-startup safety reviews;



Preventive Maintenance: inspection and testing programs; full service maintenance programs; root cause analysis; and improvement upgrades;



Control Systems: alarms; interlocks; monitoring systems; computer monitoring and control systems; and backup and fail-safe systems;



Training: rigorous employee selection process; new employee training; and periodic recertification testing;



Auditing: internal audits and outside/independent evaluations.



In the event of a release, the facility has written procedures and a full emergency response plan in place, along with trained personnel to respond to the emergency. Emergency response drills are held periodically to insure that responders are proficient in the use of mitigation systems and that notification procedures are followed. The facility works with the Local Emergency Planning Committee and the Iberville Parish Community Awareness and Emergency Response Group to maintain and enhance emergency notificati
on systems such as the Community Alert Notification (CAN) system. Alarms can be sounded at the facility and, if necessary, throughout the community.



Changes to improve safety are constantly being implemented at the facility. Employee participation programs provide employees significant opportunities for input. Internal reviews and audits provide a means of self-check and identify areas for improvement. Learnings from incidents and incident investigations are shared with all employees as a means of safety improvement. Actions to prevent a recurrence of an incident are tracked to insure timely completion. Our improvement process allows all employees to contribute to the successful operation of the facility. The facility is constantly striving for the highest standards in safe and environmentally sound operation.



The Mexichem Fluor Inc. St. Gabriel facility was designed and constructed with prevention of catastrophic releases as a primary goal. In addition, facility personnel are well aware of the hazards associated with the process and work to insure that the facility is operated in a safe, environmentally sound manner. The entire St. Gabriel site is strongly committed to the safeguarding of human health and the environment.



Additional Emergency Contacts are provided below:



Name/Title Telephone # 24-Hour Telephone #



Production Supervisor (225)642-6310 (225)642-0094

On-Duty Shift Leader (225)642-6316 (225)642-0094