Solids Program Case Study
DATA SUMMARY:
Switching from a liquid to a solid chemical program provides enhanced safety, improved PPE efficiency, simplified storage and disposal, and increased operational efficiency
OVERVIEW
In March 2015, at a Client’s central utility plant in San Diego, California, an incident brought the critical need for safe chemical handling practices to light.
A site engineer was performing his routine task of topping off a chemical barrel for the cooling tower liquid chemical treatment program with isothiazolin, a very hazardous biocide. Despite wearing the prescribed Personal Protective Equipment (PPE), which included a face shield, chemical apron, and rubber gloves, he sustained a serious injury.
The isothiazolin chemical spilled onto his apron and then ran down onto his pants. He did not realize the extent of the spill until he arrived home and removed his work clothes, revealing blisters on his shins.
OUR SOLUTION
The safety incident accelerated a decision that had already been under consideration for several months: transitioning from liquid chemicals to solid chemicals. Within a week of the incident, the client ordered solid chemicals and feed equipment which was installed and commissioned by Capture H2O. By the time the engineer returned to work, he found the liquid barrels gone and solid feeders in their place.
The transition to a solid chemical program has led to:
1. Enhanced Safety through reduced spill risk and easier handling. Solid chemicals eliminate the risk of spills that can occur with liquid chemicals, thereby minimizing direct contact and potential chemical burns. Solid chemical feeders are also easier to handle compared to heavy liquid barrels, reducing the likelihood of accidents caused by lifting and pouring.
2. Improved PPE Efficiency, because even if PPE is compromised, there is no liquid to seep through protective clothing.
3. Simplified storage and disposal, since solid chemicals require less stringent storage conditions compared to liquids. They also take up a significantly smaller footprint, holding chemicals in a solid, concentrated form which is dissolved directly at the point of application. Disposal of solid chemical containers is simpler and safer, with fewer regulatory constraints and lower environmental impact.
4. Operational efficiency, through streamlined chemical handling processes, which allows for quicker and safer refills. Managing the solid chemical feed with smart controllers optimizes chemical use in the system, allowing for optimal scale, corrosion and bacteria control while minimizing water and chemical consumption. And reduced downtime and fewer incidents mean that workers can focus more on productive tasks rather than dealing with chemical safety protocols.
Site:
Central Utility Plant
PROGRAM:
Solids
PROJECT SCOPE:
Transitioning of customer site from a liquid chemical program to a solid chemical program
DATA SUMMARY:
Enhanced safety, improved PPE efficiency, simplified storage and disposal, and increased operational efficiency
SUMMARY
The switch from liquid to solid chemicals not only improved safety for employees, but also enhanced overall operational efficiency at the site. The accident, while unfortunate, served as a catalyst for change, demonstrating the substantial benefits of solid chemicals in preventing injuries and promoting a safer working environment. This proactive move by the client ensured a safer workplace, safeguarding their employees’ health and well-being while optimizing their maintenance processes.
