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The loading and unloading of benzyl chloride is complex and terminal solutions must be designed with the utmost care. Keeping operators safe in an efficient working environment while minimizing exposure risks and optimizing productivity is crucial.
What is Benzyl Chloride?
Benzyl chloride, also known as (chloromethyl) benzene is a corrosive, colorless liquid with a strong, irritating smell that can be toxic when exposed to skin, eyes, nose, and mouth. The chemical is commonly used in making dyes, plasticizers, drugs, lubricants, resins, and cosmetics.
In the United States, benzyl chloride is a “tight-fill” (closed-loop) loading operation and is loaded or unloaded into rail cars via chemical hoses or 316 stainless steel loading arms. Benzyl chloride, if not handled properly can cause serious injuries and personal protective equipment (PPE) is required. Additionally, because operators are on top of the vehicles during the loading process, high-quality, well-designed fall prevention is essential to ensure increased throughput, without compromising operator safety.
Benzyl chloride is typically shipped in 10,000 gallon DOT-103 insulated or non-insulated tank cars with safety valves. The rails cars themselves are ~ 9′ outside diameter with an overall length of ~45’ to 55′, with a 6’ x 6’ center opening or off-set crash box openings.
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Our experts simplify the complexBulk Chemical Specialist
“As subject matter expert, I’ll leverage my years of experience as your personal consultant throughout the project to ensure you get a world-class solution.”Ray Evans-Bulk Chemical Market SpecialistContract# 47QSAWA19D0085View Full Text
Typically, as a starting point, we will need to know answers to these questions for your project
- The Railcar connection locations need flexibility – Do you know what the breadbasket connections look like?
- Are you using liquid and vapor arms/hose as two separate devices or a piggyback arm?
- Is the loading station indoors or outdoors?
- Is the loading area temperature controlled?
- How are you going to spot your railcars
Our highly trained technical sales team will undertake a detailed site survey prior to undertaking any work to check and clarify all dimensions, obstructions, access issues and other salient points. Our challenge is to provide the safest working environment – protecting operators and the equipment – while simultaneously enabling you to improve throughput and productivity.
Your Project Needs
Whether you are looking for a turn-key installation, on-site supervision or a maintenance program, SafeRack is positioned to assist you. We can do as little or as much as you need. Our project management and supervision team is the best in the business at supporting your company’s needs.
- Collaborative Design – Our loading platform specialists will work with you one on one, if you design to design the best loading solution for your specific needs
- Contract review – drawings and associated documents relating to the contract prior to site arrival
- Risk Assessment – Undertaking a site risk assessment
- Shipment Inspection – Detection of any shipping damage or abnormalities
- Material Receiving – Supervised off-loading and transport at site
- Installation Management – Supervised Installations and Coordination
- Start-up & Commissioning – On-site training for both users and maintenance personnel
Generally speaking, SafeRack recommends rigid pipe loading arms where possible for the following reasons:
- Balanced throughout their movement envelope
- Designed not to hit the ground – protecting the asset and the operator
- Ergonomic – one man operation
- Fitted with manual or actuated valves.
- Fitted with optional purge/vent facilities
- Can be moved into position with ease and left hanging in the air while the operator prepares the tanker connection
- Parked neatly
- Annual pressure test
- Are difficult to stow neatly when not in use
- Can be dropped
- Can be driven over
- Are very heavy to use if fitted with a valve at the tanker connection point
- Cannot be easily heated or have vent/purge valves fitted to it
- Prone to catastrophic failure
Tank truck loading and unloading procedures for toxic chemicals such as benzyl chloride are similar to railcar applications and regulatory requirements of the DOT should always be consulted before transport. Approved DOT trailers include MC 307 or low-pressure chemical ISO containers. Trailers and ISOs are typically bottom unloaded with a two-valve extension pipe flanged to the top of the trailer.
All trailers must be equipped with pressure relief valves for safety and trailers with bottom outlets must be equipped with remote controlled stop valves.
Our highly trained technical sales and design team will conduct a thorough site survey to determine the dimensions, obstructions, access issues, and any other specifics for your facility. Our goal is to design a safe access solution that provides the safest working environment possible to protect operators while improving throughput and productivity at your loading facility.
Typical Benzyl Chloride Loading Platform
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Below are some of the loading and unloading solutions for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
Benzyl Chloride Loading Arms
Benzyl chloride is typically loaded into railcars or tank trucks via boom-supported 316 stainless steel loading arms or chemical hoses with a flange connection. The arm or hose contains a top inlet with a control valve to ensure that it self-drains after use. A by-pass arm supports a mechanical loading arm to improve handling. Best practices indicate installation of one liquid and one vapor arm, or mounting both the liquid and vapor hoses on one by-pass arm.
When unloading, a rigid self-draining 316 stainless steel arm with Fluorocarbon (FKM), Kalrez or Viton seals, or a braided 316 stainless steel chemical hose are typically used. Purge lines can be fitted to the arm for nitrogen purging. Parking latches with proximity sensors can also be incorporated into the total system to ensure the arm is correctly stowed when not in use.
Loading Gangways and Safety Cages
Wide access gangways (48″- 60″) improve safe access and egress to and from vessels in a marine environment. Wide gangways also reduce the risk of the operator’s PPE getting caught, torn, or damaged, improving productivity and safety. Powered gangway solutions including hydraulic and pneumatic options make lifting and lowering the gangway ergonomically safe and easy to maneuver.
Gangways are fitted with a two-rail safety cage for the railcar crash box. A centered 6’x6’ or 7’x8’ safety cage which sits directly over the crash box is typical. This configuration provides a safe, secure work environment for operators.
GX SELF-ADJUSTING STAIR (SAS) GANGWAY
SafeRack’s NEW GX SAS gangway uses Retractalok power-assist technology to allow operators to raise or lower effortlessly with the pull of a rope and push of a pedal. Tested in the most critical applications, this revolutionary new gangway outperforms all others. Available in multiple lengths and widths. Learn More
Benzyl Chloride Eye Wash/Drench Showers
ANSI guidelines state that Eye Wash/Drench Showers need to be located 10 seconds or 55’ (16.8m) from contaminants or hazardous materials.
Eyewash stations need to be on the same horizontal plane with no obstructions.
Our standard combination Drench Shower/Eyewash Unit saves limited space and fits easily into any work environment.
Benzyl Chloride Spill Containment
Spill containment pans are an essential component of any loading operation that involves toxic chemicals such as benzyl chloride. Our installations prioritize site safety and environmental protection at your facility.
Benzyl Chloride Grounding
Benzyl chloride is a highly combustible liquid and vapor. Industry best practices for safety include the grounding of all vessels before starting the loading and unloading processes.
- Ground controllers — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA, and EX requirements
- Non-sparking tools are also highly recommended while working around benzyl chloride
Benzyl Chloride Safety Gates
Safety Gates provide safety for visitors and operators at the top of any stairs and at any opening at your facility to ensure proper fall protection and operator safety at all times.
YellowGate Safety Gates
SafeRack’s industrial safety gates are the most flexible fall protection solution on the market. Adjustable openings can be modified between 16″ and 36″ and are field adjustable requiring nothing more than a wrench. Learn More
Benzyl Chloride Options
- Lighting – Lighting over and under the platform provides safety for operators. For overcast days or second shifts, lighting is essential for improved safety and increased productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve safety and productivity for loading operations.
- Operator Shelter – Depending on your site requirements, an operator or guard building may be necessary on the loading platform. This can be customized to meet specific site requirements.
- Wheel Chocks – Railcar Wheel Chocks provide fast blocking of all types of railcars and meet OSHA regulations to safely prevent railroad cars from moving during loading or unloading operations. This is a requirement by the Department of Homeland Security.
Personal Protective Equipment PPE Requirements
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary.
Skin Protection: Wear chemical protective clothing including gloves, aprons, and boots. Coveralls or long sleeve shirts and pants may be necessary for some operations. A chemical protective, full-body encapsulating suit and self-contained breathing apparatus (SCBA) may also be required. Suitable materials include butyl rubber, neoprene rubber, Viton®, Viton®/butyl rubber, Barrier® – PE/PA/PE, Silver Shield® – PE/EVAL/PE, Trellchem® HPS, Trellchem® VPS, Saranex®™, Tychem® BR/LV, Tychem® Responder® CSM, Tychem® TK. The following materials should NOT be used: natural rubber, polyvinyl chloride. Recommendations are NOT valid for thin neoprene rubber gloves of 0.3 mm or less.
Respiratory Protection: Up to 5 ppm:
(APF = 10) Any chemical cartridge respirator with cartridge(s) providing protection against chlorine*; or any supplied-air respirator*.
*Reported to cause eye irritation or damage; may require eye protection.
APF = Assigned Protection Factor
Recommendations apply only to National Institute for Occupational Safety and Health (NIOSH) approved respirators. Refer to the NIOSH pocket guide to chemical hazards for more information.
Use local exhaust ventilation and enclosure, if necessary, to control the amount in the air. Consider using a corrosion-resistant exhaust ventilation system separate from other ventilation systems. It may be necessary to use stringent control measures such as process enclosure to prevent product release into the workplace. Use backup controls (e.g. double mechanical pump seals) to prevent the release of this material due to equipment failure.
Customer Reviews5 5We are very satisfied with the personnel and products from SafeRack.
Our sales rep David Daniel is very positive and always smiling. This matches our business model. NuStar is one of the best places to work and SafeRack fits in perfectly. Mr. Daniel expresses an interest in satisfying the customer and offers to assist in any way possible. We are very satisfied with the personnel and products from SafeRack. NuStar is impressed with the excellent service SafeRack provides.By Jerry Hilgendorf from NuStar Energy on 11/8/124 5Very pleased with my salesperson.
I was very pleased with my salesperson, Jason Stewart. He was very knowledgeable and helpful. I liked getting the drawings for approval prior to construction, to ensure I was getting just what I needed. We like the safety protection of the fall cage, the high-visibility color, the ease of movement so that an employee doesn’t have to strain to raise and lower the gangway.By Mike Lehman from Intrepid Potash Wendover, LLC on 5/3/114 5Time saving, good quality product, with the latest technology.
Time saving, good quality product, with the latest technology. As usual, Chris Hite was very quick with his response to our needs.By Hanspeter Dietiker from Lhoist North America on 1/7/135 5Provides peace of mind knowing that we are being proactive in protecting our employees.
There really is no reason NOT to have one if you have an application for it. Provides peace of mind knowing that we are being proactive in protecting our employees.By Randy Watson from Evergreen Transport, LLC on 1/28/135 5We needed an Aluminum Self-Adjusting Stair
I really liked the responsiveness of the sales team and short lead time. You have a very good product.By from Siemer Milling Company on 3/16/205 5I consider all areas to be excellent.
Every time I reach out to Molly, she is quick to respond or if needed to do a sight visit she is readily available. Molly does an excellent job of responding to our needs. I would recommend buying these products. Products are high quality and competitively priced.By Julio Delgado from The Lubrizol Corporation on 4/18/17
SUCCESSFUL BENZYL CHLORIDE LOADING PROJECTS
Benzyl Chloride 101
Things to know about Benzyl Chloride
Benzyl chloride is regulated by the U.S. Department of Transportation (DOT) and is classified as a corrosive and flammable material with the DOT identification number UN 1738.
Benzyl chloride is used as a chemical intermediate in the manufacture of dyes, synthetic tannins, pharmaceuticals, perfume, and flavor products. It’s also used as a photographic developer and as a gum inhibitor in gasoline.
Operators should wear approved PPE equipment including impervious clothing, footwear, gloves, splash goggles, and/or respirator when handling this chemical.
Benzyl chloride should be stored in a cool, dry, well-ventilated area and away from incompatible substances such as moisture and most metals. Keep away from oxidizing agents and sources of ignition.
Benzyl chloride is toxic by inhalation and/or ingestion. It’s extremely destructive to human tissue, mucous membranes, and the upper respiratory tract. Extreme exposure can result in pulmonary edema (a build-up of fluid in the lungs) which can be fatal. With an odor threshold of 0.044 parts per million (ppm) OHSA has set a permissible exposure limit (PEL) of 1 ppm for handling this chemical.
First-aid measures for exposure include:
- Removing operators from the source of exposure and into fresh air
- Remove contaminated clothing immediately
- Wash skin thoroughly with soap and water
- Flush eyes with tepid water for 15 minutes.
- If ingested, rinse the mouth but do not induce vomiting.
- If conscious and alert, give a cupful of water and seek medical attention immediately.
Benzyl chloride is corrosive to most metals and therefore not compatible with aluminum, bronze, and carbon steel. Galvanized and 316 stainless steel materials of construction and powder coating are suitable alternatives.
Is your plant or facility compliant with ANSI, OSHA, and local safety codes? We can help!
EMERGENCY EYEWASHES / SHOWER EQUIPMENT AND THE ANSI/ISEA Z358.1 – 2014 STANDARD
Following eye contact, you must start washing with water immediately to prevent permanent damage. In the event of skin contact, you must start washing with water immediately to prevent slow-healing chemical burns.
Are you aware that ANSI guidelines state that Eye Wash/Drench Showers need to be located 10 seconds or 55′ from contaminates or hazardous materials and located on the same horizontal plane, with no obstructions? If bottom loading/unloading, an additional shower should be located at grade as well. SafeRack provides the above equipment plus much more needed to keep employees safe and expedite bulk chemical loading and unloading.
OSHA Regulation Experts – Does your existing chemical safety equipment or chemical loading systems meet OSHA’s latest requirements? SafeRack’s professional technical sales consultants are available to meet with your team to make recommendations to keep your facility in front of OSHA’s ever-changing country and region-specific standards and regulations, including lifeline and trolley beam fall arrest systems, metal stairs, and access platforms.
The SafeRack approach is a collaborative one. Let’s call it The SafeRack Way. We have, over many years amassed a great deal of experience and understanding of the safety aspects involved in loading road tankers and railcars, as well as the behavioral habits of the operators.
Experts In Chemical Loading
- Acetic Acid
- Acetic Anhydride
- Acrylic Acid
- Aluminum Chloride
- Aluminum Sulfate
- Ammonium Hydroxide
- Ammonium Nitrate
- Benzyl Chloride
- DEF (Diesel Exhaust Fluid)
- Diethylene Glycol
- Dodecylbenzene Sulfonic Acid
- Ethyl Chloride
- Ethylene Dichloride
- Ethylene Glycol
- Ethylene Oxide
- Ferric Chloride
- Ferrous Chloride
- Hydrochloric Acid
- Hydrofluoric Acid
- Hydrofluorosilicic Acid
- Hydrogen Peroxide
- Hydrofluoric Acid
- Hypochlorous Acid
- Isopropyl Acetate
- Liquid Argon
- Liquid Nitrogen
- Maleic Anhydride
- Methyl Chloride
- Methyl Ethyl Ketone
- Methyl Methacrylate
- Molten Sulphur
- Nitric Acid
- Phosphoric Acid
- Phosphorus Trichloride
- Renewable Diesel
- Sodium Cyanide
- Sodium Hydroxide
- Sodium Hypochlorite
- Styrene Monomer
- Sulfuric Acid
- Sulfur Dioxide
- Titanium Tetrachloride
- UAN (Urea Ammonium Nitrate)
- Vinyl Acetate
- Vinyl Chloride
- Zinc Chloride
- Specialty Chemical
North America’s largest loading terminal
World-leading designer, manufacturer, and installer of truck and railcar loading platforms
As one of the primary railcar loading points, Hardisty is one of the major crude oil hubs in North America and a major origination point of pipelines that export to the United States. SCS was asked to supply and construct a SafeRack crude oil loadout terminal spanning nearly half a mile. The USD Hardisty terminal can load up to two 120-railcar unit trains per day and consists of a fixed loading rack with 62 railcar loading positions enclosed, separate control, operator and mechanical buildings, as well as a unit train staging area and loop tracks capable of holding multiple unit trains simultaneously. SCS also supplied and installed boom-supported loading arms with supply and vapor management systems.
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Located in South Carolina
Located in South Carolina
Located in South Carolina
Located in South Carolina
Located in South Carolina