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Home / Industries / Bulk Chemical Loading / Hydrogen Peroxide (H2O2) Handling Design, Loading, and Installation.
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Although no two Hydrogen Peroxide Loading solutions will be identical, the product itself determines much of the critical design criteria that will ensure that optimum safety and productivity can work together in harmony.
Hydrogen Peroxide is a pale blue liquid chemical compound that’s slightly more viscous than water. It is used as an oxidizer, bleaching agent, and antiseptic. In very high concentrations it has also been used as a fuel propellant in missiles and rockets.
Hydrogen Peroxide is unstable by nature and slowly decomposes in the presence of light. Because of its instability, hydrogen peroxide is typically stored with a stabilizer in opaque containers.
In the United States, Hydrogen Peroxide is typically a “tight-fill” (closed-loop) loading operation and can be transported into rail cars, tank trucks, or Iso-containers via 3” aluminum or stainless steel loading arms or reinforced polyethylene chemical hoses. Tank cars are typically unloaded via a self-priming pump. Railcars can also be unloaded by means of compressed gas, however, this is not a recommended practice because any foreign material in the line can create a dangerous situation.View Full Text
Hydrogen peroxide, 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, robust, well-designed fall prevention is essential to ensure increased throughput, without compromising operator safety.
Hydrogen peroxide is typically shipped in 10,000 gallon DOT-103 insulated or non-insulated tank cars with safety valves and vents that meet the DOT specification for the transportation of Hydrogen peroxide and other like commodities. The rails cars themselves are ~ 9′ outside diameter with an overall length of ~45’ to 50′, with a 6’ x 6’ center crash box openings.
Typical Hydrogen Peroxide 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.
Hydrogen Peroxide Loading
Hydrogen Peroxide is typically loaded into railcars or tank trucks via boom supported aluminum or stainless steel loading arms or chemical hoses with a 150# flange connection. The arm or hose will have a top inlet with a control valve to ensure that it is self-draining after use. If using a by-pass arm, the hose is supported along the length of a mechanical loading arm to improve handling. When loading you can install one liquid and one vapor arm, or a 3” boom supported arm with vapour return hose running along the loading arm. Stainless steel camlok fittings or TODO dry breaks are the preferred coupling methods.
For unloading, typically you would use a rigid aluminum or stainless steel self-draining loading arm with EPDM, PTFE or Viton seals. Purge lines can be fitted to the arm, for nitrogen purging. Additional features such as overfill warning indicators or parking latches with proximity sensors can be incorporated into the total system to ensure the arm is correctly stowed when not in use before any rail movement can occur.
Hydrogen Peroxide Loading Gangways and Safety Cages
A wider access gangway (48″-60″ is preferable) as it helps improve access and egress to and from the vessel. In addition, a wider gangway will reduce the risk of the operator’s PPE getting caught, torn or damaged, and will improve productivity and safety. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used.
Each gangway will be fitted with a two-rail safety cage for the railcar crash box. This will be a centered 6’x6’ safety cage to sit directly over the cashbox. This will provide a safe, secure work environment for your operator when connected to their breathing apparatus
GX FLAT RAMP ACCESS (FRT) GANGWAY
SafeRack’s NEW GX-FRT is a flat ramp model popular with railcars. It features a slip-resistant walk surface and, with the use of the telescoping extension, eliminates gaps on narrow railcars. Learn More
Hydrogen Peroxide Eye Wash/Drench Showers
ANSI guidelines state that an 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.
Therefore, we would propose the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment.
Hydrogen Peroxide Spill Containment
Spill containment pans will be provided at the point of loading operations and is an essential piece of equipment in overall site safety and environmental protection
Hydrogen Peroxide Grounding
Black Liquor is not normally combustible. However risk of fire does exist in the presence of TRS gases. These fumes are flammable and can be ignited by heat or flame. Vapors have been known to travel back to ignition sources and flashback.
- Vehicle grounding and bonding — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA, and Ex requirements
- Non-sparking tools are also recommended while working around this product
Hydrogen Peroxide Safety Gates
Safety Gates will be installed at the top of stairs and any other openings to ensure operator safety at all times.
YellowGate Safety Gates
SafeRack’s line of industrial safety gates is the most flexible product on the market with the ability span openings between 16” and 36” and is field adjustable with nothing more than a wrench. Learn More
Hydrogen Peroxide Options
- Lighting – Lighting both over and under the platform will be provided. For overcast days or second shift, lighting is essential for improved safety and improved productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve the safe and productive loading operation from the operator’s perspective.
- Operator Shelter – Depending on your site requirements, consideration should be given to the requirement of an operator or guard building 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
Mandatory Safety Attire: H2O2 should never come in contact with combustible materials such as cloth or leather. Stepping in even a small puddle of concentrated H2O2 can initiate combustion of leather footwear.
Eye/Face Protection: Wear “snug fitting” chemical safety goggles with a full face shield.
Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Best practice includes protective chemical, full-body encapsulating suit made of vinyl, neoprene, PVC or polyethylene. As well as, a self-contained breathing apparatus (SCBA). Suitable materials include: butyl 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: neoprene, nylon, polyvinyl chloride
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 a 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. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs
MAJOR HYDROGEN PEROXIDE PRODUCERS WHERE WE HAVE SUCCESSFULLY EXECUTED AMMONIA LOADING PROJECTS
Customer Reviews5 5Safe Access Gangway
You guys were able to meet our need for expedited shipping and produced three-fold downs and had them out the next day in order for us to complete a project. That was outstanding.By T. Hart from Fall Protection Systems on 6/26/205 5Great customer service.
SafeRack has incredible customer service and a great sales team. We had a little issue with our procurement and SafeRack logistics, but it was resolved promptly. I couldn’t be more pleased with their customer service and how they made my delivery a top priority. Excellent!By David Farbacher from United States Steel Corporation on 2/19/194 5Absolutely brilliant product!
Received the product in only two days time! Love the safety and ease of operation, as well as the price. We will be using this with our other clients as well. Absolutely brilliant product!By G.C. Mohan from Flexiflo Corp. on 9/9/125 5SafeRack provided us with the equipment and knowledge.
We needed to replace a very old derailer quickly and SafeRack provided us with the equipment and knowledge to get this done.By Jeff Erickson from Sherwin Williams on 2/27/125 5Very Satisfied with our Custom Stairs
Bud was on the ball, got with the program, and sent my steps right away. Very thankful for his help!!By B. Baugh from Sinclair Wyoming Refining Company on 7/9/205 5Allows operators safe access to the top of rail cars.
We used to take product samples from rail cars as well as open vent hatches for unloading. This can now be done at our unloading zone as opposed to hundreds of yards down the track where our stationary stand resides. This also allows operators safe access to the top of rail cars without having to use ladders or a safety harness to tie off.By Blake from Michelin North America, Inc. on 3/4/15
Hydrogen Peroxide 101
Things to know about Hydrogen Peroxide
Hydrogen Peroxide is regulated by the U.S. Department of Transportation (DOT) and is classified as a corrosive and flammable hazardous material with the DOT identification number UN 2014.
Hydrogen peroxide is a clear, colorless liquid, and is used solely in the form of an aqueous solution. It can be mixed with water in any proportion. The chemical is odorless at low concentrations, and slightly pungent at higher concentrations.
Hydrogen peroxide has strong oxidizing properties, but it also has a low toxicity and is a relatively “user friendly” chemical at low strengths, less than 10 percent. However, in concentrations greater than 35 percent safety precautions must be observed to prevent accidents and possible injuries. In concentrations up to 52 percent (UN 2014) it’s classified as an oxidizer and at concentrations greater than 52 percent (UN 2015) hydrogen peroxide is classified as both an oxidizer and a corrosive and must be labeled and placarded accordingly.
Hydrogen peroxide is used in the pulp and paper industry as a bleaching agent. Paper mills employ it to bleach or whiten different kinds of pulps. Hydrogen peroxide can also be found in both inorganic and organic chemical applications, as well as, industrial and municipal wastewater applications, and it is also used for etching, polishing and cleaning in the metals industry.
While hydrogen peroxide is non-combustible, the chemical can decompose when it comes into contact with anything organic, which can produce enough heat and oxygen to start a fire.
Only properly trained and equipped personnel should be permitted to (un)load Hydrogen peroxide tank cars and tank trucks. Operators should wear approved PPE equipment including impervious clothing, footwear, gloves, and goggles.
Hydrogen peroxide is dangerous to human health, and as a corrosive chemical, acute exposure can cause severe skin burns and eye damage. Do not breathe fumes, mist, or vapors as they can be fatal if inhaled. Use only outdoors, or in a well ventilated area.
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 do not induce vomiting, but immediately call your local poison control center. Aspiration into the lungs can cause fatal chemical pneumonitis. If ingestion has occurred, assume there is a risk of aspiration into the lungs.
Hydrogen peroxide is sensitive to light and heat and can become unstable when exposed. Keep away from open flames, hot surfaces and sources of ignition. Incompatible materials include any combustible materials and flammable liquids.
Hydrogen peroxide is corrosive to most metals including bronze, brass, carbon and milled steel, so great care should be taken to avoid contact with these materials. However, aluminum and stainless steel have little to no effect when exposed to Hydrogen peroxide.
Always use large amounts of water to dilute and wash away any spills. Never use mops, rags, or other combustible materials. A water hose should be available and within easy reach for dilution and flushing of any spilled H2O2.
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
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