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Home / Industries / Bulk Chemical Loading / Hypochlorous AcidHypochlorous Acid (HOCl) Handling Design, Loading & Installation
Innovative Loading Solutions to Optimize Safety & Increase Efficiency
What is hypochlorous acid?
Hypochlorous acid, also referred to as electrolyzed water (EW), is a weak acid that forms when chlorine dissolves in water, forming hypochlorite. It contains 5.25% sodium hypochlorite (NaOCl) which is a very strong oxidizer for bleaching textiles and is effective in cleaning stains and killing microorganisms, such as bacteria and molds. Hypochlorous acid (HOCl) has been found to have strong disinfection properties when dissolved in water. In most cases, hypochlorous acid is non-toxic and has been identified as an effective cleaning agent and sanitizer. Recently it has also been identified in clinical studies conducted by the Environmental Protection Agency as an effective disinfectant against COVID-19.
In the United States, HOCl is a “tight-fill” (closed-loop) loading and unloading operation in which the product is loaded into rail cars via chemical hoses or 3” stainless steel loading arms. If not handled properly, HOCl can cause serious injuries and personal protective equipment (PPE) is recommended. Additionally, because operators access equipment from the top of vehicles during the loading process, well-designed fall prevention is essential to ensure operator safety and increased efficiency. HOCl is typically shipped in 26,000 gallon DOT-103 rubber lined, insulated or non-insulated tank cars with safety valves. The rails cars themselves are ~ 9′ outside diameter with an overall length of ~45’ to 50′, with a 6’ x 6’ center opening or off-set crash box openings.
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View Full TextYour Customized Project
To successfully meet the needs of your HOCl facility, the following questions must be considered:
- Railcar connection locations require 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 out?
- Is the loading area temperature controlled?
- How will you spot your railcars?
Our expert technical team will conduct a thorough site survey prior to the start of your project to check and clarify all dimensions, obstructions, and access issues. Our goal is to provide the safest working environment, protecting operators and the equipment they use, while improving throughput and productivity at your HOCl facility.
Your Project Needs
Whether you are looking for a turn-key installation, on-site supervision, or a safety maintenance program, we are prepared to assist you. Our project management and supervision teams are the best in the business, ready to do as much or as little as you need to improve safety and efficiency at your HOCl loading facility.
- Collaborative Design – Our loading platform specialists will work with you one-on-one to design the best loading solution for your facility.
- Contract Review – We will review all drawings and associated documents relating to the contract prior to site arrival.
- Risk Assessment – We will conduct a thorough site review to assess risks at your facility.
- Shipment Inspection – Our team will inspect all deliveries to detect any shipping damage or product abnormalities.
- Material Receiving – We are available for supervised off-loading and transport on-site as needed.
- Installation Management – We are also available for supervision and coordination of installations as needed.
- Start-up & Commissioning – On-site training is available for users and maintenance personnel as required.
Loading Arms
Generally speaking, we recommend rigid pipe loading arms wherever possible because they are:
- Balanced throughout their movement envelope
- Designed not to hit the ground, protecting the asset and the operator
- Ergonomic – requiring one-person 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
Hoses:
We find hoses to be an inferior product and do not generally recommend them as they:
- Require an annual pressure test
- Are difficult to stow neatly when not in use
- Can be dropped & 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 them
- Are prone to catastrophic failure
Hypochlorous Acid 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.
Hydrofluorosilicic Acid Loading
Hydrofluorosilicic acid is typically loaded into railcars or tank trucks via boom-supported PTFE-lined loading arms or chemical hoses with flanged end connections. The arm or hose will have a top inlet with a control valve to ensure that it is self-draining after use and is supported by a by-pass arm along the length of a mechanical loading arm to improve handling. One liquid and one vapor arm can be installed, alternatively, both the liquid and vapor hoses can be mounted on one by-pass arm. For unloading, typically a rigid self-draining PTFE lined loading arm with EPDM, Fluorocarbon, Nitrile, or PTFE seals would be used. Purge lines can be fitted to the arm for nitrogen purging. Additional features such as 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.
Loading Gangways and Safety Cages
A 36″-48″ wide access gangway is preferred 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 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 crash box. This will provide a safe, secure work environment for your operator.
GX SELF-ADJUSTING STAIR (SAS) GANGWAY
Our GX SAS gangways use Retractalok power-assist technology allowing operators to raise or lower effortlessly. Tested in the most critical applications, this revolutionary new gangway is light as a feather and solid as a rock, outperforming all others. Available in multiple lengths and widths. Learn More
Hydrofluorosilicic Acid Eye Wash/Drench Showers
ANSI guidelines state that an eyewash/drench shower must be located 10 seconds or 55’ (16.8m) from contaminants or hazardous materials. Eyewash stations should be located on the same horizontal plane with no obstructions.
Therefore, we suggest the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment.
Hydrofluorosilicic Acid Spill Containment
Spill containment pans will be provided at the point of loading operations and are an essential component in your overall site safety and environmental protection plan. Hydrofluorosilicic Acid Grounding
Hydrofluorosilicic acid is not a combustible or flammable material; however, industry best practice includes the grounding of all vessels before starting the loading or unloading process. - 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 recommended while working around this product.
Hydrofluorosilicic 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
Our industrial safety gates are the most flexible product on the market with the ability span openings between 16” and 36” and are field adjustable with nothing more than a wrench. Learn More
Hydrofluorosilicic Acid Loading Safety Options
- Lighting – Lighting both over and under the platform will be provided. For overcast days or second shifts, adequate lighting is essential for improved safety and productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve safety and productivity from the loading operator’s perspective.
- Operator Shelter – Depending on your site requirements, an operator or guard building might be considered 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 such as gloves, aprons, and boots. Coveralls or long sleeve shirts and pants may be required in some operations. Wear a chemical protective, full-body encapsulating suit, and self-contained breathing apparatus (SCBA). 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 very thin neoprene rubber gloves (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. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs Customer Reviews
5 5The quick delivery cannot be beat.All of my experiences with this purchase were positive. Travis McCraine was very responsive and ensured I had what I needed. The delivery was very quick and the product is exactly what I expected. The feature I liked most is the flexibility of this loading system. It’s adaptive to many different truck heights, and the SafeRack team made this purchase very easy and the quick delivery cannot be beat.
By Jason Stelmaszak from The Andersons on 11/25/134 5Just the right amount of assistance to make sure that our purchase and installation went great.Dana Hamor identified that the our rail was just a few fractions of an inch off and suggested that we purchase shims so that the product would fit properly when it arrived at our site instead of going through trial and error to get it right. Overall my experience was very satisfactory. Ordering was easy and the sales department offered just the right amount of assistance to make sure that our purchase and installation yielded the results we were after without being overly intrusive.
By Jonathan HIghtower from BASF on 3/23/115 5SafeRack is a quality vendor that always meets our requirements.I had no issues on this purchase. I got the information I needed to make my decision, it met all of our requirements. Field reviewed the product and really liked it. You are a quality vendor, the product is exactly what we needed, and we like the responsiveness of sales.
By Thomas Hopkins from NuStar Logistics on 11/19/104 5Customer service was great.We now comply with fall protection requirements. It keeps our guys safe. While these systems are expensive, the benefit outweighs the initial cost. Customer service was great – I had the drawings and assembly instructions a week before the rack arrived. Ray Evans was extremely helpful. Keep up the good work, SafeRack
By Craig Pataky from Westway Terminals on 2/11/114 5The product looks great.Scott Hite was very responsive. The product looks great.
By Jeff Rhude from Milk Specialties on 12/19/105 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 2/19/19SUCCESSFUL HYDROFLUOSILICIC ACID LOADING PROJECTS
Hydrofluosilicic Acid 101
Things to know about Hydrofluosilicic Acid
Hydrofluosilicic acid is regulated by the U.S. Department of Transportation (DOT) and is classified as a corrosive hazardous material with the DOT identification number UN 1778.
Most commercially available hydrofluosilicic acid contains 23 to 25 percent pure acid. As mentioned above, it’s a dangerous corrosive chemical that can release hydrogen fluoride when it evaporates; and can damage the lungs if breathed in.
Only properly trained and equipped personnel should be permitted to load or unload HSA tank cars and tank trucks. Operators should wear approved PPE equipment including impervious clothing, footwear, gloves, goggles, and a respirator.
Hydrofluosilicic acid is dangerous to human health, and as a corrosive chemical, acute exposure can cause severe skin burns and eye damage. Do not breathe dust/fumes/mist/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 the 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.
Best practice includes storing in a cool, dry environment in well-sealed containers, and away from any oxidizing agents. Avoid storage near extreme heat, ignition sources, or open flame. Environmental precautions include preventing chemicals from reaching drains, sewers, or open waterways.
HSA is corrosive to most metals including aluminum, brass, carbon and stainless steel, so great care should be taken to avoid contact with these materials. However brass and bronze, galvanized steel are acceptable materials for construction.
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.
Why SafeRack?
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
- Acetonitrile
- Acrolein
- Acrylic Acid
- Acrylonitrile
- Aluminum Chloride
- Aluminum Sulfate
- Ammonia
- Ammonium Hydroxide
- Ammonium Nitrate
- Aniline
- Benzene
- Benzyl Chloride
- Bromotrifluoromethane
- Butadiene
- Carbon Dioxide
- Caustic
- Chlorine
- Chloroform
- Chlorosulfonic Acid
- DEF (Diesel Exhaust Fluid)
- Diethylene Glycol
- Dimethylformamide
- Dodecylbenzene Sulfonic Acid
- Ethanol
- Ethyl Acetate
- Ethyl Chloride
- Ethylene
- Ethylene Dichloride
- Ethylene Glycol
- Ethylene Oxide
- Ferric Chloride
- Ferrous Chloride
- Hexane
- Hydrochloric Acid
- Hydrofluoric Acid
- Hydrofluorosilicic Acid
- Hydrogen Cyanide
- Hydrogen Peroxide
- Hydrofluoric Acid
- Hypochlorous Acid
- Isopropyl Acetate
- Liquid Argon
- Liquid Nitrogen
- Liquid Oxygen
- Maleic Anhydride
- MDI
- Methanol
- Methyl Chloride
- Methyl Ethyl Ketone
- Methyl Methacrylate
- Methyl Isocyanate
- Molten Sulphur
- Nitric Acid
- Oleum
- Phenol
- Phosphoric Acid
- Phosphorus Oxychloride
- Phosphorus Trichloride
- Polypropylene
- Renewable Diesel
- Sodium Cyanide
- Sodium Hydroxide
- Sodium Hypochlorite
- Styrene Monomer
- Sulfuric Acid
- Sulfur Dioxide
- Titanium Tetrachloride
- Toluene
- Toluene Diisocyanate
- Turpenitne
- UAN (Urea Ammonium Nitrate)
- UREA
- Vinyl Acetate
- Vinyl Chloride
- Xylene
- Zinc Chloride
- Agro-Chemical
- Specialty Chemical
- Petrochemical
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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