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Home / Industries / Bulk Chemical Loading / Toluene (C7H8) Handling Design, Loading, and Installation.
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Although no two Toluene 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.
In the United States, Toluene is typically a “tight-fill” (closed-fill) loading operation and is loaded into rail cars via chemical hoses or 3” carbon steel loading arms. Toluene, if not handled properly can be fatal and Personal Protective Equipment (PPE) is required. Additionally, because operators are on top of the vehicles during the loading process, fall prevention is essential, not only for safety but increases throughput.
Toluene is typically shipped in insulated tank cars, equipped with external heating coils and a safety relief valve set for 75 psi. The temperature of the contents must be above 60 degrees F or (16 degrees C) when the car is unloaded. If needed the tank car can be heated to 68 degrees, but do not exceed 104 degrees F or 40 degrees C.View Full Text
Typical Toluene Loading Platform
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?
In addition, we undertake a detailed site survey to check and clarify all dimensions and other salient issues.
Toluene Loading Arms
Toluene is typically loaded into railcars via chemical hoses or loading arms.
The current best loading practice is to use a 3″ chemical hose or a carbon steel loading arm with quick-acting coupling, often in the form of Hammer Unions with stabber pipe. The hose or arm will have a top inlet with a control valve to ensure that it is self-draining after use and is supported along the length of a mechanical loading arm to improve handling; this is known as a by-pass arm.
You can install one liquid and one vapor arm, or mount both the liquid and vapor hoses on one by-pass arm. Break-away couplings can be fitted near the inlet of the hose for additional safety in the event of a premature departure.
Loading Gangways and Safety Cages
A wider access gangway (36″-48″ 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
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Toluene 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.
Toluene 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 Toluene is highly flammable, and industry best practice includes the grounding of all vessels before starting the (un)loading process.
- Ground controllers — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA and Ex requirements
Toluene 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
- 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
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary.
Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Coveralls or long sleeve shirts and pants 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 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
Customer Reviews4 5Dependable, quality product and order accuracy.By Darius Tanching from Alaa Industrial Equipment Factory on4 5Wonderful to work with.By Dan Costello from TXI Cement on5 5Kim Anderson was very helpful.By Chris Moucka from Safety-Kleen Systems on4 5I am now aware of different types of containment solutions for future projects.By Paul Bowker from Triple Crown Enterprises LTD on5 5I was very pleased with the service I received.By Liliana Serb from Kemira Water Solutions, Inc. on5 5Excellent customer service.By Josh Fuentes from Titan Lansing Transloading on
Things to know about Toluene
As an Aromatic in the Petrochemical family tree, Toluene Diisocyanates are classified as hazardous materials under the Department of Transportation’s Hazardous Materials Regulations. Thus, the unloading of tank trucks or rail cars must be done in strict accordance with those regulations. Toluene, also known as methylbenzene, is an organic chemical compound with the chemical formula of C7H8. Insoluble in water, Toluene is a colorless liquid with an odor similar to paint thinners.
In commercial applications, toluene is a solvent found in paint thinners, nail polish remover, glues, and correction fluid. Toluene can even be found in the explosives industry, where it is essential in making the flammable, explosive compound known as TNT or trinitrotoluene.
Toluene is a highly flammable liquid and it can cause mild damage to the skin and the eyes. However, the most-common hazard associated with this chemical is inhalation. Products containing toluene can produce dangerous fumes which can cause nausea, headaches, unconsciousness, and even death if inhaled.
Only properly trained and equipped personnel should be permitted to unload tank trucks. Operators should wear an approved respiratory protective device, and impervious clothing, footwear, gloves, and goggles.
OSHA Permissible Exposure Limit (PEL) @ 5 parts per million
Petrochemicals are made from either petroleum or natural gas feedstock. A wide variety of petrochemicals are created/produced depending on the process.
- Aromatics – Aromatics are hydrocarbons that consist exclusively of the elements carbon and hydrogen. Common Aromatics are Benzene, Toluene, and Xylenes. Often used for creating Dyes, synthetic detergents, fibers, and plastics.The catalytic reforming of naphtha produces aromatics, which include benzene, toluene, and xylene. Together they are referred to as BTX and are predominantly obtained from petroleum refineries by the extraction from the reformate produced in catalytic reformers using naphtha obtained from petroleum refineries.
- Olefins – The most reactive class of hydrocarbons tend to crack. Common Olefins are Ethylene, Propylene, and Butadiene. Often used for creating plastics, and synthetic rubber. Chemical plants produce olefins by steam cracking of natural gas liquids like ethane and propane. Olefins include ethene, propene, and butadiene. Ethylene and propylene are chief sources of both plastic products and industrial chemicals. Butadiene is mainly used in the production of synthetic rubber.
- Synthesis gas (SynGas) – A mixture comprising of carbon monoxide, carbon dioxide, and hydrogen. Common Synthesis Gas is Ammonia and Methanol. Often used for creating Fertilizers and explosives.Synthesis gas is a mixture of carbon monoxide and hydrogen used to make ammonia and methanol. Ammonia is used to make the fertilizer urea, and methanol is used as a solvent and chemical intermediate. Steam crackers are not to be confused with steam reforming plants used to produce hydrogen and ammonia.
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.
With the best intentions in the world, if a system is designed that is inconvenient or difficult to operate, it becomes the operator’s mission to bypass, abuse, and generally defeat that system. This could result in the (un)loading procedure being far more dangerous than no system at all.
To avoid this, SafeRack has developed industry-leading safe access solutions, seamlessly integrating loading arms and ancillary 3rd party equipment to be user friendly with the operation of loading becoming cleaner, more automated, and far safer.
From Scope Development to Installation and Training – SafeRack understands how proper training prolongs the life of your equipment, reduces long-term maintenance costs, and protects the safety of employees. From installation and commissioning through to long-term preventative maintenance programs, our Aftermarket Team offers a full menu of training options that can be tailored to suit your site needs.
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