HYDROCHLORIC ACID PRODUCT STEWARDSHIP MANUAL
Hydrochloric Acid Product Stewardship Manual
Page 1
Table of Contents
INTRODUCTION
4
PRODUCT STEWARDSHIP
4
MANUFACTURING LOCATIONS
4
MANUFACTURING PROCESS
4
PHYSICAL & CHEMICAL PROPERTIES
5
Grades Available
Concentration Units & Conversions
Certifications
Dilution of Hydrochloric Acid
SAFETY & HANDLING
Safety Data Sheet (SDS)
Toxicological Properties
Personal Protection Equipment
Safe Handling
Safety Showers & Eyewash Stations
General First Aid
First Aid Procedures
EMERGENCY RESPONSE PLAN & CONTACTS
Emergency Action Plan
Emergency Response Plan
General Spills
How to Respond to Spill Events
5
5
6
6
9
9
9
9
10
10
11
11
11
11
12
12
12
STORAGE TANKS, PIPING SYSTEMS, & OTHER EQUIPMENT
13
Storage Tanks
Labeling
Sizing
Materials of Construction
Venting & Vacuum Relief Device
Fume Scrubbers
Receiving Pipeline & Inlet/Outlet Nozzles
Level Measurement
Tie-Downs
Cleaning, Inspection & Preparation
Containment Systems
Piping
Pumps & Meters
Valves
13
13
13
14
15
15
16
17
17
17
17
18
19
19
SHIPPING HYDROCHLORIC ACID
19
Hazardous Materials Transportation System (Regulatory)
Hydrochloric Acid Shipping: Tank Cars, Tank Trucks
Tank Cars
Tank Truck
Hydrochloric Acid Product Stewardship Manual
19
20
20
21
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UNLOADING HYDROCHLORIC ACID SOLUTIONS
22
Unloading Procedures & HazMat Training
General Unloading System Requirements
Tank Car Unloading
Unloading with Pad Air
Tank Truck Unloading
Pad Air Quality - Point of Use
Pad Air System Maintenance
Unloading by Pump
22
22
23
24
25
26
27
28
ANALYTICAL GUIDELINES
28
Sampling
Analytical Methods
28
29
REFERENCE MATERIALS
29
The Chlorine Institute – Reference Pamphlets
Association for Rubber Products Manufacturers,
29
29
TECHNICAL DATA
30
Appendix A: Specific Gravity vs. Concentration Chart for Hydrochloric Acid
Appendix B: Specific Gravity Corrections Factors According to Temperature
Appendix C: Boiling Point of Hydrochloric Acid at Atmospheric Pressure
Appendix D: Freezing Point of Hydrochloric Acid
Appendix E: Viscosity of Hydrochloric Acid
Appendix F: Specific Heat of Hydrochloric Acid
Appendix G: Partial Vapor of HCl over Hydrochloric Acid Solutions
Appendix H: Heat of Formation for Hydrochloric Acid
Appendix I: Heat of Solution for Hydrochloric Acid
Appendix J: Materials of Construction for Handling Equipment in Hydrochloric Acid Service at Temperature up to 71 °C (160 °F)
CONTACT US
Hydrochloric Acid Product Stewardship Manual
30
30
31
32
33
34
35
36
37
38
39
Page 3
Introduction
Manufacturing Locations
The preparation of hydrogen chloride gas is credited to Basilius
Valentinus in the 15th Century. However, it was first prepared
commercially by means of the Leblanc process by reacting
sulfuric acid with salt.
Olin is the largest Hydrochloric Acid producer in North America
with truly integrated manufacturing and distribution sites
throughout the United States and Canada. The capabilities of
these sites are similar with slight differences in the
concentrations of product available to meet specific market
needs. Olin is uniquely positioned to service your Hydrochloric
Acid needs.
Today, Olin synthesizes hydrogen chloride by burning
hydrogen gas and chlorine gas together in specially designed
burners. Hydrochloric Acid, muriatic acid, or HCl, is simply the
aqueous solution of hydrogen chloride prepared by dissolving
the gas in water.
Hydrochloric Acid is used by a wide range of industries. Uses
include acidizing of petroleum wells, boiler scale removal, steel
pickling, metal cleaning, ore reduction, production of corn
syrup, sodium glutamate and alcohol denaturant. It is also
used in the manufacture of pulp and paper, textiles, paints,
soaps and detergents, and leather.
Olin manufactures Hydrochloric Acid at Bécancour, Que.,
Charleston, Tenn., McIntosh, Ala., and Niagara Falls, N.Y.
Through our network of manufacturing facilities, terminals,
and shipping equipment, we can ship just about anywhere
within the United States and North America. For more
information about your specific needs, contact an Olin Sales
Representative.
Manufacturing Process
Product Stewardship
At Olin, our Product Stewardship program is guided by our
core values – Act with Integrity, Drive Innovation and
Improvement, and Lift Olin People. We are committed to the
safe handling and use of our products – and enabling all of our
collaborators throughout the value chain to do the same. As a
responsible corporate citizen and certified to RC14001®:2015,
we assess our products' safety, health, and environmental
information and take appropriate steps to protect employees,
public health, and the environment.
Ultimately, our product stewardship program's success rests
with each individual involved with Olin products – from the
initial concept and research to the manufacture, sale,
distribution, use, disposal, and recycling of each product.
Hydrochloric Acid Product Stewardship Manual
In the chlor alkali process, a saturated sodium chloride
solution (brine) is electrolyzed to produce a dilute sodium
hydroxide (caustic soda) solution. During electrolysis, chlorine
gas is formed in the anode section of the cell and hydrogen gas
is produced in the cathode section. The two gases are
collected separately, dried, and purified.
For the synthesis of the hydrogen chloride molecule, hydrogen
and chlorine are introduced in a specially designed furnace and
are burned together, without air or oxygen.
The hydrogen chloride gas is then cooled and sent to a
scrubber to be absorbed in water and form Hydrochloric Acid.
The desired Hydrochloric Acid concentration is obtained by
controlling the ratio of hydrogen chloride and fresh water fed
to the scrubber system.
Page 4
Physical & Chemical Properties
Hydrochloric Acid is a solution derived from dissolving hydrogen chloride gas in water. It has a pungent odor, fumes strongly in
humid air, and varies in appearance from clear/colorless to pale yellow. It is completely miscible with water and alcohol.
When distilled in an open container, Hydrochloric Acid solutions form an azeotropic mixture with a constant boiling point of 108.6 °C
(227.5 °F) at 101.3 kPa. The azeotropic concentration is 20.2% weight by weight hydrogen chloride. When Hydrochloric Acid
solutions with a concentration less than 20.2% are distilled, the resulting vapor phase is rich in water; otherwise, it is more
concentrated in hydrogen chloride.
Hydrochloric Acid is one of the strong, extremely active mineral acids. It dissolves most common metals, releasing hydrogen and
reacts with metal oxides and hydroxides to form chloride salts. It is very irritating to the skin and mucous membranes and can cause
severe burns. Appropriate care must be taken when handling Hydrochloric Acid to prevent injury to personnel and/or damage to
equipment and the environment. This Product Stewardship Manual contains information on how to safely handle Hydrochloric
Acid solutions.
Table A: General Physical Data for Different Concentrations of Hydrochloric Acid (HCl)
Physical Data
27.92% HCl (% w/w)
31.45% HCl (% w/w)
35.21% HCl (% w/w)
Degree Baumé (°Bé)
18 °Bé
20 °Bé
22 °Bé
Specific Gravity at 15,6 °C (60 °F)
1.1417
1.1600
1.1789
Weight of 1 Imp. Gallon at 15,6 °C (60 °F)
11.44 lbs.
11.62 lbs.
11.81 lbs.
Weight of 1 U.S. Gallon at 15,6 °C (60 °F)
9.53 lbs.
9.68 lbs.
9.84 lbs.
Weight of 1 m3 at 15,6 °C (60 °F)
1142 kg
1160 kg
1179 kg
Freezing Point (approximate) *
-65 °C
(-85 °F)
-45 °C
(-49 °F)
-32 °C
(-26 °F)
Boiling Point (approximate) *
97 °C
(207 °F)
81/84 °C
178/183 °F
61-62 °C
(144 °F)
Viscosity at 20 °C (68 °F)
1.52 cps
1.63 cps
1.82 cps
*Note: Hydrochloric Acid has a strong tendency to supercool, and freezing points are difficult to determine.
Grades Available
Hydrochloric Acid is commercially available in various HCl concentrations. Typically, Hydrochloric Acid solutions are designated by
their density expressed in degrees Baumé (°Bé). The most common concentrations are 20°Bé and 22°Bé.
Note: At a density above 22.5 °Bé, the vapors from a Hydrochloric Acid solution are significantly more concentrated in HCl gas. See
other considerations in the Safety & Handling section (pg. 9).
Concentration Units & Conversions
In Appendix A (pg. 30), there is a table with equivalence between degrees Baumé, Specific Gravity and HCl concentration.
Here is the conversion formula between Specific Gravity and degrees Baumé:
Specific Gravity =
Degrees Baumé =
Hydrochloric Acid Product Stewardship Manual
145 –
145
(145 – °Baumé)
145
Specific Gravity
Page 5
The concentration for Hydrochloric Acid is often expressed in percentage hydrogen chloride per unit of weight of solution or % HCl
by weight or % w/w HCl.
The concentration for Hydrochloric Acid can also be shown as grams of HCl per liter of solution or Grams/Liter or gpl.
It is possible to convert from % w/w HCl to gpl when the specific gravity of the solution is known. Please refer to Appendix A for the
complete table of concentrations and specific gravity.
Grams/Liter HCl
Specific Gravity
% w/w HCl =
Grams/Liter HCl =
% w/w HCl
100%
X
X
Sp. Gr.
100%
1000 Grams/Liter
X
1000 Grams/Liter
Certifications
Olin’s Hydrochloric Acid solutions are well-suited for use in a variety of industrial and municipal applications. We offer product
certification upon request for various industry and regulatory standards. Contact your Olin sales representative to discuss
specifications, certifications, and product grades available in your particular market.
Dilution of Hydrochloric Acid
The dilution of Hydrochloric Acid to a given concentration requires the addition of either water or weaker acid. The dilution reaction
generates varying amounts of heat, so dilution equipment and containers should be properly designed to withstand the expected
heat gain. The addition of acid to water and mechanical mixing will help distribute the heat generated more evenly and prevent the
formation of hot spots in the solution. Constant mixing prevents localized boiling in the solution and results in a safer dilution
operation.
The amount of water or dilute acid required may be calculated either by weight or by volume according to the following methods:
A) Dilution Calculation by Weight:
1. To prepare a pre-defined amount of dilute solution using a strong solution and diluting with water or a weak solution, use
the following formula:
X=
D (A – B)
(A – C)
and
Y=D–X
where:
X = quantity of water or weak solution to be used in mixture
Y = quantity of strong solution to be used in the mixture
D = desired quantity of the final solution
A = strength percent by weight of strong solution
B = strength percent by weight of desired solution
C = strength percent by weight of water or weak solution
Note: If water is used for dilution, then C = 0
2.
To prepare a dilute solution of desired concentration from a pre-defined amount of a strong solution and an unknown
quantity of water or weak acid solution, use the following formula:
X=
Y (A – B)
(B – C)
and
D=X+Y
where:
X = quantity of water or weak solution to be used in mixture
Y = quantity of strong solution to be used in the mixture
D = desired quantity of the final solution
Hydrochloric Acid Product Stewardship Manual
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A = strength percent by weight of strong solution
B = strength percent by weight of desired solution
C = strength percent by weight of water or weak solution
Note: If water is used for dilution, then C = 0.
3.
To prepare a stronger solution from a pre-defined amount of water or weak solution and an unknown quantity of a strong
solution, use the following formula:
Y=
X (B – C)
(A – B)
and
D=X+Y
where:
X = quantity of water or weak solution to be used in mixture
Y = quantity of strong solution to be used in the mixture
D = desired quantity of the final solution
A = strength percent by weight of strong solution
B = strength percent by weight of desired solution
C = strength percent by weight of water or weak solution
Note: If water is used for dilution, then C = 0.
The “Rectangle Method:” This method can best be explained with the following example.
We wish to dilute a solution of 31.5% Hydrochloric Acid by weight with water to a 5% solution. The 31.5% concentration is the
typical value for 20°Bé acid.
Draw a rectangle with intersecting diagonals and insert figures expressing the strength of the two starting solutions in the lefthand corners of the rectangle as shown. The strength of the stronger acid is written in the upper left corner and that of water in
the lower left corner. The concentration of water is, of course, zero.
In the center, insert the desired 5% strength of the solution. Now subtract the figures on the diagonals, the smaller from the
larger, and write the results at the other end of the opposite diagonals. These figures then indicate how many parts by weight of
the solution shown on the other end of the horizontal line must be taken to obtain a solution of the desired strength.
Therefore, in our example, 5 parts of 31.5% acid and 26.5 parts of water are required to make 31.5 parts of the final 5%
solution.
31.5
5
5
0
Hydrochloric Acid Product Stewardship Manual
26.5
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If, 100 parts, e.g., 100 kilograms of the final solution are needed, the weight of concentrated acid and water may be calculated as
follows:
Weight of 31.5% acid =
Weight of water =
5 X 100
31.5
26.5 X 100
31.5
= 15.9 kg
= 84.1 kg
If the strong acid is diluted with weaker acid, replace the zero by the concentration of the weak solution. For example, if 2% acid
is used to dilute 31.5% acid, then 3 parts of 31.5% acid and 26.5 parts of 2% acid are required to make a 5% solution. If 100 parts,
e.g., 100 kilograms of the final solution are needed, the weight of concentrated acid and water may be calculated as follows:
Weight of 31.5% acid =
Weight of water =
3 X 100
31.5 – 2
26.5 X 100
31.5 – 2
= 10.17 kg
= 89.8 kg
B) Dilution Calculation by Volume:
The volume of water, which must be added to a given solution of Hydrochloric Acid to dilute it to the desired concentration, may
be calculated by the formula:
V=
100 H (A – B)
R (B – C)
where:
V = volume parts of water or dilute acid required per 100 volume parts of original strong solution
A = percent Hydrochloric Acid by volume of original strong solution
B = percent Hydrochloric Acid by volume of desired solution
C = percent Hydrochloric Acid by volume of weak solution or water
H = specific gravity of original solution
R = specific gravity of weak solution or water
Note: If water is used, C = 0, R = 1.0
Hydrochloric Acid Product Stewardship Manual
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Safety & Handling
Safety Data Sheet (SDS)
The following health and safety information is intended to
provide general guidelines only. Hydrochloric Acid is a highly
corrosive and reactive compound. To prevent personnel
injuries and environmental exposure, this product
stewardship manual and the most current SDS should be
reviewed and understood. Never handle any Hydrochloric
Acid solution before you have read and understood the
relevant SDS. The SDS may also provide additional
information that is not contained in this manual.
The SDS should be readily accessible to all persons where the
product is being used. It is your responsibility to ensure that
the most up to date SDS, provided by the supplier, is available
to and understood by all employees who work with
Hydrochloric Acid. To obtain an SDS, visit Olin’s website at
www.olinchloralkali.com or call Olin’s Division Headquarters
at 423-336-4850.
Personal Protection Equipment
A PPE hazard assessment can help a facility determine what
PPE will protect individual(s) performing work for process
operations. Consult The Chlorine Institute Pamphlet 65,
Personal Protective Equipment for Chlor Alkali Chemicals and
a qualified safety or industrial hygiene professional before
conducting a job hazard assessment.
Hazard assessments should be performed for each job task.
The results of the hazard assessment can be used to select
the level of PPE to protect individual(s) against the hazards of
the task. Hazard assessments should be reviewed on a
periodic basis and whenever operating practices, procedures,
or conditions change. The PPE recommendations for several
common Hydrochloric Acid tasks below are based on The
Chlorine Institute Pamphlet 65 guidance.
To prevent injuries to personnel or the environment, follow
the safety and handling procedures outlined in this manual.
All employees should be instructed in the properties of
Hydrochloric Acid and safe operating procedures and
practices including:
• Toxicological Properties
• Personal Protection
• Safe Handling
• First Aid Procedures
• Safety Shower & Eyewash
Always review the Safety Data Sheet (SDS) before handling
Hydrochloric Acid.
Toxicological Properties
Hydrochloric Acid is a strong acid which will present a serious
health hazard if improperly handled. It is corrosive to the
skin, eyes, mucous membranes, and the respiratory tract.
Accidental skin or eye contact with this material can cause
pain, severe burns, permanent tissue or eye damage. Vapors
or mists of Hydrochloric Acid represents a hazard to the
respiratory tract.
If inhaled, may cause irritation, burns or permanent damage
of the lungs and the respiratory system. Ingestion may cause
damage to the gastrointestinal tract with the potential to
cause of ulceration or perforation. See the SDS for additional
information on potential exposure hazards.
Hydrochloric Acid Product Stewardship Manual
• Basic PPE required for routine work duties – such as
monitoring the process operations – should include a
hard hat, safety glasses, and the availability of safety
goggles and face shield. It is especially important that
the face and eye protection match the potential
hazards.
• When work duties include performing sampling
activities, line breaking such as disconnecting unloading
hoses, or maintenance activities, full PPE should be
used, including full face respirator, rubber (Neoprene or
equivalent) jacket and pants, hard hat, rubber
(Neoprene or equivalent) gloves, and boots.
• In addition to each person’s individual PPE, every
Hydrochloric Acid handling area should be equipped
with the appropriate emergency PPE including full-face
Page 9
respirators for vapor/potential misting situations,
chemical resistant suits for emergency response
personnel, and safety shower and eyewash stations.
This equipment should be kept clean and in good
working order and be easily accessible. The storage area
for safety equipment should be labeled with a complete
listing of its contents.
Safe Handling
• Know the location of the nearest safety shower and
eyewash fountain and confirm it is functioning before
performing any work in that area.
• Always handle Hydrochloric Acid in a way that prevents
spillage. Hydrochloric Acid can make floors slippery.
Serious falls and injuries, complicated by Hydrochloric
Acid burns, may result if Hydrochloric Acid is not
immediately cleaned from floors, stairs, or other
walkways.
• Avoid bodily contact with any form of Hydrochloric Acid,
and immediately flush exposed area with copious
amounts of water.
• Do not use mild alkali materials to neutralize
Hydrochloric Acid on skin and in the eyes. Doing so may
significantly increase the severity of chemical burns (see
First Aid section, pg. 11).
• Do not mix Hydrochloric Acid with alkalis except under
the direction of trained personnel. This should only be
performed in equipment or facilities that have been
designed to handle these types of reactions. Because of
the large heat of reaction, spattering may occur.
adequate ventilation at all locations where the acid is
being handled. The choice of appropriate respiratory
protection will vary depending upon the expected vapor
concentrations in air.
• Hydrochloric Acid itself does not present a fire hazard.
However, hydrogen gas is formed when the acid comes
in contact with most metals. Hydrogen gas may form an
explosive mixture with air.
Safety Showers & Eyewash Stations
According to OSHA regulations, safety showers and eyewash
units need to be located in areas that have the potential for
exposure, such as unloading stations, process pumps, control
valves, and spill containment areas. OSHA refers companies
to the ANSI Standard Z358.1 which further defines issues such
as accessibility and visibility.
According to ANSI, these safety appliances should be located
on the same level as the hazard, without access impediments
such as steps, curbs, or doors, and be located within 10
seconds of reach. They should also be visible even when
someone’s vision is impaired. Color-coding, reflective tape, or
some similar method should be used to distinguish them
from surrounding equipment, handrails, or walls, so that
everyone working in the area will know their location.
For more information, consult the most current edition of
American National Standards Institute/International Safety
Equipment Association (ANSI/ISEA) Z-358.1 for additional
information.
• The neutralization of Hydrochloric Acid liberates
significant heat and can be a violent reaction. This
reaction becomes more pronounced as the Hydrochloric
Acid strength increases. Application of a water spray to
the spill before neutralization occurs is recommended
to reduce the vigor of the neutralization reaction and
the generation of heat. Consult government regulations
for proper disposal of acid and neutralized material
residues.
• Make sure that Hydrochloric Acid spills, residues, or
products of neutralization are not discharged directly
into sewers or streams in violation of federal, province,
state, and local requirements.
• Vapors given off by Hydrochloric Acid solutions are
suffocating and irritating when inhaled. They are also
corrosive to most metals and other materials of
construction. Therefore, it is important to maintain
Hydrochloric Acid Product Stewardship Manual
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General First Aid
Prompt response to bodily exposures is critical to minimize
potential injurious consequences. Ensure that medical
personnel are aware of the chemical(s) involved if exposure
or injury occurs.
Always review the most current Safety Data Sheet (SDS)
and provide it to medical personnel administering care
to injured persons. To obtain an SDS, call Olin Division
Headquarters at 423-336-4850, or visit Olin’s website
at www.OlinChlorAlkali.com.
First Aid Procedures
Eye Contact: Immediately flush with water for a minimum of
30 minutes, holding eyelids open and occasionally lifting the
upper and lower eyelids to ensure water reaches the affected
areas. Remove contact lenses if present and can be easily
removed.
A sensation of heat indicates the water is effectively diluting
the Hydrochloric Acid – continue rinsing despite the
temporary discomfort.
Do not transport the victim unless the recommended flushing
period is completed or if flushing can be continued during
transport. Do not use soap. Seek medical attention
immediately.
Skin Contact: Immediately flush with large quantities of clean
water for at least 30 minutes. If there is Hydrochloric Acid on
the head and face, do not remove goggles until after this area
has been thoroughly flushed with water. Remove
contaminated clothing and jewelry.
Clothing that has come in contact with Hydrochloric Acid
should not be worn until it has been washed thoroughly.
Discard contaminated shoes. Seek medical attention
immediately.
Ingestion: DO NOT induce vomiting. Immediately drink large
quantities of water. DO NOT give anything by mouth if the
person is unconscious or having convulsions. Seek medical
attention immediately.
Inhalation: Move to fresh air immediately. If breathing is
difficult, give oxygen. If breathing stops, provide artificial
respiration. Induce artificial respiration with the aid of a
pocket mask equipped with a one-way valve. Seek medical
attention immediately.
Before work continues, adequately ventilate the work area,
and equip personnel with proper respiratory protection.
Hydrochloric Acid Product Stewardship Manual
Emergency Response Plan & Contacts
Each facility should maintain current procedures for handling
emergencies occurring both on-shift and after hours. If your
facility meets the requirements of 29 CFR 1910.38 and
external personnel will be expected to resolve the
emergency, then you must have an Emergency Action Plan
(EAP) that describes how employees will respond to different
emergencies.
Sites with ten or more employees must maintain a written
EAP, although a written EAP is desirable for sites of any size.
Periodic drills should be conducted to verify employees know
the EAP and can carry out the duties identified in the EAP.
Including local emergency response agencies in facility drills
can also enhance the effectiveness of drills and
communication activities with the community.
In addition to the standard requirements for Emergency
Action Plan and Emergency Response Plan for chemical
manufacturing and storage facilities, there are requirements
specific for Hydrochloric Acid.
In the USA, Hydrochloric Acid is considered a controlled
substance under the EPA Risk Management Plan (RMP)
Program. Any facility storing 15,000 lbs. or more of
Hydrochloric Acid at a concentration of 37% by weight (23
°Bé) or higher must submit an RMP with the EPA.
In Canada, any facility storing more than 3,000 liters of
Hydrochloric Acid must prepare and submit an Emergency
Response Assistance Plan (ERAP) to Transport Canada for
approval.
In addition, the facility must prepare and submit an
Environmental Emergency Plan (E2 Plan) to Environment and
Natural Resources in Canada.
Emergency Action Plan
In general, an EAP should address:
• Means of reporting fires and other emergencies.
• Evacuation procedures and emergency escape route
identification.
• Procedures for operating critical controls prior to
evacuation.
• Accounting of all employees.
• Rescue and medical duty assignments.
• Names/job titles to contact in emergencies.
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Emergency Response Plan
How to Respond to Spill Events
An Emergency Response Plan (ERP) is to be maintained for
sites that meet the requirements of 29 CFR 1920.38 and 29
CFR 1910.120, where site employees will also act in a First
Responder role.
Step 1 – Evacuate and Activate
The ERP has additional detailed procedures that specifically
address First Responder roles such as training, emergency
recognition and prevention, PPE and emergency equipment,
decontamination procedures, and establishing incident
command, to name several components.
The ERP should be periodically revised with your Local
Emergency Planning Committee (LEPC) to ensure compliance
with local, province, state, and federal requirements.
Like EAPs, it is important to conduct frequent Plan drills.
Including your LEPC or outside responder in facility drills can
provide important insight into plan strengths and weaknesses
and can also strengthen relationships with the community.
General Spills
In general, when encountering a leak or spill, the primary
focus should be to always maintain your personal safety as
well as those around you.
Consult your EAP or ERP regarding specific actions to take
when encountering a spill event and you will be seeking
assistance from external personnel.
It is important to prevent Hydrochloric Acid from spilling onto
soil, storm sewers, or into waterways. Since it is a strong acid
with a low pH, Hydrochloric Acid can threaten the survival of
most wildlife, especially in aquatic environments.
Hydrochloric Acid solutions are very corrosive with concrete,
most metals, and minerals. Care must be taken to avoid
contact with critical structural elements to prevent building
and infrastructure damage. If Hydrochloric Acid was in
contact with a building or infrastructure element, the
affected area must be thoroughly rinsed, inspected, and
repaired.
• Evacuate all personnel from the area and restrict access.
• Maintain safe refuge away from and upwind of the spill
area.
• Activate the site’s Emergency Plan.
o If external personnel will perform Response duties,
activate the Emergency Action Plan.
o If facility persons will perform Response duties,
activate the Emergency Response Plan.
Step 2 – Suit up and Remediate (only trained facility
personnel or trained external personnel should perform
these functions)
• Suit up with appropriate PPE per SDS and never respond
alone.
• Isolate and contain the spill with use of inert materials
(ex: sand, dirt, etc.).
• Recover as much chemical as possible for re-use.
• For unusable material, transfer liquids and residues to
an approved Hazardous Waste container for proper
disposal.
• Manifest and dispose of unusable materials, residues,
and their containers consistent with all local, province,
state, and federal regulations.
• Neutralize affected area with weak, buffered alkalis.
• Decontaminate all equipment, PPE, and materials.
• Launder any clothing or jewelry prior to re-use.
Step 3 – Report
• Immediately report spills in accordance with local,
province, state, and federal regulations.
Consult the SDS to determine the Reportable Quantity (RQ)
threshold for this material. Federal law requires that if the
spill is greater than the RQ it must be immediately reported
to the National Response Center (NRC) at 800-424-8802.
Consult local, province, state, and federal regulatory
agencies for specific requirements unique to your location.
Additional regulatory reporting requirements may vary by
jurisdiction.
Hydrochloric Acid Product Stewardship Manual
Page 12
Storage Tanks, Piping Systems, & Other
Equipment
Labels should comply with OSHA’s HAZCOM Standard
(CFR1910.1200) and with Canada’s WHMIS (Workplace
Hazardous Materials Information System) for Canadian sites.
Hydrochloric Acid users are responsible for building and
maintaining a properly designed storage and handling
system. The initial capital cost should be secondary to these
primary objectives.
A properly designed and installed system that meets the
objectives of safety and maintenance is generally most
economical in the long term. The following items are
important considerations when installing a new storage and
handling facility or upgrading existing site equipment. Key
factors must be kept in mind when handling Hydrochloric
Acid:
•
Hydrochloric Acid is highly corrosive and can be
hazardous to personnel.
•
Vapors from concentrated Hydrochloric Acid solutions
are pungent and can cause irritation when inhaled.
•
The weight of 22 °Bé Hydrochloric Acid is 1.2 times
that of water.
•
Solution temperature and strength will affect corrosion
rates with various materials.
Storage tanks should be located to minimize piping runs. It is
equally important to locate storage and piping in low traffic
areas to minimize potential exposure to personnel.
All Hydrochloric Acid storage tanks should have the following
mechanical features:
•
•
•
•
•
•
Filling inlet at the top of the tank
Outlet to the process
Vent connected to a scrubber
Pressure/vacuum relief device
Manway
Level indicator
Unlike other corrosive chemicals, overflow outlets are not
preferred due to the fuming potential and the gas
management requirements associated with Hydrochloric Acid
solutions.
Labeling
Tanks, piping systems, and other handling systems should be
clearly labeled to identify chemical contents. Labels or
stencils noting the entire, formal product name, e.g.,
“Hydrochloric Acid,” are preferred and especially beneficial to
contractors and others not intimately familiar with the tank
farm.
Hydrochloric Acid Product Stewardship Manual
HYDROCHLORIC ACID
A recommended practice is to post the Class 8 – Corrosive
placard with the UN number (UN 1789) on the storage tank
and the unloading connection point.
Labeling of pipelines provides critical information regarding
the intended contents and associated product hazards.
General pipeline labeling indicating the product and flow
direction can be especially helpful when performing linetracing activities.
The labeling of receiving pipelines, particularly near the
delivery connection point, is important because it can provide
an additional layer of protection against accidental delivery of
the wrong chemical by providing a visual reference of
intended contents for delivery and unloading personnel.
The ASME/ANSI A13.1 standard for pipe marking, requires an
employer to use labels that state what a pipe contains and
what possible hazards are related to that substance. Always
review all federal, province, state, county, city/municipality
labeling requirements.
Storage Tanks
Sizing
The receiving vessel should be part of the bulk storage system
strategy. The receiving tank should be large enough to easily
accommodate a full inbound bulk shipping container,
compensate for likely transit times, and tank heels.
The consumption rate and the mode of deliveries are the
determining factors in deciding the size of the storage tank.
Sufficient storage space should be provided to allow flexibility
in receiving bulk shipments of Hydrochloric Acid.
Page 13
Procedure for Spark Testing Elastomeric Sheet Lining is based
upon the principle that a rubber liner is not conductive, and
unless it has a defect, no electrical current is passed between
the liquid stored inside the tank and the tank shell.
Predictions of liner failure can be made by charting the
conductivity test results over time.
Fiberglass Reinforced Plastic
Tanks made of fiberglass-reinforced plastic (FRP) should
adhere to ASME RTP-1 standards. Components and methods
of construction should be carefully reviewed with the tank
manufacturer with special attention paid to the type of acidcompatible resin utilized and the method of filament winding.
It is generally accepted that a storage tank is of adequate size
if its capacity is 1.5 times the capacity of the tank car or tank
truck, or this latter capacity plus the volume of two weeks'
consumption, whichever is the larger. This means the storage
tank should have a capacity of at least 30,000 – 50,000 liters
(7,900 – 13,200 USG) in the case of tank truck deliveries, and
at least 120,000 liters (32,000 USG) in the case of tank car
deliveries.
In the case of tank truck shipments, it is recommended that
the storage tank should be large enough to enable shipments
to be made in the larger 33,000 liters (8,800 USG) units since
the smaller volume trailers may not always be available on
short notice.
Materials of Construction
A summary of proper materials of construction can be found
in Appendix J (pg. 38). Hydrochloric Acid storage tanks are
normally constructed of rubber-lined steel, fiberglass
reinforced plastic (FRP), and poly tanks.
Rubber-Lined Steel
Lined, steel storage tanks should be made of welded steel
meeting the requirements of the American Petroleum
Institute (API) Standard 650 or API 620. These standards
address materials of construction, design, fabrication,
erection, and test requirements for atmospheric tanks. Wall
thickness is dependent on the size of the tank only; no
corrosion allowance is needed since the steel is protected by
the lining.
Tanks made of carbon steel can be quickly compromised if
the rubber liner fails and as such a frequent integrity test is
warranted. Rubber liner integrity can be determined via a
conductivity test wherein a low current, high voltage signal is
passed through the lined tank. The conductivity test IP-4-13
Hydrochloric Acid Product Stewardship Manual
Additionally, the mode of tank filling, such as use of
compressed air or pump transfer, should be reviewed with
the tank manufacturer since factors such as the volume of
compressed air or possible tank vacuums will likely require
incorporation of additional design considerations.
FRP service life can be extended by application of an ultraviolet (UV) inhibitor for tanks intended for outdoor
placement. Like other tanks, FRP tanks should be inspected
on a scheduled, periodic basis, with particular attention to
evidence of cracking of the shell and nozzle areas.
Poly Tanks
High-density polyethylene (HDPE), cross-linked (XHDPE) and
linear (HDLPE), have been successfully used in Hydrochloric
Acid service and are typically known as poly or plastic tanks.
However, fabricator experience, resin, product strength,
mechanical hammer, temperature, sunlight exposure, and
pipe connection methods are important variables influencing
vessel performance. If cross-linked HDPE is used, it is
important to confirm that the resin chosen is suitable for
Hydrochloric Acid. Additionally, tanks should comply with
ASTM D-1998, “Standard Specification for Upright
Polyethylene Storage Tanks.”
Poly tanks have excellent chemical resistance and are often
chosen for smaller volume vessels. Lateral expansion and
contraction of the tank wall is a significant concern with poly
tanks as the walls will tend to flex depending upon the
product level inside the tank. The mechanical hammer
associated with compressed air chemical deliveries,
automated valve cycling, and pump operations that introduce
structural stress on poly tanks are other significant factors
affecting tank service lifetimes.
Additionally, the use of adapted bulkhead type fittings may
significantly shorten the life of the tank because of the
tendency to experience stress cracking around the cutout for
this type of fitting. As with FRP, poly vessels are sensitive to
Page 14
ultraviolet (UV) degradation and should incorporate the use
of a UV inhibitor for outdoor installations. Long-term contact
with Hydrochloric Acid causes embrittlement of the polymer
so that a sudden mechanical shock can cause a catastrophic
failure of the tank. As with other non-metallic piping and tank
materials, an inspection and replacement plan should be
developed for poly tanks, so they are replaced before failure
occurs.
Fabricator Evaluation
The fabrication and lining processes are critical to long-term
success when storing Hydrochloric Acid. Industry experience
has shown merely utilizing chemically compatible material
alone is not a guarantee for lengthy tank service lifetimes.
The aggressiveness of Hydrochloric Acid dictates that special
evaluations of the fabricator and the material of construction
should be performed, regardless of the type of construction
chosen. In addition to fabricator expertise, always consult
with your tank manufacturer to ensure the tank is of
adequate design to handle the corrosivity and density
associated with this product.
the tank and related appliances, i.e., fume scrubber
capabilities.
Changes in piping diameter or length, scrubber size or
scrubber fluid levels, or mode of product transfer should be
reviewed with the tank manufacturer’s engineering
department. System alterations can adversely impact the
venting capacity of the tank and may require a re-sizing of the
vent to a larger diameter. FAILURE TO ADEQUATELY SIZE THE
TANK VENT CAN RESULT IN TANK STRESSES AND POSSIBLE
CATASTROPHIC VESSEL RUPTURE.
Fabricators should be selected based on:
1. Their experience in fabricating tanks intended for this
product.
2. The performance record of their tanks in Hydrochloric
Acid service.
3. The fabrication process used.
Once a fabricator is determined, it is important that the
manufacturers’ recommendations on installation and
preventative maintenance are strictly followed. Capital, tank
location, and desired service life will dictate the choice of the
material of construction. However, if the storage tank is
properly specified and maintained, useful lifetime can be
maximized.
Venting & Vacuum Relief Device
Adequate venting is critical for ensuring the tank is not
subjected to excessive pressure or vacuum conditions. When
unloading shipping containers by compressed air padding, the
tank will be subjected to a nearly immediate, large volume of
compressed air at the end of the shipping container
unloading process, as well when transfer lines are cleared.
All tanks, regardless of material of construction, should have
vents sized to allow a complete and rapid depressurization of
the shipping container into the storage tank. Tank vent
diameters should be carefully sized to limit pressure
development in the storage tank after consultation with the
tank manufacturer about expected operating conditions of
Hydrochloric Acid Product Stewardship Manual
Olin requires the use of a fume scrubber for venting
Hydrochloric Acid storage tanks. Since an open-toatmosphere vent is not recommended for Hydrochloric Acid
storage tanks, there must be a vacuum relief device or
vacuum break system to prevent collapsing of the storage
tank if a rapid draw-down or consumption of Hydrochloric
Acid occurs. The vacuum break system must be resistant to
corrosion and resistant to freeze if the storage tank is located
outside. If the tank vent should open to the atmosphere
through a combined safety relief valve and vacuum breaker
assembly, the exhaust should be directed away from the tank
and directed to a properly engineered/designed scrubbing
device.
Fume Scrubbers
Acid fume scrubbers are based upon the principle of piping
acid gases/vapors from the parent storage tank into a smaller
tank filled with specified amounts of either an absorbing
media or neutralizing chemical. There are specific engineering
guidelines addressing items such as the appropriate diameter
of the vent gas pipeline feeding the scrubber; the distance
the vent pipe is immersed into the liquid contained in the
scrubber, as well as the size and type of sparging device
Page 15
which aids in diffusing the incoming gas stream. For batchdesign scrubbers, the amount of scrubbing solution in the
scrubber tank must be carefully monitored to prevent
excessive backpressure on the parent storage tank, or to
prevent incomplete reaction of the scrubber solution and acid
gas.
Fume scrubbers are available in a variety of design
configurations and can utilize various absorbing media to
neutralize acid gas fumes. Batch scrubbers require manual
removal and replenishment of the absorbing solution and are
often chosen for small gas volume operations. Scrubbing may
occur via an immersed plenum or via a packed tower. Sites
which have heavy gas loads often prefer a single pass, packed
tower design. Aqueous systems are prone to rapid scrubbing
solution saturation, particularly those with large volumes of
acid gas. Transload facilities or plants receiving tank car
deliveries using an aqueous scrubber often prefer the singlepass design for this reason.
• Aqueous water scrubbers are preferred in applications
where ambient temperatures are not conducive to
freezing of the scrubber solution, and in instances
where the scrubber solution can be re-used in the
customer’s process. Aqueous-based scrubbers capture
and dissolve the fumes within the water to produce a
weak-strength Hydrochloric Acid solution and heat. The
solution continues to increase in strength unless
replaced frequently. A single-pass scrubber design
works best for water-based scrubbers subjected to a
high acid gas load.
• Alkali scrubbers utilize a dilute alkaline solution to
neutralize the incoming acid vapors. Significant amounts
of heat will be generated during neutralization. The
neutralized material is typically a salt, which must be
disposed of in accordance with regulatory
requirements. Dilute sodium hydroxide solution is
frequently utilized as the neutralizing chemical.
Typically, sodium hydroxide scrubbing solutions have a
strength of 20 percent by weight or less to minimize the
amount of salt produced which under certain conditions
can cause clogging of the sparger and piping dispersing
Hydrochloric Acid (hydrogen chloride) gas into the
neutralizing agent. Other chemicals such as dilute
potassium hydroxide solutions may also find application
in alkali scrubbing.
With both aqueous and alkali-based scrubbers, pH
measurement or titration is an effective and affordable
approach to maintain the desired operating pH. A robust
control system is required to effectively capture the HCl
vapors from the storage tanks.
Hydrochloric Acid Product Stewardship Manual
Regardless of type of fume scrubber utilized, the services of a
competent, qualified engineering firm should be sought out
when designing a fume scrubber. The expected operating
conditions, including but not limited to the mode of product
transfer and expected volume of air and acid gas likely to be
introduced into the scrubber, should be reviewed with the
manufacturer to properly design the scrubber and its
appliances. Scrubber solutions will generate heat when
exposed to Hydrochloric Acid gas vapors so scrubber piping
and tanks must be designed to accommodate temperature
increases during operation.
Finally, it is imperative the scrubber be well-maintained
throughout its service life. Improperly designed or poorly
maintained fume scrubbers may operate inefficiently (not
fully react with or remove the hydrogen chloride gas vapors),
and under certain conditions can lead to unsafe workplace
conditions, premature failure of the parent storage tank, and
liquid and vapor product losses. Use of written operational
checklists and maintenance logs are suggested to maximize
fume scrubber lifetime and performance. Since batch
scrubbers must be manually replenished, they generally
dictate presence of a more robust maintenance and
operations program.
Receiving Pipeline & Inlet/Outlet Nozzles
Tanks should be designed to address normal product supply
and periodic maintenance activities. Pipe diameter guidance
will vary depending on site layout, as well mode of delivery.
The receiving pipeline should be equipped with a drain valve
(where practical) near the delivery hose attachment point
routed to containment. This valve can be used to collect
delivery samples or relieve hose and pipeline pressure after
unloading is completed. Two-inch flanged piping is typical for
most tank truck serviced locations, while larger diameter
piping is common for other delivery modes (tank car) to
facilitate rapid product transfer.
• Top filling is generally preferred for Hydrochloric Acid
tanks. Top-fill nozzles are typically installed on the roof
of the tank. Bottom-filled tanks are not recommended
for Hydrochloric Acid storage tanks.
• Tanks should be designed to address normal product
supply and periodic maintenance activities. Most outlet
nozzles are located as near the bottom as practical.
Where outlet nozzles are not located at tank floor level,
a low point drain should be installed to remove product
heels for maintenance activities.
• A side or roof-mounted manway, typically 18- or 24inches diameter, should be incorporated into the design
to facilitate future maintenance needs.
Page 16
Level Measurement
A level measurement system is important for maintaining
process operations and for avoiding a possible overflow
condition during inbound chemical delivery. External “sight
glass” gauging devices are not recommended due to their
potential for leakage and accidental impact.
Electronic gauging devices utilizing pressure differential,
ultrasound, or radar are frequently utilized for tank inventory
measurement. Level indicators that are not immersed in the
product typically perform best, but all electronic level
transmitters should be assigned a scheduled, periodic
recalibration cycle to ensure accurate readings over the long
term.
Equipping the indicator to activate an alarm or automatic
shut-off at preset inventory levels can provide an important
additional layer of protection against accidental tank
overflow conditions. Use of a second high-level device,
independent of the regular level transmitter, is desirable.
Posting the maximum allowable storage tank volume in a
location clearly visible to unloading personnel will facilitate
calculation of available volume for incoming chemical. This,
coupled with a local level readout in clear view at/from the
unloading station, will allow the unloading staff (and delivery
driver for tank truck shipments) to monitor tank levels more
effectively during filling.
Tie-Downs
Tanks should be adequately secured using tie-downs installed
from the factory to prevent tank movement from high winds
or seismic activity.
Cleaning, Inspection & Preparation
Tank cleaning and inspection should be part of a scheduled,
periodic maintenance program for Hydrochloric Acid storage
equipment. Tank cleaning frequencies will be influenced by
factors such as the amount of product throughput and vessel
inspection activities. Tank cleaning residues are hazardous
and should be disposed of in accordance with local, province,
state, and federal regulations.
Tanks should undergo scheduled visual, and mechanical
inspections by qualified, trained personnel. Inspectors should
adhere to the American Petroleum Institute (API) 653
standard or equivalent for inspecting and repairing steel
tanks.
Keep detailed inspection records, both from visual
inspections and the non-destructive testing (NDT) data
obtained during mechanical inspections, for future reference.
Hydrochloric Acid Product Stewardship Manual
New or repaired piping and tank systems should be water
tested under use conditions before being placed in
Hydrochloric Acid service.
Containment Systems
Tanks should be installed on an appropriate foundation
capable of supporting the weight load of a full tank, taking
into consideration soil and sub-soil attributes. Reinforced
concrete foundation pads are preferred. The tank pad or
foundation should be designed to minimize moisture
exposure and entrapment to the tank bottom. Elevating pads
above the containment system floor is a preferred design
concept to achieve this goal.
A well-designed handling system should incorporate effective
secondary containment to collect potential drips or spills in
product storage and unloading areas. Secondary containment
regulations often vary by location, so it will be important to
review local codes/city ordinances, as well as province, state,
and federal requirements in the design phase. In general,
containment systems should be capable of holding at least
110 % of the largest tank capacity found in the contained
area. For outdoor tanks in high rainfall locations, additional
capacity should be considered.
Incompatible chemicals should be separated by walls within
the overall containment area. Containment system drain
piping should be dedicated to Hydrochloric Acid.
Concrete is typically the preferred choice for bulk storage
containment systems. A well-designed system will have
reinforced floors and walls. The concrete should be sealed
with an industrial coating to extend containment lifetime and
to limit the potential of chemical migration through cracks or
open expansion joints. The effectiveness of industrial coatings
will be largely influenced by the overall condition of the
concrete, amount of surface preparation before application,
and the type of coating applied. Two-part epoxy coatings and
acid resistant rubber linings are preferred. The use of cinder
blocks for containment walls is not preferred because of their
porous nature and relatively weak strength.
Maintenance and housekeeping practices wherein systems
are kept in good repair and any leakage is promptly cleaned
up can greatly extend containment system integrity.
Maintenance becomes critical as minor imperfections that
allow chemical to contact the concrete structure may not be
adequately rinsed away from rainfall or housekeeping events.
Containment systems may vary by design and material of
construction for non-metallic tanks or small volume storage
applications such as “day” tanks. Double-walled tanks are
often considered for vessels if there is limited room for the
Page 17
tank and containment system. Use of a liquid-detection
monitor in the open space between the tank walls can
provide notification of internal vessel failure. The doublewalled feature does, however, impede the ability to perform
important visual inspections of the tank wall (refer to tank
manufacturers guidance).
Shipping container unloading stations should also incorporate
secondary containment to collect leaks, spills, or wash-down
water. Reinforced concrete is generally the preferred
material for tank truck unloading station containment
systems because most unloading areas must be able to
accommodate delivery equipment weight loads.
The presence of railroad ties and the occasional need for
track maintenance make removable containment pans
preferable to concrete sumps or pits for tank car unloading.
Polyethylene or fiberglass reinforced plastic (FRP)
containment pans are available from many containment
system vendors for liquids collection between track rails.
They offer the benefit of being removable for future track
maintenance purposes. Routing of the containment system
drains should avoid exposure to incompatible chemicals.
Piping
There are a number of acceptable materials of construction
for Hydrochloric Acid piping systems. Each material of
construction presents unique attributes, and in some
instances requires special care in installation and inspection
to help ensure successful long-term use. Structural strength,
chemical resistance, and operational conditions are
important factors to consider when selecting piping materials
of construction.
• Carbon steel piping lined with rubber, polyvinyl chloride
(PVC), chlorinated polyvinyl chloride (CPVC),
polyvinylidene fluoride (PVDF) or
polytetrafluoroethylene (PTFE) are the preferred
materials of construction. Carbon steel lined piping
offers structural rigidity, greater mechanical durability,
avoids shattering concerns at low ambient
temperatures and is impervious to degradation when
exposed to sunlight. All metal rigid pipes must be
schedule 40 or higher.
• Plastic materials are generally used in lower mechanical
stress applications. However, they have recommended
temperature ranges that should not be exceeded. In
many instances, ambient conditions exceed these
recommendations and elevate the risk of fracture. A
related factor is ultraviolet damage as a result of longterm sunlight exposure. Repeated sunlight exposure will
weaken monomer bonds, making the pipe more prone
Hydrochloric Acid Product Stewardship Manual
to fracture. Use of plastic-based components such as
polyethylene, polypropylene, and rigid PVC should be
reviewed with the supplier before installation,
especially in sub-freezing climate applications. All pipes
made of plastic materials must be schedule 80 or
higher.
• Fiberglass reinforced plastic (FRP) has been used
successfully for Hydrochloric Acid service, but it requires
extreme diligence in carefully managing all aspects of
fabrication and installation. Successful service is
typically dependent upon fabricator experience (those
specializing in manufacturing pipe expressly intended
for Hydrochloric Acid), selecting the correct resin
composition and the curing process (avoiding cobalt
naphthenate chemical cures), and using certified
installers that employ stringent quality assurance
methods, to name several critical aspects.
Adequate pipeline support is important regardless of material
of construction. However, support becomes increasingly
critical for nonmetallic systems as they generally have lower
structural strength and require additional support
consideration. Proper spacing of the support system (e.g.,
hangers, trays, or clamps) will be influenced by the pipe size,
operating temperature range, and the weight load of the
filled pipe. Special care is required with hangers, support
devices, and clamps to ensure a smooth contact surface, free
of rough edges. They should not compress or distort the pipe
but should allow axial movement resulting from changes in
thermal expansion and contraction. Because of these factors,
use of a continuous support system should be strongly
considered for non-metallic pipe runs.
Underground piping is not desirable, but where it cannot be
avoided, the pipe should be placed in an impermeable trench
with adequate drainage and protected by a removable cover
to allow for convenient inspection of piping.
Flanged connections must always be used for unloading
Hydrochloric Acid. An acid-resistant, flexible rubber hose with
built-in flanges is recommended to connect tank cars and
tank trucks to permanent piping. Viton®, neoprene, and butyl
rubber are typical gasket materials of construction for
handling Hydrochloric Acid.
A four-bolt flange of lined carbon steel construction provides
structural rigidity and will withstand the rigors of hose
torque, weight, and stresses associated with product
transfers. Avoid use of unlined metals for hose connectors in
Hydrochloric Acid service. Lined carbon steel flanged fittings
provide protection against chemical attack of the metal and
Page 18
offer the mechanical strength required during a typical
unloading operation.
For end-use applications such as dosing meters, smalldiameter PVC/CPVC tubing is often used. As with larger
diameter piping, proper support is required. A protective
enclosure such as a conduit or equivalent device should be
used where foot or vehicular traffic is likely.
Pumps & Meters
Hydrochloric Acid is a hazardous material; therefore, pumps
should be selected carefully. The expected service conditions
must first be thoroughly reviewed before a safe and reliable
design can be engineered. Material selection must be based
on expected service temperatures, pressures, concentrations,
and impurities. Once an application has been determined, a
pump manufacturer should be consulted for design use and
final pump selection.
Centrifugal, diaphragm, and magnetically driven pumps are
more common for high volume transfers or for recirculationtype activities. Regardless of application, all internally wetted
components must be constructed of Hydrochloric Acid
compatible materials. Typical materials of construction for
acid pumps include: polyvinylidene fluoride (PVDF),
polypropylene (PP), polytetrafluoroethylene (PTFE), polyvinyl
chloride (PVC or CPVC) or fiberglass reinforced plastic (FRP)
components.
For tank car and tank truck unloading, self-priming pumps are
preferred since Hydrochloric Acid tank cars, and some tank
trucks, do not have bottom outlet valves. The use of non-selfpriming pumps will require the addition of compressed air to
the shipping container to establish pump prime.
Sealless, mag-drive pumps are also preferred in Hydrochloric
Acid service to eliminate the potential for packing gland leaks
posed by pumps utilizing seals.
Design features are influenced by the type of pump selected.
Positive displacement pumps should incorporate a pressure
relief device to protect against ‘dead-heading’ situations
whereas mechanically sealed centrifugal pumps should
employ a seal-shaft shroud to help prevent potential seal
leakage from being slung onto nearby personnel or
equipment. A low-amp cut-off switch should be considered
for magnetically driven pumps to protect against “burn-out”
resulting from operating under damaging low or no-flow
conditions.
Valves
When selecting valves for Hydrochloric Acid service, it is
important to fully understand the service requirements for
Hydrochloric Acid Product Stewardship Manual
each application and have a good working knowledge of the
performance characteristics of each valve type and available
materials of construction.
As mentioned below, several different valve designs can be
used with Hydrochloric Acid and are generally chosen based
on intended service and maintenance experience. The types
of valves commonly employed in Hydrochloric Acid service
are the ball, plug, diaphragm, and butterfly valves. Each is
available in several basic body patterns and with different
design features unique to a particular service and/or specific
application.
Note - Check and butterfly valves are not recommended for
positive shut-off applications.
• Ball Valves are preferred over plug valves of equal size
due to the lower turning torques for ball valve
operation. Additionally, ball valves provide tight shut-off
when closed and offer minimum resistance to flow
when fully open.
• Plug Valves are used less than ball valves of equal size
due to the higher turning torques for plug valve
operation.
• Diaphragm Valves are used less than ball valves of
equal size due to the higher turning revolutions
required for diaphragm valve operation.
• Butterfly Valves are typically used in applications where
low-pressure drop and throttling are necessary. When
installing butterfly valves in lined steel and dual
laminate piping systems, compatible spacers are
required on both sides of the butterfly valve so the
wafer disc can turn unobstructed through its quarter
turn movement.
Shipping Hydrochloric Acid
Hazardous Materials Transportation System
(Regulatory)
The safe transport of hazardous materials such as
Hydrochloric Acid involves several different organizations:
• Regulatory Agencies (U.S. Department of
Transportation, Transport Canada, U.S. Coast Guard,
others)
• Chemical Manufacturer (Olin)
• Carriers (Railroads and Trucking)
• Tank Car/Tank Truck/Equipment Owners (various)
• Customer
Page 19
The carrier’s (railroad, trucking, and marine towing company)
responsibility in the hazardous transportation system is to
safely move the Hydrochloric Acid shipping containers from
the shipper to the customer. The carrier must comply with a
variety of regulations governing the movement of hazardous
materials from agencies, including the Department of
Transportation, Transport Canada, the Association of
American Railroads, and individual state regulatory agencies.
Each of these organizations plays an important role in the
safe shipment of hazardous materials.
Shipping Mode
Regulation/Enforcement Agency
Rail
(USDOT) Federal Railroad
Administration (FRA); Transport Canada
Roadway
USDOT – Federal Motor Carrier Safety
Administration; Transport Canada
Waterway
U.S. Coast Guard; Transport Canada
Pipeline
USDOT – Pipeline & Hazardous
Materials Safety Administration
(PHMSA); Transport Canada
Regulatory Agencies are the governing bodies in the
transportation arena that oversee the safe movement of all
hazardous materials whether by land, air, or water. They
define and enforce the rules covering the safe handling and
transport of hazardous materials.
Each regulatory agency has an enforcement arm to assure
compliance with record-keeping and equipment regulations.
Penalties, including fines and potential jail terms for
corporations and individuals, can be imposed for violations of
regulatory requirements.
While the U.S. Department of Transportation (and Transport
Canada for Canadian shipments) regulates the movement of
hazardous materials by rail, road, and pipeline, enforcement
of these regulations in the U.S. is carried out by different
agencies depending on the mode of shipment.
Olin’s responsibility in the hazardous material transportation
system includes the safe operation of its loading facilities as
well as maintaining and delivering the transportation
equipment in good working order for shipment whether
owned, leased, or contracted by Olin. A variety of inspection
and maintenance procedures are carried out before the
shipping container is offered for shipment after loading.
Olin’s goal is to ensure the safety of our personnel and, to the
extent possible, all those who come in contact with a
shipment of Hydrochloric Acid, while effectively using our
fleet and complying with all applicable laws.
Hydrochloric Acid Product Stewardship Manual
It is important to note that in the case of tank cars (empty
after use), the customers or end-users become the shipper of
record when they offer the Hydrochloric Acid container for
shipment back to Olin.
Carriers (rail and truck) rely on the shipper (Olin and/or the
customer) to provide them with clean, safe, and secure
Hydrochloric Acid shipping equipment.
The Hydrochloric Acid customer’s responsibilities in the
hazardous materials shipping process are similar to Olin’s.
Customers must follow the appropriate regulations in the
handling and unloading of Hydrochloric Acid containers, and
in the case of tank cars and barges, prepare them for
shipment back to Olin.
A customer’s goal is to safely handle and unload Hydrochloric
Acid containers, comply with all regulatory requirements, and
where applicable, prepare the container for safe shipment
back to Olin.
As the legal “shipper of record,” customers assume full
responsibility for proper inspection, preparation and
securement of tank cars released to the carrier. Failure to
adequately prepare containers for reverse movement may
result in regulatory fines or citations.
Hydrochloric Acid Shipping: Tank Cars, Tank Trucks
At Olin, Hydrochloric Acid is shipped in tank cars and tank
trucks, only. The fittings present on the tank cars and tank
trucks, as well as the recommended unloading procedures,
are described in the following pages.
For more detailed information regarding shipping container
configurations or unloading procedures, contact Olin’s
Technical Services Group.
Tank Cars
Olin owns and/or leases a fleet of rubber-lined tank cars that
meet DOT specification 111A100W5. Tank cars have
capacities ranging from 70-90 metric tons (77 ST-100 ST). The
tendency is to use tank cars of the larger capacity. It is
recommended to install a storage tank of 140 tons (26,200
Imp. Gal. or 31,500 U.S. Gals) to accept the full contents of an
inbound tank car.
Page 20
Numerous important regulatory, environmental, safety, and
health informational items are available on each tank car.
Tags and stenciling display required regulatory, car
maintenance, and operating information as well as safety,
spill mitigation, and first-aid information along with
emergency response contacts.
Tank trucks used in Hydrochloric Acid service must meet
standards issued by the regulatory agencies (U.S. DOT,
Transport Canada) and include equipment that conforms to
the Department of Transportation (DOT) or Motor Carriers
(MC) designations, which as of the year 2017 were MC-307,
DOT-407, MC-312, and DOT-412 designations. Rubber-lined
or fiberglass reinforced plastic (FRP) trailers of 24–38 metric
tons (26 ST-42 ST) (4,500 to 7,300 Imp. Gal. or 5,400 to 8,800
U.S. Gals) capacity are available for shipping Hydrochloric
Acid, based on over-the road weight limitations. Product
unloading configurations include bottom discharge or a topunloaded dip-leg arrangement.
Hydrochloric Acid tank cars do not have bottom outlet valves.
They are unloaded through a 3 in. diameter flanged eduction
pipe located in the dome. A 2 in. rubber acid hose equipped
with flanges is normally used for unloading and must be
provided by the customer.
The acid is discharged by the application of compressed air or
by use of a customer-supplied pump. The tank car fleet
presents different air inlet arrangements. The air connection
consists of either a 1 in., 2 in., or a 3 in. standard flange
depending upon tank car’s manufacturer and date of
production. Tank cars are protected by a flanged Pressure
Relief Valve, or a Rupture Disc. The Rupture Disks are made of
graphite and are usually fitted with a diffusing cap and are
rated at 165 psig. This pressure rating is stenciled on the side
of the car and is not to be confused with the unloading
pressure.
When unloading tank cars via a compressed air pad, never
exceed the Pressure Relief Valve or Rupture Disk rating
stenciled on the tank car. As a general rule, a 25 psig (172
kPa) air pressure pad should be adequate for most transfer
applications. One pound of air pressure will provide a static
lift of approximately 61 cm (2 feet) for 20 °Bé Hydrochloric
Acid. In applications where more than 25 psig of compressed
air pad is required, customers should consider use of a fixed
pump for tank car unloading.
Tank Truck
Olin contracts with trucking companies to deliver
Hydrochloric Acid solutions by tank truck, also known as
cargo tanks. In some areas of the United States, Olin operates
its own trucking fleet for delivery of the product.
Hydrochloric Acid Product Stewardship Manual
Olin Hydrochloric Acid tank trucks typically have a doublevalve arrangement on the outlet port. The internal valve is
pneumatically operated and can be closed remotely in case of
an emergency. The unloading connections on each tank truck
are typically located at the rear. A specification plate
specifying tank fabrication, inspection, and other regulatory
information is typically located on the driver’s side of the
trailer frame near the front. Transport regulations require
these trailers to be inspected on a scheduled frequency,
including internal and external visual inspections as well as
leak, thickness, and pressure testing. These inspection dates
are stenciled on the front head or on the front driver side of
the trailer.
Tank trucks can be unloaded by the driver or by properly
trained employees (DOT/Transport Canada function-specific)
at the customer’s or end user’s facility. Delivery tractors are
equipped with an air compressor for pneumatic product
transfer. Onboard pumps are not available for Hydrochloric
Acid tank trailers.
Compressed air is applied up to a maximum of 25 psig to
displace the acid out of the tank truck through the eduction
pipe.
Page 21
Trailers are equipped with a rupture disk set at approximately
30 psig to protect the tank truck from over pressurization.
As a general rule of reference, one pound of air pressure will
provide a static lift of approximately 61 cm (2 feet) for 20 °Bé
Hydrochloric Acid. In applications where more than 25 psig of
compressed air pad is required, customers should consider
use of a fixed pump for tank truck unloading.
When unloading the tank truck, a flanged 2-inch compatible
transfer hose connects the trailer outlet to the receiving
pipeline. For additional information on the size and location
of fittings, contact Olin’s Technical Service Group.
Unloading Hydrochloric Acid Solutions
Unloading Procedures & HazMat Training
Establishment of robust unloading procedures should occur
before product is received and then be reviewed on a
periodic basis or revised when operational practices dictate.
Unloading procedures will be unique to each facility,
receiving area, and delivery mode. However, well-written
unloading procedures include several common attributes and
components.
Although the primary focus of the unloading procedure is to
ensure the correct product is safely delivered into the storage
facility, it also should be written to address unexpected
events such as spills or other incidents. All procedures should
be documented with periodic training provided to ensure
personnel understand the procedure requirements. Verbal
procedures for unloading should be avoided as they can foster
inconsistency between staff members and an ever-changing
standard.
Use of pre- and post-unloading checklists offers the
advantage of physically carrying the key elements of the
unloading procedure to the work area for review/completion.
Errors that can potentially occur from relying upon
recollection of the formal unloading procedures can be
avoided. Checklists help ensure all key unloading items are
reviewed/inspected and encourage consistency between
different staff members.
Typical components include:
• Review of paperwork (bill-of-lading/shipping papers and
certificate of quality) to verify they match the shipping
container placard and receiving pipeline label.
• Delivery address and purchase order numbers are
verified.
Hydrochloric Acid Product Stewardship Manual
• Ensure adequate tank space exists to safely receive the
entire shipping container contents, regardless of
delivery mode.
• Safety shower and eyewash units have been located
and verified operational.
• PPE has been inspected and donned.
• Mechanical inspection of the shipping container and
transfer hoses has been completed.
Because it is a hazardous material (Hazmat), all personnel
handling Hydrochloric Acid must be properly trained or
“qualified” on the topics of General Awareness, Function
Specific, Safety, and Security as required by 49CFR 172.704
(U.S. DOT) and Transport Canada’s Transport of Dangerous
Goods Act S.C. 1992, c.34 (Canada) before handling this
product. Regulations require Hazmat personnel to undergo
this training at least once every three years.
General Unloading System Requirements
Customers should carefully consider the way that
Hydrochloric Acid will be received and handled at their
facilities. Each receiving location needs adequate equipment,
facilities, personal protective equipment, and procedures to
safely unload this chemical. Personnel should be prepared to
deal with both normal and abnormal situations. Unloading
system features to consider include:
1. Hydrochloric Acid unloading operations must only be
performed by properly trained personnel who
understand the hazardous materials they are handling.
2. All workers must wear proper protective equipment and
clothing per the function specific task being conducted.
They also must strictly observe all prescribed safehandling procedures and practices. Contact with
Hydrochloric Acid can cause severe burns to skin and
eyes. If inhaled, it may cause mild irritation to severe
burns of the lungs and respiratory tract.
3. Safety showers/eyewash stations and other personal
protection equipment should be located in close
proximity to the unloading connections. However, the
safety device should be located so that it will not be
affected by an accidental release event if that were to
occur. This critical equipment must be easily and quickly
accessible by those who need it. For example, someone
with Hydrochloric Acid in their eyes will have impaired
vision making it difficult to locate the eyewash unless it
stands out very clearly from the surrounding
equipment. They would also have difficulty with stairs,
curbs, narrow walkways, turns or other obstacles on the
way to the safety shower/eye wash. By ANSI Standard,
these safety appliances should be located on the same
Page 22
level as the hazard, void of access impediments such as
steps, curbs, doors, and be located within 10 seconds of
reach, and approximately within 55ft.
4. Safe, unobstructed access to and from work areas
around unloading connections is required for both
routine operation and emergency situations.
5. Leak containment systems (catch pans under tank cars,
paved pads under tank trucks) should be provided for
those places where spillage may occur. This includes the
transfer hose connection drain valves, pump seals, and
valves. These systems should provide positive control
for leaks or spills that might occur during the handling
of Hydrochloric Acid. It is important to make sure that
the materials of construction for the containment
equipment are compatible with all Hydrochloric Acid
concentrations that might be handled in the system.
The containment system should be designed and
operated such that accidental mixing with other
chemicals does not occur. Containment liquids should
be verified or tested prior to reuse, recycle, or disposal.
6. Adequate lighting is available in all work areas,
especially at the unloading connections.
7. Adequate supplies of water (equipment rinsing and spill
cleanup), or other utilities should be readily available.
8. Flexible unloading hoses should:
• Be made of acid-resistant material with a spiral wire
wound structure.
• Have 4-bolt flanged lined steel connections.
• Have a suitable pressure rating for the service where
they are used.
• Only be used to connect the Hydrochloric Acid
transportation equipment to the unloading piping.
Generally, only one length of hose should be used to
prevent safety and handling problems. If situations
require use of multiple sections of hose for
unloading, corrective actions should be identified to
minimize the length of the unloading hose.
9.
The unloading area should be roped off/barricaded
and warning signs posted during unloading operation
to help ensure the safety of anyone passing by the
area.
10. Tank cars and tank trucks should be chocked to
prevent accidental movement during the unloading
operation.
11. Level indicating devices and communication
procedures should be used to ensure that there is
Hydrochloric Acid Product Stewardship Manual
enough space in the receiving tank for the entire
product load.
12. If a pad gas unloading system is used, air is the
preferred pad gas. A point of use/ particulate filter
should be installed on the source air to prevent carryover into the Hydrochloric Acid in the tank car or tank
truck during unloading. The source air line should be
equipped with a regulator set to a maximum of 25 psig
to prevent over pressurization of the shipping
container. If any other compressed gas is used, the
customer should exercise due caution and Olin should
be notified. Gases other than air can have additional
hazards associated with them. For example, inert
gases, like nitrogen, can present a potential suffocation
hazard to workers who work on the tank car, tank
truck, or storage facility.
13. The vent system on the receiving tank should be
properly sized and discharged to a fume scrubber
designed to handle Hydrochloric Acid vapors (see
Storage Tanks, Piping Systems & Other Systems section
for details).
14. In the case of tank car unloading systems, access by
roadway to the unloading station should be considered
as a backup in case truck shipment becomes
necessary.
Other sections of this product stewardship manual contain
additional information on the design and operation of
Hydrochloric Acid handling facilities. Additional industry
specific information can also be found in The Chlorine
Institute Pamphlet 98, Recommended Practices for Handling
Hydrochloric Acid in Tank Cars; Pamphlet 150, Recommended
Practices for Handling Hydrochloric Acid in Cargo Tanks; and
Pamphlet 163, Hydrochloric Acid Storage and Piping Systems
at www.chlorineinstitute.org. If you have any questions or
need additional assistance, contact your Olin representative.
Tank Car Unloading
Tank Car Unloading must be conducted by qualified
personnel according to Transport Canada Dangerous Goods
(TDG) and Department of Transportation (DOT) regulations.
Placards on each side of the tank car, as well as the valve tags
should be reviewed and compared against the Bill-of-Lading
and certificate of quality prior to unloading to confirm the
product ordered is the product delivered.
The tank car should be accurately spotted at the unloading
station, the hand brake applied, wheels blocked by standard
wheel clamps (wheel chocks) and the DOT/TDG-required blue
flag “Stop – Tank Car Connected” signs displayed as a
protection against disturbance during unloading. Derail
Page 23
attachments are recommended at open ends of the siding at
least 1½ car lengths away.
Adequate personal protective equipment should be worn
during the unloading. Ensure that safety showers and eye
wash fountains are operational before beginning any active
operational tasks that may expose personal to unexpected
drips or residues.
An elevated platform and gangway system should be
provided for safe access and egress from the top of the tank
car. The platform should incorporate fall protection devices
such as protective cages, or equivalent fall arrest systems.
The pad gas filtration device and hose connection, as well as
the receiving pipeline are typically located within arm’s reach
of the unloading platform, which limits hose length and
associated clutter, while maximizing convenience for
component access.
Tank cars require a four-bolt flanged connector to attach to
the product outlet valve. Because of the elevated potential
for “mechanical hammer” and other unloading stresses, the
transfer hose should have a robust support system in place to
limit stresses on the tank car connection. Because of these
unloading stresses, a fluoropolymer lined, flanged metal
connector is preferred for tank car unloading.
The dome fittings and safety appliances should be inspected
for evidence of leaks or other defects before unloading to
prevent possible acid sprays after the tank is subjected to air
pressure.
The following equipment is on the top of every Olin-owned
Hydrochloric Acid tank car:
A) 3” Flanged Unloading Valve with Blind Flange
(connected to the eduction pipe)
B) 2” Flanged Vapor Valve with Blind Flange
C) Fill Hole Cover (for loading purposes)
D) Pressure Relief Valve (or Rupture Disc)
Unloading with Pad Air
The storage tank vent must be connected to a fume scrubber.
Both the storage tank vent and the fume scrubber should be
inspected to ensure proper working order prior to beginning
the product transfer operation. If a scrubber is not available,
contact Olin’s Technical Services Group.
IMPORTANT: The fume scrubber must be capable of handling
the pad air/air flow during unloading, and capable of handling
the gas surge at the end of the unloading process when the
tank car is empty, as well as have adequate capacity for
accommodating a compressed air purge of the transfer lines
and hoses.
1. Before unloading, verify the receiving storage tank can
hold the entire contents of the tank car.
2. Confirm the scrubber is online, tested, and ready for
use.
3. If platform is present, lower gangway and ensure fall
protection systems are in place.
4. With proper tools, remove seal and carefully open the
dome cover of the car and inspect for leaks or signs of
corrosion or damage. Inspect for any signs of solution
around the PRV. Report any anomaly to Olin Technical
Services Representative and/or Sales Representative.
Important: Make sure the Unloading Valve (A) and the
Vapor Valve (B) are fully closed before removing the
Blind Flanges. The loading hatch (C) should never be
opened during the unloading operation.
5. At this step and beyond, it will be important to wear all
PPE to protect against accidental chemical exposure,
which could occur during “line breaking” types of work.
Remove the Blind Flange on the Vapor Valve (B), Install
a 3-way Air/Vent fitting, Connect the scrubber vent pipe
and pad air supply line to the fitting.
6. Open the Vapor Valve (B) to relieve pressure in the tank
car to the fume scrubber.
7. Once the pressure inside the tank car is relieved,
remove the acid Unloading Valve Blind Flange (A).
8. Connect the valve to the unloading hose connected to
the transfer line going to the storage tank.
Important: While all Olin HCl tank cars are equipped
with an Unloading Valve, some shippers offer tank cars
with a non-valved outlet connection capped with Blind
Flange. A pre-inspection program should be in place to
identify cars that aren’t equipped with unloading line
Hydrochloric Acid Product Stewardship Manual
Page 24
valves. Facility procedures should be developed to
handle tank cars without this important safety feature.
9. Cautiously open the Unloading Valve (A) on the tank
car.
10. Slowly open the pad air supply valve allowing
Hydrochloric Acid to flow into the unloading hose then
shut off the air supply and check for leaks. If no leak is
found, slowly re-open the air shut-off valve and apply
pressure until there is a normal flow of acid into the
storage tank. At the same time, watch the pressure
gauge to ensure the air pressure does not rise above the
design pressures of tank car’s Pressure Relief Device,
storage tank and scrubbing unit.
Important: Should a leak develop during unloading,
close the air supply shut-off valve. Open the Vapor
Valve to relieve the pressure inside the tank car to the
fume scrubber. Ventilate the area and contain the spill.
your company to ensure all required actions have been
completed for safe and secure return of the tank car.
Once complete, have the tank car’s return shipment
paperwork prepared in accordance with DOT regulation
for a residue tank car and return the tank car to Olin in
accordance with the instructions on the shipping
document.
18. A final inspection of the tank car is required before it is
released for return shipment. A written format is
advisable for follow-up and record keeping.
As the legal “shipper of record,” you, the customer, are
responsible for ensuring the tank car is prepared for
safe return shipment before release to the carrier.
Failure to adequately prepare the tank car may result
in you accruing regulatory fines determined by the FRA
or Transport Canada.
Tank Truck Unloading
11. A drop in air pressure and the sound of air rushing
through the acid discharge line is an indication the tank
car is empty. Sufficient air should be allowed to blow
through the line to free it of residual acid liquids and
vapors.
When unloading Hydrochloric Acid tank trucks, the safety
aspects of the operation should be uppermost in the minds of
personnel. The unloader must verify that the requirements
for receiving, and spotting have been completed before
beginning transfer operations.
12. Close the air supply shut-off valve and open the vent
valve. Close the Unloading Valve (A).
The references in the previous tank car section will also apply
to the unloading of tank trucks. Although the acid unloading
and air connections are found in different locations and the
time required for unloading is different, the unloading
concept is the same.
13. When the tank car and the airline are at atmospheric
pressure, disconnect the air line. Close the Vapor Valve
(B). Disconnect the vent pipe and the air/vent 3-way
fitting.
14. Disconnect the acid unloading hose from the Unloading
Valve. Important: Care should be taken to prevent any
acid from dripping on personnel, on the tank car or
adjacent equipment. Any drippage from the acid line
should be caught in an acid-resistant receptacle. Any
surface of the tank car or personal protective
equipment being worn which is exposed to Hydrochloric
Acid should be immediately and thoroughly rinsed with
water, with the acid and rinse water collected and
handled per applicable regulatory requirements.
15. Install the Blind Flanges on both the Unloading Valve (A)
and the Vapor Valve (B). All Blind Flange bolts must be
tool tight.
16. Ensure that all four “UN 1789” placards are in the same
position as received and are legible.
17. Remove the DOT/TDG blue warning signs and track
derails to allow railroad access to the tank car. Review
and complete the pre-release checklist developed by
Hydrochloric Acid Product Stewardship Manual
As with the tank cars unloading procedure, the receiver of the
inbound delivery is responsible for checking and accepting
the Hydrochloric Acid before unloading. Procedures should
be established and followed to be certain the product is
acceptable before unloading.
The unloading area must be large enough for easy turning
and positioning of the tractor and trailer. Wherever possible,
drive-through unloading stations are preferred over backing
of the tank truck into the unloading station. The tank truck
should be parked on a level unloading surface to ensure
complete product unloading.
The surface of the unloading area should contain potential
spills and allow recovery, re-use, or clean-up of any
Hydrochloric Acid spilled during the unloading process. The
wheels of the vehicle should be carefully blocked, and the
brakes applied during the unloading.
Most tank trucks are equipped with an internal valve, an
auxiliary product outlet valve, a two- or three-inch flanged
fitting for unloading hose attachment, and a front and rear
Page 25
driver’s side emergency shut-off device. In addition, each
tank truck is also equipped with a one-inch air connector for
pneumatic product transfer.
additional engineering control “point-of-use filter” is
recommended for the pad air system at the point of use or
connection point to the shipping container.
The delivery driver normally unloads tank trucks. They are
responsible for following the proper safety rules and
operating procedures as prescribed by the recipient, Olin, and
government regulations.
This filter will help ensure pad air quality while eliminating
contaminants such as oil and or solid particulates from being
introduced into the shipping container and product from the
pad air system. This recommended engineering control
requires the following components to be appropriately
designed and installed, along with good operating practices.
If the truck driver is performing the unloading, it remains the
customer’s responsibility to verify the driver has attached the
unloading hose to the proper tank connection and that the
tank has enough available capacity to receive the full load,
and that the scrubber is online and working properly.
A plant representative should accompany the driver during
the high-risk part of the unloading activities, such as when
the tank truck is being connected and when the connections
are broken after unloading has been completed.
The Department of Transportation requires that the entire
truck unloading operation be attended by a competent
unloader who is alert, located within 25-feet of the trailer,
and has an unobstructed view of the unloading hoses. If the
plant representative is in close proximity to the Hydrochloric
Acid hose connection points, they should don and also wear
all applicable personal protective equipment.
In addition to being trained in the use of proper protective
equipment and specific unloading procedures and
equipment, site personnel assisting the delivery driver should
be trained in the location and activation of the emergency
shut-off device. Note: All tank trucks are equipped with an
emergency shut-off device located at the driver’s side front
and rear of the tank truck.
The recipient is responsible for providing competent and
knowledgeable supervision, safety equipment special to the
site, and a properly designed and maintained unloading area.
The exact steps of the unloading operation will depend on
each site’s unique configuration.
Additional information on Tank Truck unloading facilities and
procedures is available from The Chlorine Institute, Pamphlet
150, Recommended Practices for Handling Hydrochloric Acid
in Cargo Tanks at www.chlorineinstitute.org.
Pad Air Quality - Point of Use
As a customer receiving chlor alkali chemicals such as
Hydrochloric Acid, it is important to understand and
implement a proper air padding system for unloading any of
these chlor alkali corrosive liquids. Air padding systems can
be a significant source of product contamination and require
on-going inspection and maintenance to prevent failure. An
Hydrochloric Acid Product Stewardship Manual
Note: The diagram that follows represents components
within a properly designed pad air system. Proper installation
and maintenance of pad air systems can significantly
minimize contaminants from entering the shipping container
during unloading.
Safety features should include isolation valves, pressure
regulator, pressure relief valve, point of use filter, check
valve, pressure gauge, and purge/vent valve for safe line
evacuation prior to disconnection.
Piping (in green) used downstream of the point-of-use filter
must be made of product-compatible material to protect
against chemical vapor introduction and corrosion.
The Pad Air connector and hose must be made of productcompatible material and be part of an effective pad air
system maintenance program.
Figure 1:
All components shown in green
must be compatible with the
corrosive liquid being transferred.
Suggested Filter Arrangement
Point-of-Use Filter:
The point-of-use filter requirements should include:
•
A location close to or at the shipping container — all
‘downstream’ components must be chemically
compatible.
•
A high-efficiency filter with a rating of 1.0 micron or
less.
•
A pressure drop indicator and auto-drainer.
Page 26
Safety Features: Pressure Regulator, Pressure Gauge, &
Pressure Relief Valve
The use of high pressure on the pad air systems has the
potential to overpressure the shipping container, resulting in
the activation of the safety relief valve on shipping containers
and the potential of a chemical leak.
It is often misunderstood that unloading rates are directly
related to pad pressures. As a general guide, the volume of
compressed air and piping diameter, not the pressure of pad
air, have the greatest influence on unloading rates.
In most applications, it is important for the pad air delivery to
be regulated so that it does not exceed 25 psig using a
pressure regulator. A pressure gauge equipped with a
diaphragm made of compatible material of construction such
as Teflon® (PFA, FEP PTFE) should be installed to allow the
control of the pressure during the unloading process.
A good safety practice includes the installation of a pressure
relief device set to a maximum operating pressure of 30 psig,
immediately downstream of the pressure regulator. The
pressure relief device provides redundant protection against
possible shipping container over-pressurization if the
pressure regulator fails.
-
Typical safety relief valve settings: approx. 32-35 psig
tank trucks, approx. 165 psig tank cars.
Isolation Valve
As shown in Figure 1 (pg. 26), it is imperative that the
isolation valve nearest to the shipping container be in the
closed position any time it is not actively being used to apply
air, including when the unloading process is stopped. This
isolation valve helps ensure corrosive vapors do not back flow
into the air system.
Pad Air Piping Material of Construction
Experience has clearly shown that when dealing with
corrosive liquids, a careful selection of the pad air system’s
material of construction at point of use is critical to provide
adequate structural strength, chemical resistance, and
prevent product contamination.
Materials of construction are especially critical for
Hydrochloric Acid. Iron or copper-based metals are not
compatible with Hydrochloric Acid and will corrode over time.
When exposed to these chemical vapors, the resulting
corrosion and rust produced will enter the pad air and
contaminate the product, as well as the shipping container.
At the point of use or where sections of piping may be
exposed to chemical vapor, (green section shown in Figure 1),
Hydrochloric Acid Product Stewardship Manual
chemical-resistant piping is recommended. For a lined piping
system, the liner offers the chemical resistance needed, while
the metallic piping offers structural strength.
Liners such as Polypropylene, Teflon® (PFA, FEP PTFE), PVDF
(fluorinated polyvinylidene) and PVC/CPVC
(polyvinylchloride/chlorinated polyvinylchloride) are
compatible with Hydrochloric Acid.
Note: Although solid PVC or CPVC piping offers an adequate
product corrosion barrier to chlor alkali products, it is not
suitable for use in compressed air service primarily because
of the safety risk from shattering and injury to personnel.
These materials do not provide the structural strength of
lined metallic piping.
Pad Air System Maintenance
A timely and effective maintenance program is critical for
ensuring delivery of clean, water droplet-free, oil-free, and
particulate-free pad air to the shipping container.
Despite the implementation of scheduled preventative
maintenance programs and well-trained personnel, failures
can occur and go unnoticed, regardless of equipment design
or configuration.
A white rag test should be performed at least once monthly
to provide a redundant verification of proper operation. To
be effective, the white rag test should be performed at the
shipping container end of the pad air hose by introducing
compressed pad air into a clean white rag at regular full flow
rates, not throttled, for one to two minutes.
Performance of the white rag test should incorporate safety
provisions such as hearing and eye protection, avoidance of
line-of-fire body positioning, use of the buddy system, hand
protection, and a means to mechanically secure the rag to the
end of the discharge system.
Any particulate matter, moisture, or discoloration observed
indicates a failure in one of the system’s upstream
components and should prompt further investigation.
System maintenance practices will vary by the age of the
system, equipment design, manufacturer, and operating
environment or conditions, but several general guidelines are
applicable in all situations.
An inspection checklist should be used to confirm that all
components of the system have been inspected or serviced
and that any noted deficiencies are corrected. Maintenance
guidelines issued from the compressor manufacturer should
be consulted and typically represent the minimum frequency
at which maintenance should be performed.
Page 27
General inspection guidelines for delivering high-quality
padding air are shown in Table 1 (below).
Distribution hoses should be visually inspected for evidence
of damage such as bulges, cracks, or cuts to the exterior
sheathing, connector wear, or evidence of moisture, residue,
or corrosion on the connector.
Table 1: Inspection Guidelines
Hose & Connector
Before each use: Daily Visual
inspection for evidence of fatigue,
wear, or damage
White rag test at point of use
At least monthly
Trap & filter inspection/service
At least monthly
Pressure drop indicators
Daily inspection / during use
Filter replacement
Per manufacturer guidelines, white
rag test or pressure drop
Regulator or check valves
Annual preventative maintenance
Note: The information above is given merely as an example. Actual
operating conditions, age of system, system design, and frequency of use
should be considered when developing inspection and maintenance
frequencies. Over time, experience and inspection data records may
indicate need for further adjustment of maintenance cycles.
Unloading by Pump
Where unloading with “pad air pressure only” is not possible,
the tank car or tank truck may be unloaded using a pump.
Pump unloading is favored by customers desiring to
minimize/control fume generation in the receiving storage
tank/fume scrubber.
It is recommended that self-priming, sealless, centrifugal
pumps be used to prevent packing leaks which may occur
with pumps equipped with packing or mechanical seals.
Sealless pumps should be equipped with low amperage flow
safety switches to ensure the pump is not operated in a dry
or deadheaded state to prevent catastrophic pump damage.
The pump manufacturer should be consulted before selecting
a pump to review the expected operating conditions, such as
the required vertical lift distance from the shipping container
to the storage tank or process, type of service (continuous or
intermittent), and desired flow rate to determine the best
pump for your particular application, and pressures required
for safe and continued uses in this environment.
The pump should be located at ground level for ease of
maintenance service. The pump should be located within a
containment area to collect or contain any leak or dripping
from the hose and/or sampling. The pump inlet and discharge
should be equipped with drain valves to remove any acid in
Hydrochloric Acid Product Stewardship Manual
the unloading hose or transfer piping when hoses are
disconnected, or pump maintenance is required. Customers
may utilize the drain valves located on the pipeline or pump
for product sampling activities as well.
Note: To limit exposure to acid fumes, Olin requires customers
to conduct closed manway unloading when pump unloading.
When unloading Hydrochloric Acid by pump, a modest
amount of pad air is still required to be connected to the
shipping container to prevent a vacuum condition during
unloading which could damage the vessel by collapsing. A
proper engineering evaluation and system design is required
to ensure an adequate amount of air is applied during the
entire unloading process to avoid vacuum application to the
shipping container.
The procedures and equipment necessary for pump
unloading will be determined by the type of pump selected
and whether provisions are available for a closed-loop vapor
exchange between the storage tank and shipping container.
Additional details may be obtained by contacting Olin’s
Technical Service Group.
Analytical Guidelines
The accurate determination of Hydrochloric Acid assay is
influenced by many factors including sample point selection,
sample technique, sample handling, analytical methodology,
and analytical equipment and technique. This manual
describes a number of important guidelines to improve the
accuracy of assay determination of Hydrochloric Acid in the
shipping container (tank truck or tank car).
The steps and guidance presented should be thoroughly
reviewed for applicability at a particular site with a hazard
review covering the site-specific functions to identify the best
procedures and personal protective equipment (PPE) for the
health and safety of site personnel and the environment.
Refer to the Safety Data Sheet (SDS) for Hydrochloric Acid for
additional information on appropriate PPE.
Sampling
Whenever possible, the sample should be collected directly
from a properly designed/engineered sample point installed
directly on the unloading piping where there is flow through
the sample point.
Procedures should be in place to ensure the sample point is
purged sufficiently to provide a representative sample of the
shipping container. Consult the SDS for appropriate PPE to be
worn during sample collection activities.
Page 28
All wetted surfaces of sample collection equipment (thief,
bottles, and bottle cap inserts) should be nonmetallic. Sample
bottles should be cleaned and flushed with the sample media.
Reference Materials
Fill the bottle to the desired amount but no more than twothirds of its capacity to avoid over-pressurization, leakage, or
bottle bulging which may occur as the product warms in
storage.
The Chlorine Institute offers a wide variety of safety and
technical information associated with Hydrochloric Acid.
Analytical Methods
Specific Gravity and Concentration:
All analytical work with open containers of Hydrochloric Acid
should be performed with appropriate PPE and in a
laboratory hood to minimize exposure of personnel and the
workplace to the product’s corrosive liquid or vapors.
Place a sample of Hydrochloric Acid in a clean and dry
hydrometer cylinder. Insert the standard hydrometer.
Wait a few minutes to allow the temperature of the
hydrometer to equal that of the sample. Read the
intersection of the bottom of the meniscus with the stem of
the hydrometer.
Take the temperature of the sample at the time that the
specific gravity is read and correct the reading using.
Refer to Appendix A (pg. 30) of this manual to determine the
HCl concentration and for additional technical details.
The Chlorine Institute – Reference Pamphlets
Contact the Chlorine Institute at www.chlorineinstitute.org to
access the pamphlets referenced in this publication.
Pamphlet 65, “Personal Protective Equipment for Chlor Alkali
Chemicals” – Provides personal protective equipment
recommendations for working with Hydrochloric Acid.
Pamphlet 98, “Recommended Practices for Handling
Hydrochloric Acid in Tank Cars” – Provides recommended
practices for handling Hydrochloric Acid in Rail Cars.
Pamphlet 150, “Recommended Practices for Handling
Hydrochloric Acid in Cargo Tanks” – Provides recommended
practices for handling Hydrochloric Acid in Tank Trucks.
Pamphlet 163, “Hydrochloric Acid Storage and Piping
Systems” – Provides storage and piping guidance for systems
handling Hydrochloric Acid.
Pamphlet 170, “HCl Emergency Response Guidelines
Handbook - Hydrogen Chloride, Anhydrous (AHCL),
Refrigerated Liquid (UN2186), Tank Car & Cargo Tank
Handling Manual” – Provides guidance for Emergency
Response with handling anhydrous HCl or Hydrogen Chloride.
Iron Content
1.
Take a 25 ml Hydrochloric Acid sample and dilute it to
50 ml with distilled water.
2.
Add 1 ml of a 10% Hydroxylamine Hydrochloride
solution and mix.
3.
Add 0.75 ml of a 1.5% o-phenanthroline reagent and
mix.
4.
Add drop by drop a solution of concentrated NH4OH
until a color begins to develop. Drop in a piece of
Congo Red paper and continue the addition of NH4OH
until the paper turns crimson.
5.
Dilute the sample to 100 ml and wait for a few
minutes.
6.
Place the sample in a Nessler Tube and compare it with
some standards prepared as above (steps 1-4), but
containing 2.0, 3.0, 4.0, 5.0, 6.0, and 7.0 ml of standard
Fe solution (0.01 mg Fe/ml), also placed in Nessler
tubes. If necessary, take an aliquot of the sample and
dilute it to 100 ml.
Hydrochloric Acid Product Stewardship Manual
ARPM - Association for Rubber Products Manufacturers
IP-4-13, “Protective Linings Technical Bulletin” – Procedures
for Spark
Page 29
Technical Data
Appendix A: Specific Gravity vs. Concentration Chart for Hydrochloric Acid
Baumé °Bé
1.00
2.00
3.00
4.00
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
10.25
10.50
10.75
11.00
11.25
11.50
11.75
12.00
12.25
12.50
12.75
13.00
13.25
13.50
13.75
14.00
14.25
14.50
14.75
15.00
15.25
15.50
15.75
Specific Gravity
(60 °F/60 °F)
1.0069
1.0140
1.0211
1.0284
1.0357
1.0394
1.0432
1.0469
1.0507
1.0545
1.0584
1.0623
1.0662
1.0701
1.0741
1.0761
1.0781
1.0801
1.0821
1.0841
1.0861
1.0881
1.0902
1.0922
1.0943
1.0964
1.0985
1.1006
1.1027
1.1048
1.1069
1.1090
1.1111
1.1132
1.1154
1.1176
1.1197
1.1219
% w/w HCl
Baumé °Bé
1.40
2.82
4.25
5.69
7.15
7.89
8.64
9.40
10.17
10.94
11.71
12.48
13.26
14.04
14.83
15.22
15.62
16.01
16.41
16.81
17.21
17.61
18.01
18.41
18.82
19.22
19.63
20.04
20.45
20.86
21.27
21.68
22.09
22.50
22.92
23.33
23.75
24.16
16.00
16.20
16.40
16.60
16.80
17.00
17.20
17.40
17.60
17.80
18.00
18.20
18.40
18.60
18.80
19.00
19.20
19.40
19.60
19.80
20.00
20.20
20.40
20.60
20.80
21.00
21.20
21.40
21.60
21.80
22.00
22.20
22.40
22.60
22.80
23.00
23.20
23.40
Specific Gravity
(60 °F/60 °F)
1.1240
1.1256
1.1274
1.1292
1.1310
1.1328
1.1345
1.1363
1.1381
1.1399
1.1417
1.1435
1.1453
1.1471
1.1489
1.1508
1.1526
1.1544
1.1563
1.1581
1.1600
1.1619
1.1637
1.1656
1.1675
1.1694
1.1713
1.1732
1.1751
1.1770
1.1789
1.1808
1.1827
1.1846
1.1866
1.1885
1.1904
1.1924
% w/w HCl
24.57
24.90
25.23
25.56
25.89
26.22
26.56
26.90
27.24
27.58
27.92
28.26
28.61
28.95
29.30
29.65
30.00
30.35
30.71
31.08
31.45
31.82
32.19
32.56
32.93
33.31
33.69
34.07
34.45
34.83
35.21
35.59
35.97
36.35
36.73
37.14
37.58
38.03
Appendix B: Specific Gravity Corrections Factors According to Temperature
Add the following correction when the temperature is below 15.5 °C (60 °F). Subtract the following correction when the
temperature is above 15.5 °C (60 °F).
ADJUSTMENT PER °F
ADJUSTMENT PER °C
Degree
Baumé (°Bé)
Specific
Gravity
Degree Baumé (°Bé)
Degree
Baumé (°Bé)
Degree
Baumé (°Bé)
Degree Baumé (°Bé)
10 – 15
0.0002
0.025°
10 – 15
0.00036
0.0450°
15 – 22
0.0003
0.033°
15 – 22
0.00054
0.0594°
22 – 25
0.00035
0.036°
22 – 25
0.00063
0.0648°
Hydrochloric Acid Product Stewardship Manual
Page 30
Appendix C: Boiling Point of Hydrochloric Acid at Atmospheric Pressure
120
248
110
230
18 °Bé
100
212
20 °Bé
90
194
176
70
22 °Bé
158
60
140
50
122
40
104
30
86
20
68
10
50
0
Temperature (°F)
Temperature (°C)
80
32
0
5
10
15
20
25
30
35
40
Weight % of HCl
Hydrochloric Acid Product Stewardship Manual
Page 31
0
32
-10
14
-20
-4
-30
-22
22 °Bé
-40
-40
-50
-58
20 °Bé
-60
-76
-70
Temperature (°F)
Temperature (°C)
Appendix D: Freezing Point of Hydrochloric Acid
-94
18 °Bé
-80
-112
-90
-130
-100
-148
0
5
10
15
20
25
30
35
40
45
46
50
55
57
60
Weight % of HCl
SOURCE: Perry, J.H. – 'Chemical Engineer' Handbook, 3rd Edition
Hydrochloric Acid Product Stewardship Manual
Page 32
Appendix E: Viscosity of Hydrochloric Acid
40
35
30
Weight % HCl
25
20
15
10
5
0
0.8
1
1.2
1.4
1.6
1.8
2
Centipoise (Cp)
at 20°C
Reference: International Critical Tables
Hydrochloric Acid Product Stewardship Manual
Page 33
Appendix F: Specific Heat of Hydrochloric Acid
1.100
1.000
BTU/lb
0.900
0.800
20 °C
60 °C
0.700
0.600
0.500
0
5
10
15
20
25
30
35
40
% HCl
20°C
Hydrochloric Acid Product Stewardship Manual
60°C
Page 34
Appendix G: Partial Vapor of HCl over Hydrochloric Acid Solutions
1000
100
110 °C
10
mm Hg
1
0.1
0.01
0 °C
0.001
0.0001
0.00001
2
6
10
14
18
22
26
30
34
38
42
46
% HCl
0°C
5°C
10°C
15°C
20°C
25°C
30°C
35°C
40°C
45°C
50°C
60°C
70° C
80°C
90°C
100°C
110°C
Hydrochloric Acid Product Stewardship Manual
Page 35
Appendix H: Heat of Formation for Hydrochloric Acid
2000
1950
1900
18 °Bé
1850
22 °Bé
1800
20 °Bé
BTU / lb
1750
1700
1650
1600
1550
1500
1450
1400
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
Weight % HCl
Hydrochloric Acid Product Stewardship Manual
Page 36
Appendix I: Heat of Solution for Hydrochloric Acid
225
200
175
150
BTU *
125
18 °Bé
100
75
22 °Bé
50
20 °Bé
25
0
0
5
10
15
20
25
30
35
40
45
Weight % HCl in solution
* Liberated with 1 lb. of HCl diluted with water at 18 °C (64 °F)
Hydrochloric Acid Product Stewardship Manual
Page 37
Appendix J: Materials of Construction for Handling Equipment in Hydrochloric Acid Service at Temperature up to 71 °C
(160 °F)
PRODUCT
PIPE AND FITTINGS
VALVES
HCl
Up to 22 °Bé
(37.1%)
• Rubber-lined
or
PTFE-lined
or
Saran-lined steel
• Diaphragm type
neoprene or
PTFE
• Fiberglass
reinforced
plastic (FRP)
• Diaphragm and
Rubber or Glass
lined Steel Body
GASKETS
PUMPS
• Neoprene
• PTFE-lined
Steel
• Viton
PUMPS SEALS
• Sealless
• Rubber-lined
Steel
• PVDF
• Kynar
Alternatives
Alternatives
Alternatives
Alternatives
• Glass-lined Steel
• PVC or CPVC
Ball Valve
(suitable for
chemical
resistance but
have limitation
with regards to
temperature
and pressure)
• Hard Rubber
• Braided or
Woven PTFE
• Pyrex
• PVC or CPVC
(suitable for
chemical
resistance but
have limitation
with regards to
temperature
and pressure)
• Stoneware
• Glass-lined
Steel
• Pyrex
• Ceramic
• Carbon or
Graphite
• Karbate
These materials are NOT compatible and NOT recommended with Hydrochloric Acid (18 °Bé to 22 °Bé):
•
Bare or Exposed Steel
•
Stainless Steel
•
Titanium
•
Copper and Copper alloys
•
Nickel and Nickel alloys
•
Aluminum
•
Chrome
•
Most metals
•
Nylon
Hydrochloric Acid Product Stewardship Manual
Page 38
Product Safety Questions? Contact Us
At Olin, safety and environmental protection are top priorities. We provide technical assistance and resources for our customers to
ensure the safe and environmentally sound use and handling of our products. Please contact your Olin representative for further
information and support.
North America Contact Information
USA: +1 833 370 3737
Canada: +1 877 304 4442
Info@olin.com
www.OlinChlorAlkali.com
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in all countries
Notice: No freedom from any patent or other intellectual property rights owned by Olin or others is to be inferred. Olin assumes no obligation or liability for the
information in this document. The information provided herein is presented in good faith and is based on the best of Olin’s knowledge, information, and belief. The
information provided herein does not, and is not intended to, constitute legal advice; instead, all information and content are for general informational purposes
only. Since use conditions at non-Olin facilities are beyond Olin’s control and government requirements may differ from one location to another and may change with
time, it is solely the Buyer’s responsibility to determine whether Olin’s products are appropriate for the Buyer’s use, and to assure the Buyer’s workplace, use, and
disposal practices are in compliance with applicable government requirements. Consequently, Olin assumes no obligation or liability for use of these materials and
makes no warranty, express or implied. The user of the information provided is solely responsible for compliance with any applicable government requirements. NO
WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
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Hydrochloric Acid Product Stewardship Manual
Form No. 102-00568-0223
Page 39