Emerald Kalama Chemical Site Rotterdam
Safety & Environmental Report 2011
Continuous improvement worker safety. These initiatives are exciting changes that will strengthen the facility and the company. A benefit of the Rotterdam facility joining the Emerald Kalama Chemical team is the sharing of ideas and technologies with its sister plant located in Kalama Washington, USA. While each facility continues to learn from the other, we are making progress towards established goals. Capitalizing on the strengths of both plants, projects initiated in 2012 show the company commitment to continuously improving operations while preserving and protecting the environment, the workers, and the community in which we operate. You can read more about the special projects, operational changes and managements’ commitment In 2012 Emerald Kalama Chemical Rotterdam contin-
to continuous improvement in health, safety and the
ues its journey as a world leader in the production of
environment in this report.
benzoic acid and its derivatives by focusing on plans to expand manufacturing operations, improve efficien-
Brenda Abke
cies in waste water management, reduce particulate
Director Health, Safety, Environment & Security
emissions, control environmental impacts and improve
Emerald Performance Materials
2011 was the first year with our new
field of safety and the environment.
owner Emerald Performance Materials.
Various employees share their thoughts in this Health,
We started the year by sharing each
Safety and the Environment Report where they talk
other’s vision related to topics such as
about their experiences related to safety and the
safety and the environment. Soon we
environment. I hope that this will be just as inspiring for
were able to conclude that when we pay
you as it was for us.
attention to safety and the environment, we are also paying attention to business economy. This resulted in 2011 in the construction of a new production plant for
Huber Claassen
plasticizers and various improvement projects in the
Site Director
02 Emerald Kalama Chemical | Safety & Environmental Report 2011
Our processes and products Emerald Kalama Chemical in Rotterdam is a global player in the field of benzoates. The production location produces a wide range of raw and auxiliary materials for application in the food and pharmaceutical industry, the beverage industry and for cosmetic, resin and adhesive manufacturers. Emerald Kalama Chemical has approximately 140 permanent employees and about 50 contractor employees.
Emerald Kalama Chemical in Rotterdam is a global
Benzaldehyde (Bald):
player in the field of benzoates. The production location
Benzaldehyde is used as a fragrance and flavour
produces a wide range of raw and auxiliary materials
ingredient in macaroons, pudding (almond flavour),
for application in the food and pharmaceutical industry,
soft drinks and various types of perfume (lily of the
the beverage industry and for cosmetic, resin and
valley, rose and jasmine). It is also used as a raw
adhesive manufacturers. Emerald Kalama Chemical has
material in the manufacture of dye for packaging
approximately 140 permanent employees and about
materials (malachite) , cough syrup (ephedrine) and
50 contractor employees.
in the production of medicines. Emerald Kalama
The products Benzaldehyde, Benzyl alcohol and Benzoic
Chemical is the largest producer of Benzaldehyde in
acid are created through an oxidation process resulting
the world.
from toluene and compressed air. A portion of the benzoic acid is upgraded through an additional purification step and
Benzoic acid (BZA): Purox B
sold as a liquid product, or after crystallization, as benzoic
Benzoic acid is used as a preservative in food and
acid flakes. Sodium benzoate is created by allowing the
cosmetics (E210) and as an additive to alkyd paints
benzoic acid to react with sodium hydroxide. All of these
to render the product easily spreadable, stronger and
products are ingredients, used to produce a wide range of
improved gloss. It is also used as a raw material for
products for industry and consumers.
plasticizers.
We have been applying the latest technology to produce the highest quality benzoic acid since 2002. This product
Sodium benzoate (NaB): Purox S
has since been sold under the brand name Purox B, while
Sodium benzoate is a natural product found in
sodium benzoate is sold under the brand name Purox S.
blueberries and it is used as a preservative (E211) in ‘light’ products such as soft drinks and sauces.
Benzaldehyde Tolueen oxidatie Benzylalcohol
Benzoëzuur Purox B Benzoëzuur Natronloog
Benzyl alcohol (Balc): This substance is applied in the paint industry as a solvent and as a raw material in the production of epoxy resins. Benzyl alcohol is also used in personal hygiene products such as shampoo, toothpaste and perfume.
Natriumbenzoaat Purox S Emerald Kalama Chemical | Safety & Environmental Report 2011 03
Environmental permit
Environmental management system
In 2011, Emerald Kalama Chemical started various
Emerald Kalama Chemical has had an
projects arising from the permit requirements as
environmental management system in place since
contained in the Environmental Management Act
1994. The current certification under the ISO
(EMA) and the Water Act. A short summary of the
14001:2004 standard is valid until January 2014.
main aspects is given below.
Various internal audits have been conducted for interim verification of the work processes in order
- RIO project phase 1: disconnection of
to continue to meet the requirements for the
uncontaminated rainwater from the process
environmental management system. It is thereby
sewer to relieve the water treatment process
determined whether the work processes meet the
and to reduce waterlogging on the terrain
requirements of the standard in practice, or to put
- Study into further reduction of benzene emissions - Started with the decontamination of past pollution in area 10A. - Several optimisations to the water treatment process - Started with a new maintenance and inspection programme of the process floors - The site of EKC has already submitted a
differently: to verify if the work is carried out as it is described. During the report year an accredited agency conducted an interim review of the environmental management system. No deviation from the standard was found. However, two areas of improvement were reported and dealt with in 2012: 1. Various tools were used within EKC to
renewed soil policy (Location Management
determine the environmental risks of the plant.
Plan for 2010-2015), which has been approved
A point of attention was that a link had to be
by the competent authority
created between the tools and the overview
- A permit has been requested from the competent authority for the construction and commissioning of the Multiple Purpose Plasticizer Plant (MP3), the demolition of the phenol tank (the tank was demolished last year) and the construction and commissioning of the carbon filtration unit.
04 Emerald Kalama Chemical | Safety & Environmental Report 2011
obtained as a result. 2. A clearer burden of proof was required in the internal audit reports.
Health and environmental action plan
OHSAS 18001 With a view to working conditions and safety, the
The year 2012 is mainly devoted to the
current safety manual was prepared in accordance
construction and start-up of the new Multiple
with OHSAS 18001. This is an internationally
Purpose Plasticizer Plant (MP3).
recognised standard in the field of working conditions and safety. The management system
Below is an overview of the key projects with
used is equivalent to ISO 14001 (environmental
regards to the environment:
management system).
RIO project
Safety day
The first two phases of the RIO project were
A safety day is being organised in 2012 for all
completed in 2012. This project is intended to
employees, whereby the subject of safety is
separate uncontaminated rain water from process
addressed in an interactive manner.
wastewater. Increasing waterlogging on the terrain will thereby be reduced and some strain will be
Safety instructions
relieved from the water treatment installation.
With regards to the transition from DSM Special Products to Emerald Kalama Chemical, the
Dissolved Air Flotation (DAF) unit
development of new safety instructions was
The DAF unit is intended for removing sludge
started with during the past year. During the
that is discharged from the anaerobic wastewater
course of 2012 these new safety instructions will
treatment to the aerobic wastewater treatment.
be introduced.
The ultimate goal is to improve the quality of the sludge in the aerobic system, (indirect) enhancement of the capacity and to avoid exceeding the limitations of the permit license regarding undissolved solids. Particle filtration Unit This project involves replacing the particle filtration unit of the process residue (tar) and natural gasfired boiler F-6005. The current particle filter (bag filter package) is no longer adequate and it is technically end of lifetime. The implementation of the proposed change is positive from an environmental perspective for reducing the emission of soot and dust particles.
Emerald Kalama Chemical | Safety & Environmental Report 2011 05
Nidal Hammoud Hassan
Less strain on the environment through the acquisition of a sludge centrifuge
“Water treatment is an issue that requires considerable attention,”
Air
stated Process Technologist, Nidal Hassan Hammoud. “It is an aspect of our business that does not produce any revenue, but we can
Production volume has decreased by
save money here. One such example is the RIO project. In the past
approximately 7% when compared to 2010. This
we processed all of the water in the water treatment plants. Now
decrease is mainly caused by a planned plant stop
clean rainwater is directly discharged into the Botlek. This reduces
of 4 weeks for maintenance activities. As a result
our water purification expenses.”
the production period was one month shorter than the previous year. The graphs also show a small
Another water purification project that cuts costs and allows for process
decrease in process-related emissions. There was
optimization is the investment in a sludge centrifuge. During the pu-
a limited increase with toluene, however, which
rification of waste water sludge is created in the treatment unit, which
was caused by several smaller disturbances.
is then processed externally. Hammoud: “Until recently this consisted of 96% water and only 4% sludge. In the sludge centrifuge sludge the sludge is concentrated to about 20%. This could lead to a significant reduction in transportation and processing costs. Moreover, the impact on the environmental is also considerably reduced.” A flotation unit was purchased in 2011. This unit, which separates sludge from the water, was taken into use this year and it can be used in future to process more wastewater. It became very clear at the end of 2011 that this is very important as we had to deal with issues in sludge leaching due to insufficient
Overview of diffusion emission (total) 30 25 20 15 10 5 0
Methane
capacity of the treatment plant, which resulted in a sludge overload. Hammoud: “We resolved the issue immediately. Since then we even are more consciously looking at preventing similar situations. We monitor the ‘health’ of the sludge three times a week. If it is found that problems could arise we can act quickly.
06 Emerald Kalama Chemical | Safety & Environmental Report 2011
■ 2006 ■ 2007 ■ 2008 ■ 2009 ■ 2010 ■ 2011
Toluene
Benzene
Total
Chris Stouten
MP3 expansion project: an enormous challenge
Total carbon dioxide levels in the air (in kton/year)
Project manager Chris Stouten was in charge of a number of
200
important projects for Emerald Kalama Chemical in 2011. One of
150
these was the MP3 expansion project. This installation for the
100
production of plasticizers will start operation in July 2012. “This is
50 0
quite a challenge ,” stated Stouten. “It’s a big investment for us and 2005
2006
2007
2008
2009
2010
2011
at the peak about 75 workers from the contractor will be involved. This will also require a lot of additional inspections to ensure that everything is going well.”
Nitrogen oxides in the air (in kton/year) 100 80
The plant for the production of plasticizers is a copy of the production
60
unit of Emerald Kalama Chemical in the US . Stouten said that during
40
the start-up he received assistance from his American colleagues. “We
20 0
are the first company in the Netherlands with such an installation, so 2005
2006
2007
2008
2009
2010
2011
help is certainly welcome.” Another project that required attention from the project manager, was the RIO project where are polluted wastewater
Toluene in the air (in kton/year)
and clean rainwater are separated. With the
2,5
application of this technique the load at the
2
water treatment plants was significantly
1,5
reduced.
1 0,5 0
Steam import is a third project. “Considerable 2005
2006
2007
2008
2009
2010
2011
heat is released by the AVR waste processor, including in the form of steam. We want to use this steam and to do so
Benzene in the air (in kton/year)
the construction of a steam pipe will start soon,” explained Stouten. “This
0,2 0,15
pipeline will be 2.8 kilometres long,
0,1
with a diameter of 50 centimetres.
0,05 0
We are the first company to be using 2005
2006
2007
2008
2009
2010
2011
steam from AVR with this new pipe, but it is expected that more companies will do so in the future. It is a wonderful project: we will need less fossil fuels for our existing boilers and as a result we will obtain a significant reduction in CO2 emissions.”
Emerald Kalama Chemical | Safety & Environmental Report 2011 07
Diana Schilperoord
Extra attention to safety with the MP3 project
There were various active projects at Emerald Kalama Chemical in
Water
2011. Safety Officer Diana Schilperoord was responsible for ensuring that safety remained in the back of everyone’s mind. The MP3 project,
In the period from September to November 2011 a
the realisation of a production plant for plasticizers, is one of the
problem occurred in the water treatment plant, caused
largest projects. “Various people from many companies are working
by an unusual event. An incidental overload of the
on this. It is therefore even more important for activities to be
wastewater treatment led to an explosive growth
coordinated so that everyone knows what the others will be doing.
of filamentous bacteria in the aerobic wastewater
This is the only way that safety risks can be reduced to a minimum.”
treatment plant. This led to five permit limitation exceedances of the prescribed calculated averages
Safety expert Schilperoord explained that the issue of safety is always
of undissolved components. The following process
on the agenda at weekly toolbox meetings. It is also always stressed for
conditions played a part here:
contractor employees that Emerald Kalama Chemical is not a “normal”
• high load;
company, or as Schilperoord put it: “A road worker must realize that he is
• shortage of nutrients;
not busy building a driveway for a house!” Extra guards were deployed for
• lack of oxygen.
the MP3 project and where one guard would normally be in place in other
The above has led to an increase in the annual total
areas, two were used here.
of floating particles by 86%. An additional amount
“We also held an extra safety inspection every day on top of the two safety inspection rounds per day,” explained Schilperoord. During such a safety inspection an Emerald representative
of wastewater was also processed externally due to these problems with water treatment. At the end of 2011 the water treatment plant was back under control and matters were back to normal.
and one of the contractors do the rounds to ensure that all of the work is being done in safe manner. Three inspections
CZV wastewater (in ton/year)
per day may seem excessive, but this is
80
not the case according to Schilperoord.
60
“Something was always found” in her experience. “You don’t only have to think of life-threatening situations, but
40 20 0
2005
2006
2007
2008
2009
2010
2011
2008
2009
2010
2011
also of smaller points of improvement or discussions. This includes areas such as housekeeping or the use of protective equipment. During such a safety inspection round the greatest aim is to keep the issue of safety fresh in the mind. It is all about the power of repetition.”
Floating particles (in ton/year) 12 10 8 6 4 2 0
08 Emerald Kalama Chemical | Safety & Environmental Report 2011
2005
2006
2007
Guus Schrijn
Keeping the issue of safety fresh in mind
In addition, the additional flow of waste water,
Guus Schrijn is licensed facilitator and project manager a senior
originating from a former project, was still not
operator and he often has to deal with the subject of safety. “I am
completely processed in the waste water plant. As
very strict in the observance of safety requirements,” he said. “My
a result, a part of this flow of waste water had to be
motto is always: “Do it safely or you don’t do it at all.” Younger
processed externally.
colleagues and company employees always need to be reminded of the possible dangers. We work in a chemical company, and no
In 2012 various actions were implemented to
matter how difficult it may be sometimes, you must never lose
optimise the functioning of the water treatment
sight of safety.”
process and also to relieve some of the pressure. The implementation of the aforementioned RIO
One example of a project that Schrijn is regularly in charge of is the
project and the installation of the DAF unit are some
cleaning of tanks. In total Emerald Kalama Chemical has more than 30
examples. A number of smaller projects were also
tanks, including 3 large ones. The large tanks are inspected once every
implemented for further improvement.
ten years by the inspection department. Schrijn: “I am responsible for preparing a schedule and a work plan in consultation with the
Soil
department of planning and logistics. The tanks must be empty or nearly empty and cleaned before
Incidents
people can enter them.”
In 2011 two limited soil contamination incidents were
During this and other projects, Schrijn has
reported to the authorities, which were immediately
extensive contact with the inspectors and work
cleaned up.
planners. During all discussions safety remains the most important issue. The project leader
Location management plan
considers it important that this topic must
In the framework of the Location Management Plan
always remain current. “If someone is unsure
(LMP) for 2010 - 2015, an agreement was reached
of not familiar with an issue, he/she must be
with the Competent Authority to report periodically
able to say so without hesitation. Rather
on the situation of historical soil pollution in critical
ask or check something a hundred times
areas. It has to be determined in these areas if there
than make a mistake once... “
is a question of spreading of the contamination. The biannual monitoring round took place in 2011 and the next round will be in 2013. Sanitation of Area 10A Soil sanitation in area 10A started in 2011 and it will take approximately three years to complete. About 100 lances were placed in a grid under the contamination in order to inject air into the contamination through the lances. The contamination is moved to the surface by the air, where it is converted by the added biofilm converted into water and carbon dioxide. Emerald Kalama Chemical | Safety & Environmental Report 2011 09
Maikel Poppelaars
Soil decontamination project to clean up benzene and toluene
“In 2011 we started with the decontamination of a part of our
Energy
terrain,” said Maikel Poppelaars, Environmental Engineer. “This was necessary because it concerns past pollution (from
In recent years, several projects have been
the seventies) of the first aquifer, which partly runs through our
implemented in order to further improve the
terrain. The installation is now finished and we have started
energy efficiency of our facilities, which have led to
the decontamination work. The project as a whole will take
significant environmental improvements.
approximately three years to complete.” During the past year energy consumption per The soil contamination mentioned by Poppelaars concerns the
tonne of product remained virtually unchanged
compounds benzene and toluene. Fortunately these substances can be
compared to 2010.
broken down with the application of a biofilm in the top 40 cm of the soil. To bring the contamination to the surface, air is injected into the
Waste
soil. Under these aerobic conditions harmful substances are broken down into carbon dioxide and water. Poppelaars: “The clean-up will
An active flow of waste policy has been used
take about three years to complete. This may seem long, but we will
on location for a number of years already. In
not even notice anything. We will regularly check
addition the developed waste prevention plan was
that to ensure that the biofilm does not contain any
approved by DCMR in 2011. This plan is intended
benzene or toluene as the pollution will then be
to further reduce the amount of waste generated
released into the air. During the initial stages this
on the site. All of the efforts taken have resulted
inspection took place every two weeks. Since no
in a reduction of the amount of standard waste
contamination was detected, inspection will now only take place every six months. This
and material to be incinerated. The total volume of waste has increased, however. This was caused
way we can keep our finger on the pulse.”
by problems with water treatment, which required
This environmental engineer is also
an amount of wastewater to be processed
involved with keeping the environmental
externally.
management system ISO 14001 up-todate, which is used to determine the
External processing of off-spec material was
environmental risks of the company
further reduced in 2011. This became possible
and to take measures when necessary
as a result of an active search process for clients
in order to keep it to a minimum. Poppelaars: “We have completed several projects to this end, such as achieving negligible soil contamination risk of the processing floor, optimisation of water purification and the engineering construction of a filter installation in the flue gases of a combustion boiler.”
10 Emerald Kalama Chemical | Safety & Environmental Report 2011
that can use the material and by producing less off-spec. Options were also considered in consultation with the customer to broaden the specification of products.
Irregularities and incidents Accidents
Incidents
Two accidents (OSHA) occurred during the
In 2011 eleven incidents had to be reported to the
past year with one accident resulting in medical
competent authority. This was an increase over the
treatment and one in absenteeism from work.
previous year, which can be largely related to the
The number of first-aid accidents increased when
temporary malfunctioning of the waste water plant.
compared to 2010. The graph below shows the
The graph below shows the trend of environment
trend of accidents, along with the targets for 2012.
incidents, along with the targets for 2012.
Overview of reports to the authorities 12 10
Overview of first aid and OSHA accidents
9 8
20
7
16
6
12
5
8
3
4 2
4 0
1 2005
2006
2007
2008
2009
2010
2011
2012
0
2005 2006 2007 2008 2009 2010 2011 2012
â– First aid â– OSHA
In 2011 the number of VGM (Safety, Health and
The causes of the above accidents and incidents
the Environment) registrations and near-misses
are always thoroughly analysed by EKC. The
recorded in the incident register increased and 780
main lessons from the analysis of accidents and
safety management audits were conducted.
incidents are incorporated into an action plan with measures to prevent accidents and incidents.
Emerald Kalama Chemical | Safety & Environmental Report 2011 11
Emerald Kalama Chemical Montrealweg 15 Havennummer 4322 3197 KH Rotterdam-Botlek, The Netherlands PO Box 1021 3180 AA Rozenburg, The Netherlands Colophon This public report contains a summary of our official Âe nvironmental report. Edition Emerald Performance Materials Design SD Communicatie, Rotterdam Photography Wim van der Spiegel Interviews Anita Schregardus Printed by De Swart Copyright Š 2012 All rights reserved. Interested parties can request the official report by contacting John Mol. E-Mail: john.mol@emeraldmaterials.com T: +31 (0)181 249 386