TABLE OF CONTENTS
Page
1.0 INTRODUCTION. . . . . . . . . . . . . . . . . . . . 1.1
2.0 OVERVIEW OF THE REGULATORY REQUIREMENTS UNDER
CONSIDERATION BY OSHA . . . . . . . . . . . . . . . 2.1
2.1 OSHA's Possible Revisions to the Current Process Safety
Management Standard. . . . . . . . . . . . . . 2.1
2.2 Alternative Approaches Under Consideration . . 2.9
2.3 Current OSHA Standards Addressing the Safe
Handling of Highly Toxic and Reactive Chemicals2.9
2.4 EPA's RMP Rule . . . . . . . . . . . . . . . .2.11
3.0 CHEMICAL AND INDUSTRY PROFILE . . . . . . . . . . . 3.1
3.1 Introduction . . . . . . . . . . . . . . . . . 3.1
3.2 Overview of Chemical Producers, Users, and Hazards3.1
3.2.1 Group 1: Acetyl Chloride Chemicals. . .3.42
3.2.1.1 Chloroacetyl Chloride
(CAS Number: [79-04-9]) . . . .3.42
3.2.1.2 Dichloroacetyl Chloride
(CAS Number: [79-36-7]). . . .3.43
3.2.2 Group 2: Acrylic Chemicals. . . . . . .3.44
3.2.2.1 Acrylamide
(CAS Number: [79-06-1]) . . . .3.44
3.2.2.2 Acrylic Acid
(CAS Number: [79-10-7]) . . . .3.46
3.2.2.3 Butyl Acrylate
(n-Butyl Acrylate - CAS Number: [141-32-2])
(iso-Butyl Acrylate - CAS Number: [106-63-8])
(sec-Butyl Acrylate - CAS Number: [2998-08-5])
(tert-Butyl Acrylate - CAS Number: [1663-39-4])3.48
3.2.2.4 2-Ethylhexyl Acrylate
(CAS Number: [103-11-7]). . . .3.50
3.2.2.5 Methacrylic Acid
(CAS Number: [79-41-4]) . . . .3.50
3.2.3 Group 3: Aluminum Chemicals . . . . . .3.52
3.2.3.1 Aluminum Chloride, Anhydrous
(CAS Number: [7446-70-0]) . . .3.52
3.2.3.2 Aluminum Phosphide
(CAS Number: [20859-73-8]). . .3.54
3.2.3.3 Aluminum Powder, Uncoated
(CAS Number: [7429-90-5]) . . .3.56
3.2.3.4 Diethylaluminum Chloride
(CAS Number: [96-10-6]) . . . .3.57
3.2.4 Group 4: Anhydride Chemicals. . . . . .3.57
3.2.4.1 Acetic Anhydride
(CAS Number: [108-24-7]). . . .3.57
3.2.4.2 Maleic Anhydride
(CAS Number: [108-31-6]). . . .3.59
3.2.4.3 Propionic Anhydride
(CAS Number: [123-62-6]). . . .3.61
3.2.5 Group 5: Antimony Chemicals . . . . . .3.62
3.2.5.1 Antimony Pentachloride, liquid
(CAS Number: [7647-18-9]) . . .3.62
3.2.5.2 Antimony Pentafluoride
(CAS Number: [7783-70-2]) . . .3.64
3.2.5.3 Antimony Sulfide
(CAS Number: 1315-04-4]). . . .3.65
3.2.6 Group 6: Aromatic Chemicals . . . . . .3.66
3.2.6.1 Benzoyl Chloride
(CAS Number: [98-88-4]) . . . .3.66
3.2.6.2 Benzyl Chloride
(CAS Number: [100-44-7]). . . .3.67
3.2.6.3 Divinylbenzene
(Mixed - CAS Number: [1321-74-0])
(o-Divinylbenzene - CAS Number: --)
(m-Divinylbenzene - CAS Number: [108-57-6])
(p-Divinylbenzene - CAS Number: [105-06-6])3.69
3.2.6.4 Nitroanilines
(Mixed - CAS Number: [29757-24-2])
(o-Nitroaniline - CAS Number: [88-74-4])
(m-Nitroaniline - CAS Number: [99-09-2])
(n-Nitroaniline - CAS Number: [645-55-6])
(p-Nitroaniline - CAS Number: [100-01-6])3.70
3.2.6.5 p-Nitrophenol
(CAS Number: [100-02-7]). . . .3.71
3.2.6.6 Picric Acid
(CAS Number: [88-89-1]) . . . .3.72
3.2.6.7 Vinyl Toluene
(Mixed - CAS Number: [25013-15-4])
(o-Vinyl Toluene - CAS Number: [611-15-4])
(m-Vinyl Toluene - CAS Number: [100-80-1])
(p-Vinyl Toluene - CAS Number: [622-97-9])3.73
3.2.7 Group 7: Boron Chemicals. . . . . . . .3.74
3.2.7.1 Boron Tribromide
(CAS Number: [10294-33-4]). . .3.74
3.2.7.2 Decaborane
(CAS Number: [17702-41-9]). . .3.75
3.2.8 Group 8: Calcium Chemicals. . . . . . .3.76
3.2.8.1 Calcium
(CAS Number: [7440-70-2]) . . .3.76
3.2.8.2 Calcium Carbide
(CAS Number: [75-20-7]) . . . .3.76
3.2.8.3 Calcium Cyanide
(CAS Number: [592-01-8]). . . .3.78
3.2.8.4 Calcium Hypochlorite
(CAS Number: [7778-54-3]) . . .3.79
3.2.8.5 Calcium Oxide
(CAS Number: [1305-78-8]) . . .3.81
3.2.9 Group 9: Chromium Chemicals . . . . . .3.83
3.2.9.1 Ammonium Dichromate
(CAS Number: [7789-09-5]) . . .3.83
3.2.9.2 Chromic Acid, solid
(CAS Number: [1333-82-0]) . . .3.84
3.2.9.3 Chromium Oxychloride
(CAS Number: [14977-61-8]). . .3.85
3.2.10 Group 10: Cyanohydrin Chemicals . . . .3.86
3.2.10.1 Acetone Cyanohydrin
(CAS Number: [75-86-5]) . . . .3.86
3.2.10.2 Ethylene Cyanohydrin
(CAS Number: [109-78-4]). . . .3.88
3.2.11 Group 11: Diisocyanate Chemicals. . . .3.88
3.2.11.1 Isophorone Diisocyanate
(CAS Number: [4098-71-9]) . . .3.88
3.2.11.2 Toluene Diisocyanate
(Mixed - CAS Number: [26471-62-5])
(2,4-Toluene Diisocyanate -
CAS Number: [584-84-9])
(2,6-Toluene Diisocyanate -
CAS Number: [91-08-7]). . . . .3.89
3.2.12 Group 12: Gallium Chemicals . . . . . .3.91
3.2.12.1 Gallium Arsenide
(CAS Number: [1303-00-0]) . . .3.91
3.2.12.2 Gallium Phosphide
(CAS Number: [12063-9-88]). . .3.93
3.2.12.3 Gallium Trichloride
(CAS Number: [13450-90-3]). . .3.93
3.2.13 Group 13: Lithium Chemicals . . . . . .3.94
3.2.13.1 Butyllithium
(n-Butyllithium - CAS Number: [109-72-8])
(sec-Butyllithium - CAS Number: [598-30-1])
(tert-Butyllithium - CAS Number: [594-19-4])3.94
3.2.13.2 Lithium
(CAS Number: [7439-93-2]) . . .3.96
3.2.13.3 Lithium Aluminum Hydride
(CAS Number: [16853-85-3]). . .3.97
3.2.13.4 Lithium Hydride
(CAS Number: [7580-67-8]) . . .3.98
3.2.14 Group 14: Nitrobenzene and Toluene Chemicals3.98
3.2.14.1 Chlorodinitrobenzenes
(Mixed - CAS Number: [25567-67-3])
(1-Chloro-2,4-dinitrobenzene -
CAS Number: [97-00-7])
(1-Chloro-2,6-dinitrobenzene -
CAS Number: [606-21-3])
(1-Chloro-3,4-dinitrobenzene -
CAS Number: [610-40-2]) . . . .3.99
3.2.14.2 Dinitrobenzenes
(Mixed - CAS Number: [25154-54-5])
(o-Dinitrobenzene - CAS Number: [528-29-0])
(m-Dinitrobenzene - CAS Number: [99-65-0])
(p-Dinitrobenzene - CAS Number: [100-25-4])3.100
3.2.14.3 Dinitrotoluenes
(Mixed - CAS Number: [25321-14-6])
(2,3-Dinitrotoluene - CAS Number: [602-01-7])
(2,4-Dinitrotoluene - CAS Number: [121-14-2])
(2,5-Dinitrotoluene - CAS Number: [619-15-8])
(2,6-Dinitrotoluene - CAS Number: [606-20-2])
(3,4-Dinitrotoluene - CAS Number: [610-39-9])
(3,5-Dinitrotoluene - CAS Number: [618-85-9])3.100
3.2.14.4 Nitrobenzene
(CAS Number: [98-95-3]) . . . 3.102
3.2.14.5 Nitrotoluenes
(Mixed - CAS Number: [1321-12-6])
(o-Nitrotoluene - CAS Number: [88-72-2])
(m-Nitrotoluene - CAS Number: [99-08-1])
(p-Nitrotoluene - CAS Number: [99-99-0])3.104
3.2.15 Group 15: Nitrogen Chemicals. . . . . 3.105
3.2.15.1 Adiponitrile
(CAS Number: [111-69-3]). . . 3.105
3.2.15.2 Ammonium Nitrate
(CAS Number: [6484-52-2]) . . 3.106
3.2.15.3 Hydrazine, anhydrous
(CAS Number: [302-01-02]) . . 3.108
3.2.15.4 Nitric Acid, fuming
(CAS Number: [52583-42-3]). . 3.109
3.2.16 Group 16: Peroxide Chemicals. . . . . 3.111
3.2.16.1 Hydrogen Peroxide
(CAS Number: [7722-84-1]) . . 3.111
3.2.16.2 Potassium Peroxide
(CAS Number: [17014-71-0]). . 3.115
3.2.16.3 Sodium Peroxide
(CAS Number: [1313-60-6]) . . 3.115
3.2.17 Group 17: Phosphorus Chemicals. . . . 3.116
3.2.17.1 Phosphorus Pentachloride
(CAS Number: [10026-13-8]). . 3.116
3.2.17.2 Phosphorus Pentasulfide
(CAS Number: [1314-80-3]) . . 3.117
3.2.17.3 Phosphorus Tribromide
(CAS Number: [7789-60-8]) . . 3.119
3.2.17.4 Phosphorus, amorphous
(CAS Number: [7723-14-0]) . . 3.120
3.2.17.5 Phosphorus, white
(CAS Number: [7723-14-0]) . . 3.121
3.2.17.6 Zinc Phosphide
(CAS Number: [1314-84-7]) . . 3.125
3.2.18 Group 18: Potassium and Sodium Chemicals3.125
3.2.18.1 Potassium
(CAS Number: [7440-09-7]) . . 3.125
3.2.18.2 Potassium Hydroxide
(CAS Number: [1310-58-3]) . . 3.126
3.2.18.3 Sodium
(CAS Number: [7440-23-5]) . . 3.128
3.2.18.4 Sodium Chlorite
(CAS Number: [7758-19-2]) . . 3.130
3.2.18.5 Sodium Hydride
(CAS Number: [7646-69-7]) . . 3.131
3.2.18.6 Sodium Hydroxide
(CAS Number: [1310-73-2]) . . 3.132
3.2.18.7 Sodium-Potassium Alloys
(CAS Number: [11135-81-2]). . 3.135
3.2.19 Group 19: Silane Chemicals. . . . . . 3.135
3.2.19.1 Propyltrichlorosilane
(CAS Number: [141-57-1]). . . 3.135
3.2.19.2 Silane, (4-Aminobutyl)-Diethoxymethyl
(CAS Number: [3037-72-7]) . . 3.136
3.2.20 Group 20: Sulfur and Similar Chemicals3.136
3.2.20.1 Chlorosulfonic Acid
(CAS Number: [7790-94-5]) . . 3.136
3.2.20.2 Diethyl Sulfate
(CAS Number: [64-67-5]) . . . 3.137
3.2.20.3 Sodium Dithionite
(CAS Number: [7775-14-6]) . . 3.138
3.2.20.4 Sodium Sulfide, anhydrous
(CAS Number: [1313-82-2]) . . 3.139
3.2.20.5 Sulfur Chlorides/Dichloride
(Sulfur Monochloride -
CAS Number: [10025-67-9])
(Sulfur Dichloride -
CAS Number: [10545-99-1]) . . 3.140
3.2.20.6 Sulfuric Acid
(CAS Number: [7664-93-9]) . . 3.141
3.2.20.7 Sulfuryl Chloride
(CAS Number: [7791-25-5]) . . 3.144
3.2.21 Group 21: Tetra-Halogen Chemicals . . 3.144
3.2.21.1 Silicon Tetrachloride
(CAS Number: [10026-04-7]). . 3.144
3.2.21.2 Silicon Tetrafluoride
(CAS Number: [7783-61-1]) . . 3.145
3.2.21.3 Stannic Chloride, anhydrous
(CAS Number: [7646-78-8]) . . 3.146
3.2.21.4 Titanium Tetrachloride
(CAS Number: [7550-45-0]) . . 3.146
3.2.21.5 Vanadium Tetrachloride
(CAS Number: [7632-51-1]) . . 3.147
3.2.21.6 Zirconium Tetrachloride
(CAS Number: [10026-11-6]). . 3.148
3.2.22 Group 22: Triazinetrione Chemicals
(Chlorinated Isocyanurates) . . . . . . 3.149
3.2.22.1 Monochloro-s-triazinetrione Acid
(CAS Number: [13057-78-8]). . 3.150
3.2.22.2 mono-Trichloro-tetra-(monopotassium
dichloro)-penta-s-triazinetrione
(CAS Number: [64474-06-2]). . 3.150
3.2.22.3 Potassium Dichloro-s-triazinetrione
(CAS Number: [2244-21-5]) . . 3.150
3.2.22.4 Sodium Dichloro-s-triazinetrione
(Anhydrous - CAS Number: [2893-78-9])
(Dihydrate - CAS Number: [51580-86-0])
(Monohydrate - CAS Number: [52671-45-1])3.151
3.2.22.5 Trichloroisocyanuric Acid
(CAS Number: [87-90-1]) . . . 3.151
3.2.23 Group 23: Miscellaneous Metal Chemicals3.152
3.2.23.1 Arsenic Pentafluoride
(CAS Number: [7784-36-3]) . . 3.152
3.2.23.2 Barium Chlorate
(CAS Number: [13477-00-4]). . 3.153
3.2.23.3 Magnesium or Magnesium Alloys
(CAS Number: [7439-95-4]) . . 3.154
3.2.23.4 Nickel Catalyst
(CAS Number: [7440-02-0]) . . 3.158
3.2.24 Group 24: Other Miscellaneous Chemicals3.160
3.2.24.1 Cyanogen Bromide
(CAS Number: [506-68-3]). . . 3.160
3.2.24.2 2,2-Dichlorodiethyl Ether
(CAS Number: [111-44-4]). . . 3.160
3.2.24.3 Diethyl Telluride
(CAS Number: [627-54-3]). . . 3.161
3.2.24.4 Perchloric Acid
(CAS Number: [7601-90-3]) . . 3.162
3.2.24.5 Tetrabromoethane
(CAS Number: [79-27-6]) . . . 3.162
3.3 Overview of Affected Industry Sectors. . . . 3.163
3.3.1 Estimates For Reactive Chemicals Not
In EPA's Toxics Release Inventory . . . 3.164
3.3.2 Estimates Based On EPA's Toxics Release Inventory3.179
3.3.3 Number of Affected SBREFA-Covered Firms For Reactive
Chemicals in EPA's Toxics Release Inventory3.200
4.0 ANALYSIS OF ACCIDENTS ASSOCIATED WITH REACTIVE
CHEMICALS . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Description of Accident Databases . . . . 4.1
4.1.1 IMIS Fatality/Catastrophe File. 4.2
4.1.2 Accidental Release Information Program (ARIP)4.7
4.1.3 The Census of Fatal Occupational Injuries (CFOI)4.13
4.2 Accident Analysis . . . . . . . . . . . .4.15
4.2.1 Analysis of the IMIS Data . . .4.15
4.2.2 Analysis of the ARIP Data . . .4.37
4.2.3 Analysis of the CFOI Data . . .4.49
4.2.4 Aggregate Estimates of Accidents, Fatalities,
and Injuries Involving the Reactive Chemicals4.55
4.2.5 Accidents Involving Reactive Chemicals Not Found
in the IMIS, ARIP, or CFOI Databases4.60
5.0 REFERENCES. . . . . . . . . . . . . . . . . . . . . 5.1
Appendix A: Detailed Tabulations of the Number of Plants Producing and/or Using
the 28 Reactive Chemicals Represented in the Toxics Release
Inventory (TRI) Database. . . . . . . . . A.1
Appendix B: Estimation of the Number of Plants and Firms With Fewer Than 10
Employees Producing and/or Using the 28 Reactive Chemicals
Represented in the Toxics Release Inventory (TRI) DatabaseB.1
Appendix C: Detailed Tabulations of Accident Data Involving the 99 Reactive
Chemicals . . . . . . . . . . . . . . . . C.1