1. 50 • November 2012 Chemical Engineering World
FeaturesCEW
M
aterial handling embraces the basic
operations in connection with the
movement of bulk, packaged and
individual products in a semi-solid or solid
state by means of gravity manually or
power-actuated equipment and within the
limits of individual producing, fabricating,
processing or service establishment.
Since injuries may result from improperly
handling and storing materials, it is important
to be aware of incidents that may occur from
unsafe or improperly handled equipment
and improper work practices when handling
and storing materials. Extent literature
indicated that approximately 30 per cent of
all occupational accidents occur in materials
handling. Chemical compatibility is an
important factor when handling chemicals
and packaging chemical wastes. Unexpected
reactions due to incompatibility have caused
serious injuries and severe damage to
equipment and buildings in the past
INTRODUCTION
„Material handling embraces the basics
operations in connection with the movement
of bulk, packaged and individual products
in a semi-solid or solid state by means
of gravity manually or power-actuated
Material Handling Safety Measures
The purpose of this article is to study
safety conditions and procedures to
prevent work risks caused by the
handling of chemical materials. In
this direction, this paper presents
a general description of the work
system of materials handling and its
elements and safety characteristics
and offers some examples of accident
prevention possibilities.
equipment and within the limits of individual
producing, fabricating, processing or
service establishment (Telsang M., 2010).‰
Unfortunately, the improper handling and
storing of materials often result in costly
injuries. Since injuries may result from
improperly handling and storing materials,
it is important to be aware of incidents
that may occur from unsafe or improperly
handled equipment and improper work
practices when handling and storing
materials (OSHA, 2002).
The basic goal of this article is to ensure
the extent that worker is aware about the
potential work hazards during handling of
chemicals and the ways to recognise them
and to protect themselves. This paper
is designed to help reduce the possible
incidence and injuries due to handling of
chemicals in the chemical industry.
Elements of Material Handling
The elements of material handling are as
follows as given in „Industrial Engineering
and Production Management‰ book by
Martend Telsang.
1. Motion: Move in most economic, safe and
efficient manner
2. Time: Provide materials on time
3. Quantity: Ensure supply of correct quantity
continuously at each manufacturing
organisation
4. Space: Ensure optimum use of space
(Telsang M., 2010).
Hazards
Hazards arising from human activity and
interaction with social, environmental
and technological systems are kind of
technological hazard. Australian industry
standards define a hazard as „A source or a
situation with a potential for harm in terms of
human injury or ill-health, damage to property,
damage to the environment, or a combination
of these (Desai Dushyant 2008).‰
In chemical processes: ÂIt is the combination
of a hazardous material, an operating
environment, and certain unplanned
events that could result in an accident
(Macdonald Dave, 2004).Ê
Different Types of Chemical Hazards
Chemicals cause health hazards if they are:
1. Target organ chemicals·they injure
specific organs in your body.
2. Toxic·cause illness or death. Toxic
chemicals are determined on the basis

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The label is the key to organising chemical products for storage. Tanks
and container should be identified with signs indicating the name of
the chemical product. No containers or cylinders of compressed gases
should be accepted without ensuring identifying labels.
of tests on laboratory animals that are
exposed to a given chemical through
inhalation, ingestion, or skin absorption.
3. Corrosive·can destroy your skin or eyes.
4. Irritants·cause reversible inflammation
when they make contact with living tissue.
5. Carcinogens·have been known to cause
cancer or have the potential of causing
cancer in humans.
6. Sensitisers·can cause an allergic reaction
on subsequent repeated exposures.
7. Neurotoxins·produce toxic effects
primarily on the central nervous system.
8. Nephrotoxins·Produce toxic effects on
kidneys.
9. Reproductive toxins·have the potential to
adversely affect the reproductive system.
10. Hepatotoxins·can adversely affect the liver.
11. Lung hazards·can irritate or damage
pulmonary tissue.
12. Skin hazards·can affect the dermal layer of
the body, resulting in rashes and irritation.
13. Eye hazards·can adversely affect the eye
or diminish the visual capacity of a human.
14. Blood system hazards·caused by
chemicals that decrease the hemoglobin
function; depriving of oxygen. Chemicals
that present physical hazards and are
covered by the Hazard Communication
Standard include combustible liquids,
flammable materials, all compressed
gases, explosives, organic peroxides,
oxidizers, pyrophoric materials, unstable
materials, and water-reactive materials.
15. Fire hazards·chemicals that have the
potential for creating a fire or aiding
an ongoing fire. These materials are
flammables, combustibles, oxidisers,
pyrophoric materials and organic
peroxides. Some of these material
are Flammables·catch fire quickly;
Oxidisers·capable of initiating or
promoting a fire in other compounds
by the release of oxygen or other
gases; Pyrophoric materials·can be
ignited as a result of contact with
oxygen in the absence of an ignition
source at temperature below 130 F;
Organic peroxides·contain both fuel,
in the form of carbon, and excess
oxygen, and thus can pose a severe
fire hazard; Compressed gases·all
compressed gases pose a physical
hazard; Explosive materials·can be
decomposed in a violent chemical
reaction with the production of heat,
pressure, and large quantities of gas;
Unstable materials·certain compounds
in their pure form can undergo vigorous
decomposition or polymerisation
under moderate conditions of shock,
pressure, or temperature; Water-reactive
compounds·can react vigorously with
water to produce a toxic or flammable
gas (abctlc.com, 2008), etc
LITERATURE REVIEW
Material handling represents about
50 per cent of production-cycle time, an equal
amount of the conversion cost, and about
25 per cent of product cost. It is one of the
few areas where costs can be substantially
reduced (Gopalkrishnan P. 2005).
Health and safety is, for many managers,
a difficult subject. It requires a broad
knowledge of many disciplines, such
as psychology, engineering, chemistry,
ergonomics and medicine, each of which is
a subject of study in its own right (Stranks
Jeremy, 8th
edition).
According to several studies and statistics,
approximately 30 per cent of all occupational
accidents occur in materials handling. This
article presents a general description of
the work system of materials handling and
its elements and safety characteristics
and offers some examples of accident
prevention possibilities (Hakkinen
Kari, 1981).
The Problem Areas in Material Handling
The problems are arises in Material
Handling Safety in chemical industry;
1. due to lack of safety awareness
and safety.
2. training of the employees.
3. due to less frequency of safety audit by
the safety officer.
4. improper co-ordination between safety
department and other departments.
drug we consume- we are inextricably linked
to it (KPMG India, Survey Report 2010).
Chemical Compatibility
Chemical compatibility is an important factor
when handling chemicals and packaging
chemical wastes. Unexpected reactions
due to incompatibility have caused serious
injuries and severe damage to equipment
and buildings in the past. A well maintained
inventory and labelling system is the best
method of ensuring hazardous materials
are being managed effectively and safely.
The inventory process allows one to check
whether chemicals are being stored properly,
and if not, provides an opportunity to
segregate according to their respective
hazard classes.
In general, chemicals can be separated into
the following hazard classes:
1. Flammable Liquids
2. Oxidisers
3. Reducers
4. Concentrated Acids
5. Concentrated Bases
6. Water-reactives
7. Toxic
8. Peroxidisables
9. Pyrophorics
10. Compressed Gas Cylinders
11. Inorganic Solids
12. Organic Solids
13. Non Flammable Liquids
Ideally, each group above should be
stored on a separate shelf with the most
hazardous combinations spaced well
apart. Flammable liquids must be stored
in an approved flammable storage cabinet
The Indian Chemical Industry
The Indian chemical industry is an integral
component of the Indian economy,
contributing around 6.7 per cent of the Indian
GDP. It touches our lives in many different
ways. Whether it is thermoplastic furniture
we use or a synthetic garment we wear or a
or explosion proof refrigerator (The
University of Western Ontario, 2009).
Although some chemicals are harmless,
most of them are hazards to personnel
safety and must be closely guarded. An
injury caused by chemical exposure can
be extremely serious.

3. 52 • November 2012 Chemical Engineering World
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Protection against chemical exposure or
contact by personnel can be accomplished
to a great degree in the design stage of
an installation. Further protection in the
form of protective clothing, respiratory
protective devices, or emergencies
devices is essential (Ireson and Grant
Second Edition).
Labeling and Re-labeling Requirements
The label is the key to organising chemical
products for storage. Tanks and container
should be identified with signs indicating
the name of the chemical product. No
containers or cylinders of compressed
gases should be accepted without ensuring
identifying labels such as Identification of
content; Description of principle hazard (eg,
flammable liquid); Precautions to minimise
hazards and prevent accident; Correct first
aid procedures; Correct procedures for
cleaning up spills; and Special instructions
to medical personnel in case of an accident
(ILO, Volume 3).
at least annually. Chemicals with expired
shelf lives and deteriorated or leaking
container should be disposed of safely. A
Âfirst in, first outÊ system of keeping stock
should be used.
The storage of dangerous substances
should be supervised by a competent,
trained person. All workers required
entering storage areas should be fully
trained in appropriate safe work practices,
and a periodic inspection of all storage
areas should be carried out by a safety
officer. A fire alarm should be situated in
or near the outside of the storage premises.
It is recommended that persons should not
work alone in a storage area containing
toxic substances. Chemical storage areas
should be located away from process
areas, occupied buildings and other storage
areas. In addition, they should not be in
proximity of fixed sources of ignition (ILO
Encyclopedia Vol. 3)
Case Study of Medilux Laboratories Pvt
Ltd Pithampur
Medilux is serving as back end support to
Pharma industry across the globe since
1988. The plant of Medilux Laboratories
is located at Pithampur, Madhya Pradesh,
well connected from all corners of India.
They used some hazardous material
including solvent (Flash Point less than
32 degree) which is very hazardous as
well as very sensitive to catch the fire
because flash point is less than 13 degree.
The list of some hazardous materials
which is used in plant are Mono Choloro
Benzene (MCB), Thionyl Chloride, Meta
Toluidine and Ethyl aceto acetate. During
visit of Medilux Laboratories Pvt Ltd some
unsafe condition and unsafe act is found
in handling of chemical which is hazardous
for human as well as plant. Couples of the
unsafe conditions which were identified
during visit were 1. Flame proof exhaust fan
is not provided in the solvent storage area;
2. Compatible storage is not provided for
HAZMAT; 3. Hydrant system is not installed
as per the TAC; 4. The space between
boiler room and D.G. room is adjacent to
the solvent storage area; 5. Mobile phone is
prohibited in solvent storage area but some
workers donÊt bother about this and use
mobile phone in solvent storage area; and
6. Many labours do not use PPE during the
manually handling of chemicals.
Suggestions for Improvement
1. Flame proof Exhaust fan should be
provided in case of emergency when high
rate of fumes release.
2. Compatible storage should be provided
for HAZMAT.
3. Fire extinguishers should be install as
per IS: 2190.
4. Hydrant system should be installed as
per TAC for effective fire protection.
5. During visit it is found that boiler room and
D.G. room is closed to the solvent storage
area and it is suggested that solvent
storage area should be away from boiler
room and D.G. room (At least 30 m).
6. Solvent storage should be isolated and
storing of other chemicals with solvent
should be avoided.
7. Highly reactive chemicals should be
stored separately.
8. During handling of hazardous chemicals
use of personnel protective equipment
should be in practiced by the workers.
All workers required entering storage areas should be fully trained
in appropriate safe work practices, and a periodic inspection of all
storage areas should be carried out by a safety officer. A fire alarm
should be situated in or near the outside of the storage premises.
Safety Management in Handling and
Storage of Chemicals
Before a new hazardous substance is
received for storage, information concerning
its correct handling should be provided to all
users. Planning and maintaining of storage
areas are necessary to avoid material
losses, accidents and disasters. Good
housekeeping is essential, and special
attention should be paid to incompatible
substances, suitable location of products
and climatic conditions.
Written instructions of storage practices
should be provided, and the chemicals
Material Safety Data Sheets (MSDSs) should
be available in storage areas. Locations of
the different classes of chemicals should be
illustrated in a storage map and in a chemical
register. All substance should be received
at a central location for distribution to the
storerooms, stockrooms and laboratories.
A central receiving area is also helpful in
monitoring substances that may eventually
enter the waste disposal system. Stored
chemicals should be examined periodically,
OBJECTIVE
The objective of this research is to study the
principles and practices of material handling;
to study the various risks during material
handling; to analyse the accident rate during
material handling; and to evaluate the level
of prevailing safety measures for material
handling in chemical industry.
METHODOLOGY
Hazard Identification/Risk Assessment
Hazards analysis is done by observing
practical hazard analysis during industry
visit. A site investigation easily can produce
a huge amount of data, necessitating that
steps be taken in the hazard identification
stage to facilitate subsequent analysis. The
purpose of Risk assessment is to identify the
unsafe condition and unsafe act during the
material handling operation in the chemical
industry. Risk assessment requires a clear
understanding of what chemicals are present
at a site, their concentration and spatial
distribution, and how they could move in
the environment from the site to potential
receptor points (Buckingham Phillip L. 2010).

4. November 2012 • 53Chemical Engineering World
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9. Workers should be trained of handling of hazardous chemicals
and also aware of chemicals properties which they are
daily handling.
CONCLUSION
Material handling is a very sensitive issue in the chemical industry
because it deals with various types of chemicals which may be
hazardous or non-hazardous but always requires safe handling
during the plant operation and also requires following various safety
standards. These standards require employee training, personal
protective equipment and written procedures, programmes and
plans for insuring worker safety when working with hazardous
material or in hazardous work environment.
References
[1] U.S. Department of Labor, OSHA 2236, 2002 (Revised) Materials
Handling and Storage, Chapter 1, pp.1
[2] Kari Hakkinen, MSc (Eng), Safety in Material Handling (1981)
[3] Martend Telsang, 2010, Industrial Engineering and Production
Management, Chapter 9, pp. 127-128
[4] Dave Macdonald, 2004, Practical Industrial Safety, Risk Assessment
and Shutdown Systems, Chapter 2, pp. 34
[5] Jeremy Stranks, The ManagerÊs Guide to Health & Safety at Work (8th
edition)
[6] The University of Western Ontario, HAZARDOUS MATERIALS
MANAGEMENT HANDBOOK (Revised Nov. 2009), Chapter 5, pp. 6.
[7] KPMG India (Survey Report) 2010, The Indian chemical industry, p.p. 47
[8] P. Gopalkrishnan, Handbook of Material Management (Edition 2005),
p.p. 131
[9] ILO Encyclopedia of Occupational Health and Safety (Vol.3) p.p. 61.10
[10] W. Grant Ireson and Eugene L. Grant, Handbook of Industrial
Engineering and Management (Second Edition) p.p. 131
[11] Dushyant Desai, Industrial Risk Assessment for Planning and
Emergency Response: A case of Ahmedabad (2008), p.p.7
[12] Buckingham Phillip L., Hazardous Waste Management (2nd Edition),
pp.869
[13]Technical Learning College, Payson, (2008), „Chemical Handling‰
browsed on 14th March from http://www.abctlc.com/PDF/Chemical%20
Handling%20Assignment.pdf
Author Details
Md Sadik Khan
Risk Engineer
Universal Sompo General Insurance Co Ltd
Email: khansadik2211@gmail.com
Dr A Dalpati
Associate Professor
Department of Industrial and Production Engineering
SGSITS
Email: adalpati@gmail.com