Page 130 - CW E-Magazine (17-12-2024)

Point of View

reactions, which have the potential to get out of control, causing grave damage to life and property. Many hazards can also be minimised
right at the process design stage by substitution of one chemical reagent by another or at times modifying the manufacturing route.

Converting batch processes to continuous ones is widely recognised today as another way to better process safety (besides other
benefits), even for low volume fine chemicals that have traditionally been made in batch reactors that have seen little fundamental design
changes over decades. The CSIR-National Chemical Laboratory (CSIR-NCL), in Pune, has built considerable expertise in this area, and
catalysed some migration to this manufacturing option, but much more is needed. Process intensification, which involves use of novel
equipment and methods, has allowed miniaturisation of chemical plants to surprisingly small size and so provided a safer production
option even for carrying out hazardous chemistry.

Challenges in India
India’s chemical industry is unique in the sheer numbers of SMEs that operate. In most, there are no dedicated SHE personnel, and
regular training is not imparted to operators and supervisors on hazardous operations. In many, operations are managed by unskilled or
semi-skilled persons or persons with limited technical knowledge. Outsourcing critical operations to third-party contractors is not uncommon
and adds another dimension to the problem.

These limitations need to be overcome through appropriate policy interventions, fiscal support by financial institutions to aid modernisation,
and hand-holding, especially by larger units that have much to share by way of technical knowhow. In many industries, lack of financial
resources is not the primary hurdle. As a reputed consultant to the industry here pointed out, much progress towards inculcating a culture
of safety (process and behavioural) can be achieved by rephrasing the challenge and making out the business case to invest in safety. In
other words, the proposition needs to switch from discussing the cost of safety and incidents to discussing the value of safety-focus on
business. Avoided penalties and shutdowns are two obvious benefits.

A glaring issue in an Indian context is that there seem to be no learnings from accidents, in large measure because there is little public
disclosure of their root causes. Most accident reports by regulatory agencies remain shrouded in secrecy, especially when there have
been no casualties. Impacted industries are loathe to talk about it, and when they do choose to cover-up causes and downplay impacts.

This runs counter to best practices elsewhere; in the US, for example, a Chemical Safety Board independently studies chemical
accidents and makes its findings public. There is no reason why a similar body cannot be created here, given the wide technical
expertise that exists. Such a National Chemical Safety Board, independent of statutory authorities such as the Central and State Pollution
Control Boards or the National Disaster Management Authority (which deals with the aftermath of accidents) ought to be established and
staffed by safety professionals. Its core mission should include conducting incident investigations; formulating preventive or mitigative
recommendations based on findings; and advocating for their implementation.

In an industrial zone or cluster of industries, it should also be mandatory for all factories to let neighbours know what chemicals and
materials they process, their extreme operating conditions and preparedness for accident prevention and propagation. This will help
nearby sites to be ready with emergency plans should the need arise.

Clear zoning needed
While the industry must be expected to do all that is practically possible to improve process safety, the fact remains that the chemical
industry will remain a hazardous one. While the industry first came up distant from population clusters, especially in Maharashtra and
Gujarat, small population clusters soon sprang up alongside, quickly grew in size and hemmed the industry, seriously amplifying risks.

Given the essential nature of the chemical industry, it is important India’s policy makers find suitable homes for it, preferably in coastal
areas for logistical and operational reasons, besides safety. State industrial development corporations and municipal bodies must ensure
sanctity of this sanctioned space and prevent encroachments.

In the near-absence of integrated manufacturing clusters – commonplace in much of the developed world – a substantial volume
of chemicals travels fairly long distances, mostly by road. This is also an unsustainable situation, given that chemical production and
demand are rising at a rapid clip. This is one more reason to create dedicated zones in which the industry can thrive in close proximity.
This aspect is only now beginning to engage regulators!
Ravi Raghavan

130 Chemical Weekly December 17, 2024

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