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The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience (2012)

Chapter: Appendix A: Statement of Task

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Suggested Citation:"Appendix A: Statement of Task." National Research Council. 2012. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience. Washington, DC: The National Academies Press. doi: 10.17226/13385.
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Appendix A

Statement of Task

The National Research Council will produce a detailed written report, conclusions, and recommendations where appropriate on the following subjects:

1. Review the current industry practice for the use and storage of MIC in manufacturing processes, including a summary of key lessons and conclusions arising from the 1984 Bhopal accident and resulting changes adopted by industrial users of MIC.

2. Review current and emerging technologies for producing carbamate pesticides, including carbaryl, aldicarb, and related compounds.

      The review should include:

2.1 Synthetic methods and patent literature

2.2 Manufacturing approaches used worldwide for these materials

2.3 Manufacturing costs for different synthetic routes

2.4 Environmental and energy costs and trade-offs for alternative approaches

2.5 Any specific fixed-facility accident or transportation risks associated with alternative approaches

2.6 Regulatory outlook for the pesticides including their expected lifetime on the market

3. Examine the use and storage of MIC at the Bayer CropScience facility in Institute, West Virginia:

3.1 Identify possible approaches for eliminating or reducing the use of MIC in the Bayer carbamate pesticide manufacturing processes, through, for example, substitution of less hazardous intermediates,

Suggested Citation:"Appendix A: Statement of Task." National Research Council. 2012. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience. Washington, DC: The National Academies Press. doi: 10.17226/13385.
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intensifying existing manufacturing processes, or consuming MIC simultaneously with its production.

3.2 Estimate the projected costs of alternative approaches identified above.

3.3 Evaluate the projected benefits of alternative approaches identified above, including any cost savings, reduced compliance costs, liability reductions, reduced emergency preparedness costs, and reduced likelihood or severity of a worst-case MIC release or other release affecting the surrounding community.

3.4 Compare this analysis to the inherently safer process assessments conducted by Bayer and previous owners of the Institute site.

3.5 Comment, if possible, on whether and how inherently safer process assessments can be utilized during post-accident investigations.

Suggested Citation:"Appendix A: Statement of Task." National Research Council. 2012. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience. Washington, DC: The National Academies Press. doi: 10.17226/13385.
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Page 155
Suggested Citation:"Appendix A: Statement of Task." National Research Council. 2012. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience. Washington, DC: The National Academies Press. doi: 10.17226/13385.
×
Page 156
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The use of hazardous chemicals such as methyl isocyanate can be a significant concern to the residents of communities adjacent to chemical facilities, but is often an integral part of the chemical manufacturing process. In order to ensure that chemical manufacturing takes place in a manner that is safe for workers, members of the local community, and the environment, the philosophy of inherently safer processing can be used to identify opportunities to eliminate or reduce the hazards associated with chemical processing. However, the concepts of inherently safer process analysis have not yet been adopted in all chemical manufacturing plants. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience presents a possible framework to help plant managers choose between alternative processing options-considering factors such as environmental impact and product yield as well as safety- to develop a chemical manufacturing system.

In 2008, an explosion at the Bayer CropScience chemical production plant in Institute, West Virginia, resulted in the deaths of two employees, a fire within the production unit, and extensive damage to nearby structures. The accident drew renewed attention to the fact that the Bayer facility manufactured and stores methyl isocyanate, or MIC - a volatile, highly toxic chemical used in the production of carbamate pesticides and the agent responsible for thousands of death in Bhopal, India, in 1984. In the Institute accident, debris from the blast hit the shield surrounding a MIC storage tank, and although the container was not damaged, an investigation by the U.S. Chemical Safety and Hazard Investigation Board found that the debris could have struck a relief valve vent pipe and cause the release of MIC to the atmosphere.

The Board's investigation also highlighted a number of weaknesses in the Bayer facility's emergency response systems. In light of these concerns, the Board requested the National Research Council convene a committee of independent experts to write a report that examines the use and storage of MIC at the Bayer facility. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience also evaluates the analyses on alternative production methods for MIC and carbamate pesticides preformed by Bayer and the previous owners of the facility.

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