Environmental Impacts of Cylinder Filling
Environmental Impacts of Cylinder Filling
ENVIRONMENTAL IMPACTS
CYLINDER FILLING PLANTS
Disclaimer
All technical publications of EIGA or under EIGA's name, including Codes of practice, Safety procedures and any other technical
information contained in such publications were obtained from sources believed to be reliable and are based on technical infor-
mation and experience currently available from members of EIGA and others at the date of their issuance.
While EIGA recommends reference to or use of its publications by its members, such reference to or use of EIGA's publications by
its members or third parties are purely voluntary and not binding.
Therefore, EIGA or its members make no guarantee of the results and assume no liability or responsibility in connection with the
reference to or use of information or suggestions contained in EIGA's publications.
EIGA has no control whatsoever as regards, performance or non performance, misinterpretation, proper or improper use of any
information or suggestions contained in EIGA's publications by any person or entity (including EIGA members) and EIGA expressly
disclaims any liability in connection thereto.
EIGA's publications are subject to periodic review and users are cautioned to obtain the latest edition.
EIGA grants permission to reproduce this publication provided the Association is acknowledged as the source
Table of Contents
1 Introduction ...................................................................................................................................... 1
2 Scope and purpose .......................................................................................................................... 1
2.1 Scope ........................................................................................................................................ 1
2.2 Purpose .................................................................................................................................... 1
3 Definitions ........................................................................................................................................ 1
3.1 Publications terminology ........................................................................................................... 1
3.2 Technical definitions ................................................................................................................. 1
4 Cylinder filling operations–environmental impacts........................................................................... 2
4.1 General environmental aspects and impacts and links to other EIGA documents .................. 2
4.2 Planning and control ................................................................................................................. 2
4.3 Waste and emissions from a cylinder filling plant ..................................................................... 3
4.4 Cylinder preparation ................................................................................................................. 3
4.5 Cylinder filling ........................................................................................................................... 6
4.6 Storage ..................................................................................................................................... 7
4.7 General ..................................................................................................................................... 9
5 References ..................................................................................................................................... 10
Appendix A—Environmental impact cylinder filling operations ............................................................. 11
Appendix B—EIGA Document links to ISO 14001 ............................................................................... 12
1 Introduction
This publication details the environmental impacts of the management of cylinder filling operations and
gives guidelines on how to reduce the impacts.
2.1 Scope
This publication does not give specific advice on health and safety issues, which must be taken into
account before undertaking any activity. On these issues the relevant EIGA documents and / or national
legislation should be consulted.
2.2 Purpose
This publication is intended to serve as a guide for the managers & personnel of Industrial Gases
cylinder filling operations, to assist in putting in place a formal environmental management system that
can be certified by an accredited 3rd party verifier. It also aims to provide a guide for operating managers
to identify and reduce the environmental impacts of these operations.
3 Definitions
3.1.1 Shall
Indicates that the procedure is mandatory. It is used wherever the criterion for conformance to specific
recommendations allows no deviation.
3.1.2 Should
3.1.4 Will
3.1.5 Can
These are elements of an organisation’s activities, products or services that can interact with the
environment. For example, use of energy or road transportation of products.
1
EIGA DOC 110/23
Any change to the environment, whether adverse or beneficial, wholly or partially resulting from an
organisation’s environmental aspects. See ISO 14001, Environmental Management System [1] 1. For
example, the contamination of water with hazardous substances or the reduction of air emissions.
4.1 General environmental aspects and impacts and links to other EIGA documents
This publication covers the environmental impact of cylinder filling operations, which are summarised in
Appendix A.
There are several linked EIGA publications that provide more details on general environmental issues,
legislation for the gas industry and operational good environmental practices. A list of these linked
documents and their links to the ISO 14001 [1] is provided in Appendix B. Appendix B also shows which
of these documents are relevant to cylinder filling plant operations.
The basic philosophy is the minimisation of waste, emissions and nuisances of any kind and their safe
and clean disposal. Also considered is the minimisation of raw materials, energy, unused equipment
and cylinders and water use. By considering the potential waste which a new process could generate,
or when engineering a plant, future problems can be avoided. This analysis is a crucial element of
Environmental Impact Assessment that is strongly recommended before any decision of industrial
investment. Waste streams should not be mixed but collected separately to aid further recycling, reuse
or recovery.
Safety data sheets (SDS) for all chemical substances should be held on site and used to determine the
best way to handle them. In particular, handling of hazardous chemicals such as Polychlorinated
Biphenyls (PCB), chemicals containing asbestos or lead or chromates have to be carried out by an
authorised contractor. Specific detailed handling conditions and disposal methods have to be written for
such hazardous chemicals. These substances will need to be disposed of as hazardous waste by a
certified waste disposal company in line with local or national regulations.
The key point in planning and control of environmental impact at cylinder filling operations is to make
sure that the responsibilities are clearly defined at the site for management and operators. The key
areas are:
• waste management (solid and liquid waste);
• energy management;
• air emissions;
• water use and disposal.
Specifically, in the following areas:
Cylinder preparation:
• purging;
• testing and maintenance;
• cleaning;
• drying;
• painting and labelling;
• valving.
1 References are shown by bracketed numbers and are listed in order of appearance in the reference section
2
EIGA DOC 110/23
Cylinder filling:
• filling;
• sampling and analysis.
Storage:
• product storage;
• underground storage.
General:
• packaging;
• vehicle washing;
• oil;
• polychlorinated biphenyl’s (PCB);
• insulation material;
• silica gel;
• electrical and electronic equipment;
• ozone depleting substances and fluorinated gases – air conditioning equipment;
• abatement systems.
Employees and contractors should have site-specific briefing information covering these areas.
Different types of waste streams, which are to be recycled, recovered, reused or treated, should be
separated according to their type and the treatment they will receive and stored safely and securely for
transportation. The suppliers of the product or materials should be contacted so that they can take back
any residuals. The containers should be suitable for transportation and clearly labelled in accordance
with the national regulation. Any liquid should be provided with some means of secondary containment
to the capacity of 110% of the largest container (or 25% of the total volume of all containers, whichever
is greater).
Cylinders that are returned to the filling plant will typically have small quantities of residual gas in them.
This should be reused or recycled if technically and economically feasible and if it is not contaminated
with other products. If it is not possible to reuse or recycle the residual gases, they should be disposed
of correctly and in line with applicable national and international regulations. In any event, the EIGA Doc
30, Disposal of Gases [2] can be consulted for advice on disposal methods. Wherever possible, product
should be recovered and reused.
The amount of purge gas should be kept to a minimum to avoid wastage; although these purge gases
themselves are not harmful to the environment this is to avoid a waste of energy. Nevertheless, purging
gases might bring a noise nuisance if no silencer is used, see Section 4.5.2. The re-use of purge gas
should be considered, e.g. high purity helium re-used as balloon gas.
Gas cylinders are reusable high integrity pressure vessels that are subject to periodic re-qualification.
3
EIGA DOC 110/23
This testing may be hydrostatic. Steps should be taken to ensure the water use is kept to a minimum
and reused or recycled. As long as the water does not contain any impurities, it may be allowed to drain
into the sewage water system. For hydrocarbon products, special attention should be given to collection
of the water. In accordance with national regulations a permit or consent may be necessary. Attention
must be given to the water discharge network to ensure these are up to date and all discharge points
are known.
Gas cylinders that are no longer suitable for use should be recycled for the metal content. They must
be rendered unfit for use before disposal so that no pressurised cylinders are sent for waste. Some gas
cylinders whose content cannot be completely eliminated, such as acetylene and some toxic gases,
may be regarded as hazardous waste. See [2], EIGA Doc 05, Guidelines for Management of Waste
Acetylene Cylinders [3] and EIGA Doc 166, Guidelines on Management of Waste Gas Cylinders [4].
Items such as valves, regulators, valve guards, dip tubes, metal pallets, etc. may have to be disposed
of when worn out. They should be rendered unfit for use before disposal. These items need to be
replaced on a regular basis. Steel, copper and non-ferrous metals should be separated and sent to a
specialist dealer for recycling. Contaminated items should be disposed of as hazardous waste through
an authorised contractor.
Items such as plastic guards, plastic valve caps, valve parts and polytetrafluoroethylene (PTFE) tape
should be collected separately for recycling, where there is a specialised company to do this. Otherwise,
they can be placed with non-hazardous general waste. Contaminated items will have to be disposed of
as hazardous waste through an authorised contractor.
4.4.8 Gaskets
Some valve materials and gaskets are manufactured with hazardous materials. These should be
handled as explained in the SDS for the material.
4.4.9 Cleaning
In some cases cylinders or cylinder equipment will need to be cleaned internally or externally, and/or
prepared for painting. There are a number of waste streams that may arise from this process, such as
wash water, residuals from shot blasting and solvents, as described in the following.
[Link] Solvents
Some solvents used for cleaning and degreasing are sources of emissions, for example, volatile organic
compounds (VOC) and ozone depleting substances (ODS). Without proper control they can cause
atmospheric emissions that may contribute to poor local air quality, depletion of the ozone layer or global
warming. It is recommended that:
• a policy is developed and an action plan is implemented to reduce the use of such products
containing VOC, ODS or greenhouse gases (GHG), for example, by introducing new products
or new technology;
• excess use of solvents is avoided and work practices are regularly reviewed to minimise
emissions;
4
EIGA DOC 110/23
• all waste and used solvent is collected and returned to the supplier for recycling or reuse and
is never disposed of into the drains or directly to the ground. If it cannot be reused it should be
disposed of by a certified waste disposal company;
More details can be found in EIGA Doc 33, Cleaning of Equipment for Oxygen Service [5] and EIGA
Doc 106, Environmental Issues Guide [6].
If cylinders need to be shot blasted, measures need to be taken to minimise and control the dust to
prevent any environmental nuisance.
As a preference, metal shot should be sent for recovery. If it is not possible to recover the waste shot
and dust it should be disposed of as non-hazardous waste. If the shot blast waste contains significant
quantities of pollutants (for example, lead or zinc) this will need to be disposed of as hazardous waste
by a certified waste disposal company in line with local or national regulations.
Oil and water mixtures have to be disposed of in accordance with applicable local or national
regulations. The oil and water may need to be separated if required. Sometimes it may be possible to
dispose of water-soluble emulsions by draining into a suitable sewage water drainage system, equipped
with an oil separator.
Acids, alkalis or other cleaning agents should be disposed of in line with local or national regulations
and never directly into the drainage system. For the disposal of detergent cleaners, see Section 4.7.2.
4.4.12 Drying
Cylinders may be baked or further purged to dry them before filling. These systems need to be designed
to optimise the use of energy and minimise the waste of purge gases.
Some paints and thinners can be sources of VOC. It is recommended that excess use of paint is avoided
and work practices regularly reviewed. Consideration should be given to using paints that are less
harmful, both to the environment and the health of employees (for example, water based or lead free).
Where possible, paint should be supplied in returnable containers.
Waste paint (solid or liquid) is treated as hazardous waste and shall be disposed of in accordance with
national regulations by certified waste disposal companies.
When using powder painting, filter systems must be used to minimise the effect on workers.
Also surplus powder may be recycled, e.g. to paint the base of cylinders where colour is irrelevant.
[Link] Labels
4.4.14 Valving
Valves and other consumables that need replacing should be disposed of as scrap metal, see Section
4.4.6.
5
EIGA DOC 110/23
[Link] Product
Product should be reused or recycled if technically and economically feasible. For the correct disposal
of product, see Section 4.4.1.
Many disposal systems (for example, scrubber systems) use acids or alkalis to clean or to absorb the
waste gases. These solutions should be disposed of as hazardous waste by certified waste disposal
contractors in line with national regulations. It is important to monitor disposal systems and keep them
well maintained so that they remain effective at preventing harmful or nuisance (for example, odour)
emissions.
Scrubber systems often contain absorbent or packing material. This should be reused or recycled if
technically and economically feasible and if it is not contaminated with other products. Waste absorbent
material must be correctly packaged to prevent degassing or other hazards. Otherwise it is treated as
hazardous waste and should be disposed of in accordance with national regulations by certified waste
disposal companies.
4.5.2 Noise
The venting of product in normal or abnormal operations may give rise to environmental nuisance. This
can often be eliminated by simple techniques such as use of a silencer or screen, or by eliminating the
need to vent the product. Regular noise surveys are recommended to ensure compliance with
applicable legislation.
The main sources of noise on a cylinder filling plant are:
• venting of residual gases;
• delivery vehicles and fork lift trucks (FLTs);
• manual or mechanical handling of the cylinders; and
• activation of a safety relief device.
• reciprocating pumps
The EIGA Doc 85, Noise Management [7] gives a comprehensive review of noise management and the
actions that should be considered.
Any cartridges or consumables should be treated in the same way as scrubber absorbent or packing,
see Section [Link].
Excess use of chemicals should be avoided and work practices regularly reviewed. For the treatment
of waste gases, see Section [Link]. Waste from the laboratory may not be the same as from production
6
EIGA DOC 110/23
and separate treatment may be necessary. Particular attention must be given to speciality and analytical
gases.
Waste and used chemicals, and their packaging, should be collected and returned to the supplier for
recycling or reuse, and never be disposed of into the drains. If they cannot be reused, these products
shall be sent to a certified waste disposal company for disposal.
Some measurement and calibration apparatus contains biotoxic metals (for example mercury, lead,
cadmium and their compounds). These shall be disposed of by certified waste disposal companies and
should be kept in designated containment during storage and hand-over to the disposal company.
4.6 Storage
The product storage system should be designed to minimise product losses. Any losses should be
handled as described in Section 4.4.1.
Any tanks or drums that have contained product should be treated in the same way as cylinders i.e.
returned for reuse, recycled or properly disposed of. If they have been contaminated by hazardous
waste, they shall be disposed of through an authorised contractor.
[Link] Maintenance
Table 1 shows the waste streams produced during the routine maintenance of storage facilities
Table 1—Waste classification and disposal
Typical waste Causes of waste genera- Possible ways to reduce How to dispose of waste
tion amount of generated waste
Product Residuals in cylinders Reuse or recycle product EIGA Doc 30, Disposal of
Losses during filling Design to reduce losses Gases [2]
Losses from storage Proper maintenance of
Speciality gases (calibration scrubbing equipment
and
purge gases)
Waste water Detergent from vehicle wash- Do not mix oil and detergent Discharge to sewage system
ing Improved maintenance under local approval
Oil from equipment
Scrap metal Cylinders, valves guards, dip Maintain to extend the life-
tubes, metal pallets, drums time
Chemicals Spent scrubber solution Avoid excess use Send for recycling or disposal
Lab chemicals Review of procedures by certified contractor
Cleaning and de-greasing
Packaging Boxes and cylinder pallets Reuse on plant Send to recycling, reuse
Solvents Cleaning and degreasing, Avoid excess use Disposal by certified contrac-
paint thinners Review of procedures tor
Dust and shot Cylinder preparation Control use Disposal by certified contrac-
blast tor
Oil Vacuum pumps Improved maintenance Send for recycling or fuel use
Mechanical equipment or disposal by certified con-
tractor
Noise Product venting Improved system design
Vehicles
Odour Product Maintenance of disposal sys- EIGA Doc 30, Disposal Of
tems Gases [2]
Silica gel Dessicant
7
EIGA DOC 110/23
Typical waste Causes of waste genera- Possible ways to reduce How to dispose of waste
tion amount of generated waste
Paint Maintenance of cylinders and Avoid excess use Disposal by certified contrac-
equipment Use lead free or water based tor
Plastic Packaging (shrink wrap, Send for re cycling or dis-
bags) posal by certified contractor
PTFE tape
Labels
Batteries/electric Use non-toxic alternatives Disposal by certified contrac-
cells tor
Cartridges/ Use more efficient cartridges Disposal by certified contrac-
consumables Run equipment efficiently tor
Insulation mate- Maintenance and modifica- Return to the supplier or
rial tions landfill disposal by certified
contractor. Special precau-
tions needed for disposal of
asbestos
Adsorbent mate- Ageing Use more efficient adsor- Return to supplier for recy-
rial/scrubber bents cling or reuse or disposal by
packing Run equipment efficiently certified contractor
Several kinds of cooling media may be in use. In the case of coolants that are liquid at normal pressures
(for example, ethylene glycol) care must be taken during operation and maintenance to prevent any
spillages or discharges into water.
For other refrigerants like HFC and Ammonia, leaks should be prevented by careful maintenance. For
CFC (if any), HCFC (R-22), or HFC (F gas) maintenance needs to be done by authorised contractors,
see EIGA Doc 192, Fluorinated Gases Management [8].
Underground storage tanks (UST) could be sources of soil and groundwater contamination through
leakage and spillage. The condition of USTs should be monitored regularly and a routine maintenance
programme established. If a tank has been leaking then immediate action should be taken.
Any unused tanks should be removed or cleaned, emptied and filled with sand [6].
Above ground storage tanks also risk contamination of soil and water if the tank starts to leak. However,
the control of tank leakage is less complicated than for underground tanks. Even a dripping valve could
easily contaminate several cubic meters of soil. Spill plates should be used.
Large storage tanks are frequently used for fuel while smaller ones could contain oil, antifreeze and
other substances. The importance of avoiding spills and correct labelling of tanks is similar regardless
of tank size [6].
All tanks must be fit for purpose to the appropriate national or international standard. Correct
maintenance and painting gives a positive visible image of the gas industry.
When filling a tank, the operator/driver shall attend the filling at all times. By installing overfill alarms,
the risk of a major spill could be further reduced. Minor spills could occur when filling or emptying the
tank and proper precautions, such as using spill plates over drains, should be taken to avoid any
environmental damage caused by this.
8
EIGA DOC 110/23
4.7 General
4.7.1 Packaging
Wooden crates and cardboard boxes should be reused or recycled. If this is not possible, they should
be disposed of as non-hazardous waste and sent for incineration with energy recovery. Suppliers should
be encouraged to eliminate unnecessary packaging or reuse it.
Detergent from vehicle washing should be directed to the sewer, but precautions should be taken to
prevent oil and debris entering drains (for example, the provision of an interceptor). In accordance with
national regulations, a permit or consent may be necessary. It is important that water containing
detergent is not directed to any oil/water separating system. This is because it will prevent the correct
functioning of such a system.
4.7.3 Oil
Oil binders and oily cloths should be recycled or disposed of as hazardous waste by a certified
contractor. There are different points of discharge:
• oil from vacuum pumps due to leaks, vapour emission, cleaning;
• oil from other machinery and vehicles (for example, FLTs);
• oil from transformers.
Improving maintenance of the vacuum pumps (and also a better design) can reduce waste from these
sources. Recommendations for control and disposal are the following:
• precautions must be taken to prevent oil from entering drainage systems, watercourses and
soil;
• oil must never be mixed with other substances, for example water, soil, solvents. Different types
of oil must always be collected separately in barrels or drums and be delivered for recycling;
• a bund (or pit) on each compressor or transformer installation should be installed to collect the
potential leaks and purges. The size of the bund should be equal to 110% of the largest
equipment of the installation;
• oil barrels or drums should be stored in a bunded area, or on a bunded pallet or catch pot, and
wherever possible protected against rainfall. The size of the bund should be equal to 110% of
the largest container.
PCBs are toxic and carcinogenic substances, and their use has been phased out in accordance with
prevailing legislation [6].
If transformers and capacitors with PCB (or equivalent substances) are present, they should be labelled
accordingly and a programme agreed for their removal. Disposal of this product and any material that
is contaminated by PCB (for example, rags, absorbent material) should be controlled by national or local
regulations.
PCB or PCB contaminated materials have to be collected into suitable sealed containers, labelled, and
then recovered and treated by certified waste disposal companies.
This should not be removed unless necessary. Non-hazardous insulation material should be returned
to the supplier or disposed of by a certified waste disposal company.
Material containing asbestos shall be identified. When removing this, special precautions and controls
are required as specified by national regulations. This will normally involve the use of a specialist
9
EIGA DOC 110/23
contractor. Material shall be disposed of by a certified waste disposal company and handled in such a
way as to prevent the release of asbestos fibres. This may include 'double' bags, or wetting the material.
The disposal of material or equipment containing asbestos has to be tracked in detail.
This is often used as a desiccant and should be sent to a specialist company for regeneration and reuse.
This should be returned to the supplier for reuse or recycling where possible. If the equipment contains
toxic materials, it should be disposed of as hazardous waste through an authorised contractor.
The gas company employees and contractors must be aware of the site emergency plans, and be
trained and competent in the requirements. The emergency plan should contain the following:
• actions in the event of environmental events such as major leakage of chemicals or oil;
• the location of absorption material to clean up spills on the floor/ground;
• actions in the event of fire and/or explosion;
• actions to contain contaminated fire water run off;
• action in the event of dispersal of hazardous materials for example, asbestos;
• action in the event of toxic or flammable gas releases;
• action in the event of severe weather, flooding and other natural causes.
The emergency plan should be regularly tested with drills, simulations etc..
5 References
10
EIGA DOC 110/23
INPUTS OUTPUTS
11
EIGA DOC 110/23
12
EIGA DOC 110/23
13
EIGA DOC 110/23
14