Bundaberg 2000+ Industrial Development

12. Hazard and Risk

12.1 Chemical Storage
Chemical Usage
Chemicals to be used at the Pulp Mill are listed in Table 12-1of this Supplementary Report. These include chemicals
to be used in the water treatment. There are no chemicals to be used at the woodchip unload dock, moist depithing
plant or associated infrastructure.

Table 12-1 Chemical Storage and Use

Raw Conc Process Cone Rate of Usage Max Packaging
Chemical Name UN # Class Where Used
(wt%) (wt%) (t/d) Inventory Group
Sodium Hydroxide 50 50 33 230 t 1824 8 II or III Pulp Mill
(Caustic)
White Liquor (Sodium 23 23 153 m 3/h 1824 8 II or III Pulp Mill
Hydroxide)
Limestone 100 100 113 1,500
Hydrogen Peroxide 59 –70 59-70% 21 150 t 2984 5.1 I, II or III Pulp Mill
2014
2015
Oxygen refrigerated 100% 100% Back-up only 10 t 1073 2.2, 5.1 Pulp Mill
liquid
Oxygen produced on site 94% 94% 78 Produced on 1073 2.2, 5.1 Pulp Mill
demand
Ozone produced on-site 10% 10% 5 - Nc Pulp Mill
H2SO4, sulphuric acid 98 98 10 72.5t 1830 8 II Pulp Mill
DTPA (100%) 25% 25% 2.1 14 Pulp Mill
Magnesium Sulphate 750 700 1 450 30 Pulp Mill
(MgSO4)
Diesel Fuel 100 100 1 10 1202 3 Site wide
Lime (Calcium Oxide) 93 93 0.44 4.4 t 1910 8 III Water Treatment
Biotreat, (Ethanolamine 50 50 0.016 400L 2491 8 Water Treatment/
solution) Pulp Mill
Hypobromous acid 7 7 Nc Water Treatment
solution
Aqueous Ammonia 25% 25% 4.6 55,100L 2672 8 III Water Treatment
Phosphoric Acid 81% 81% 1.6 10,3000L 1805 8 III Water Treatment
Sulphuric Acid 98% 98% 0.42 2,600L 1830 8 III Water Treatment
Caustic Soda 50% 0.049 1.3 t 1824 8 II Water Treatment

Relevant Standards
The following Australian Standards are recognised as being relevant to the Project:
¨ AS 1940, The storage and handling of flammable and combustible liquids
¨ AS3780-1994 The storage and handling of corrosive substances
¨ AS2508.8.010-1990 Sulphuric Acid
¨ AS4326-1995 The storage and handling of oxidising agents (AS4326-1995amdt 1-1999)
¨ AS2714-1993 The storage and handling of hazardous materials Class 5.2 substances (organic peroxides)

Storage Standards
Containment and separation of chemicals will be in accordance with the specifications of these standards. This will
include segregation of incompatible same class substances such as acids/alkalis. Maintenance and monitoring of
chemical storage areas will also be in accordance with these standards. Emergency response procedures for incidents
involving any chemicals or fuels stored on the site will be incorporated into the site’s emergency response plan.

Chemical and fuel storage tanks will be above ground.

Fugitive Emissions
The chemicals used at the Pulp Mill have low vapour pressures and therefore produce minimal fugitive emissions.
Where required by standards or good operating practice, tanks will be fitted with a scrubbing system and water trap on
vents or overflow lines where risk of emissions of volatile chemicals exists.

Silica gel traps will be fitted on the vents and overflow lines of the sulphuric acid tanks to avoid water ingress when
changing levels of acid within the tanks.

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LPG
Small amounts of LPG will also be stored on the site to provide fuel for some vehicles. Storage facilities will comply
with relevant Australian Standards.
12.2 Emergency Management

12.2.1 Training
Internal training records will be maintained as part of the site’s quality assurance and emergency management system.
These records will be made available to QFRA and other emergency services as necessary to ensure that site personnel
and emergency response agencies are well prepared to deal with emergencies on the site and to determine the need for
additional resources within QFRA.

QFRA staff will be provided with awareness training about potential high risk areas within the proposed facility.

It is noted that a range of emergency training services are available from QFRA’s Commercial Development Unit.
The advantages of including QFRA in training activities are recognised. It is also noted that the Rural Fire Brigade
can provide advice on managing wildfires.
12.2.2 Risk Studies and Emergency Planning
Comprehensive Hazard Operability (HAZOP) and Chemical Hazard Operability (CHAZOP) will be undertaken
during the detailed design stage of the Project. Input will be sought from QFRA and other appropriate emergency
response agencies.

The HAZOP/CHAZOP studies will provide a basis for development of site specific emergency response plans and
procedures.

Detailed assessment of smoke plumes will be incorporated into the fire management plan

The proponent will seek the advice and comments of the CHEM Unit of QFRA regarding detailed risk studies of
chemical hazards.
12.2.3 Cooperation with Local Emergency Services
Prior to or during commissioning of the facility, the following activities will be carried out:
¨ Local emergency service officers from services including QFRA, QAS, SES and Police will be briefed on unusual
chemical hazards such as ozone.
¨ A copy of the Hazardous Chemical Register will be provided to QFRA
¨ Emergency Management Plan and ancillary documents (including fire management plan) will be provided to
QFRA
¨ Discussions will be held with the Rural Fire Service regarding wildfire response.
¨ Information on operations of the lifting span of the bridge will be provided to local emergency services (in relation
to use of the bridge by emergency vehicles).
¨ Information on site access and associated heavy vehicle routes will be provided to the Department of Emergency
Services geographical information services section.

The site operators will maintain communications with emergency service providers and ensure that information
provided to these organisations is updated as necessary.

It is acknowledged that the QFRA fire service levy and other levies established by law will be payable by
B2K+/Project operators.
12.2.4 Emergency Response Equipment
B2K+ will provide adequate emergency response equipment on-site to meet emergencies that can reasonably be
foreseen. Details of equipment available will be provided to QFRA and other emergency services as appropriate.

B2K+ undertakes to consult with QFRA prior to installation of fire and other emergency response appliances to ensure
that equipment is compatible with mobile units operated by QFRA (for example fire hose coupling sizes). B2K+ will
also seek input from QFRA into the selection of emergency response equipment and appliances.

Water supply for fire fighting will be drawn from the Water Storage and high capacity pumps will be installed to
ensure that adequate volumes and pressures can be maintained.

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12.3 Woodchip Dock

There will be no public access to the woodchip unloading berth. The facility will operate 24 hours per day, seven days
per week.
12.4 Other Issues
Table 12-1 of the EIS has been amended to clarify the qualitative risk ratings as shown in Table 12-2.
Table 12-2 Qualitative Risk Rating
Risk Element Measure Risk Rating
Impact – People ¨ Minor injury L
¨ Major injury M
¨ Fatality H
Impact – Environment ¨ Immediate area L
¨ Localised M
¨ Regional H
Impact – Business ¨ Business interruption L
¨ Capital loss M
¨ Plant loss H
Risk Exposure ¨ Rare L
¨ Occasional M
¨ Continual H
Risk Frequency ¨ 1 per 100 years L
¨ 1 per 10 years M
¨ 1 per year H

Table 12-20 of the EIS has been updated. The revised version is shown as Table 12.3 with revisions italicised.
Table 12. 3: Emergency plan elements
Event Level of Emergency Emergency Services Resources Needed Organisational Damage Control Actions
Required
Aspects
Bush fire on site Site wide Site fire fighting team Fire fighting truck and Evacuation of affected Fire containment
water tankers workers Shutdown of affected operations
Roll call Evacuation from around fire
Potential external alert Town fire crew or rural
fire brigade sensitive areas such as
stockpiles, tank farm
Bulk diesel fuel fire Local, site and Site fire fighting crew Fire fighting Evacuation notice Evacuate from local area
external Fire suppressants Fire spread control
Communication to fire
and recovery crews
Adjacent cooling of tanks and/or
structures
Vehicle collision Local/site Ambulance Rescue Spill Management Contain fuel spillage’s
(emergency medical plan
Fire fighting capability Control ignition sources
treatment and
transport) Fuel containment
materials
Police
Fire crew (road
accident rescue,
hazardous materials
and fire control)
Earthquake Site wide Emergency response Spill containment Spill Management Evacuate from site
teams materials plan
Potential external alert Shutdown all operations
State Emergency Rescue Evacuation notice Contain fuel spillage’s
Service Communication
Control ignition sources
Cyclone/Flood Site wide Emergency response Rescue Emergency Response Evacuate from site
teams Plan
Potential external alert Shutdown all operations
State Emergency Evacuation notice Contain fuel spillage’s
Service Communication
Control ignition sources
Falls and impact Local Ambulance Site rescue equipment Evacuation Stabilise
incidents
Paramedics Communication Isolate source of incident
Rescue MSDS’s at hospital Technical rescue
Fire Crew

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The risks associated with dangerous goods travelling by road to the mill are outlined in Section 12.3.5.5 of the EIS,
with the risks being characterised as medium. In a worst case scenario, up to 20,000L of a hazardous substance may
spill onto the roadway and adjacent environment. Should such an incident occur, it is highly likely that environmental
harm would occur in the immediate vicinity and perhaps downstream for a distance should the chemicals enter a
waterway. Entry into the waterway would be likely to alter pH of the water and be toxic to aquatic organisms. These
chemicals are highly reactive and would harm organisms through direct contact or fumigation. The impact duration,
however, is likely to be short to medium in term since the chemicals are not typically persistent in the environment and
are likely to have dissipated in hours or days, particularly following effective clean-up procedures and dilution.

Ferric chloride will not be used on the site. Polymer based floculants will be used instead.

Trucks will carry fire fighting equipment as appropriate and in accordance with regulations and standards. The risk of
fire following an accident involving trucks carrying the chemicals to be used on site is considered low due to the
nature of the chemicals involved. Trucks carrying fuel have a higher risk of fire in the event of an accident. The
volumes of fuel to be transported to the site are small in the context of volumes of fuel typically transported along
highways and major roads in Queensland and the Project is not considered to significantly increase the risk of fire.

Section 12.3.5.5 of the EIS outlines management measures for these spills and will be adhered to.

Section 12.3.5.6 of the EIS identifies that the risk of single vehicle accidents involving chemical transport vehicles is
very low due to the high level of driver training (and vehicle safety standards) and that two vehicle accidents involving
chemical transport vehicles are more likely. The possible frequency adopted for the risk assessment is based on both
single vehicle and multi vehicle accidents involving chemical transport vehicles.

The proposed woodchip unloading dock will be on the opposite side of the river to the existing port and the direction
in which most chemical transport vehicles will travel from. It will reduce heavy vehicle traffic levels on the bridge
and at some intersections along the heavy transport route, thus reducing risk of vehicle accidents.

It is the contention of this EIS that vehicle accident frequencies on Fairymead Road will not increase since the actual
number of heavy vehicles will be reduced once the bridge is installed and traffic associated with Bundaberg Sugar is
diverted. This may actually improve delivery of ambulance and other emergency services in the area due to reduced
interaction with heavy vehicles.

Emergency vehicles will be able to use the bridge for access to emergencies. The bridge will need to be closed
regularly to allow passage of vehicles and the potential for this to conflict with emergency vehicle use will be
addressed in the bridge operations plan. A mechanism will be developed whereby emergency vehicles will have
priority.

It is acknowledged that traffic levels on Port Road will increase, however, pavement upgrading, intersection
treatments and other measures will be undertaken to ensure that safety standards acceptable to Department of Main
Roads and Queensland Transport are maintained.

As with any construction activity, there is a risk of construction related accidents. All relevant government safety
standards will be adhered to during construction to minimise the occurrence and severity of construction accidents.
Similarly, the site will develop site safety plans for operation of the site. All workers will be required to comply with
site safety standards.

The safety of residents and minimisation of impacts of construction activity such as cane railways on private
properties is of high importance to Bundaberg Sugar. There are no specific safety standards for construction activities
for cane railways other than the general safety systems and legislated requirements which apply under the Workplace
Health and Safety Act and other appropriate construction codes and principles which are applicable to civil
engineering work of this nature. Bundaberg Sugar does operate under a code of practice for the Sugar Milling
Industry which has general provisions for typical operations performed in sugar mills in Queensland, including
railways. There are also sets of design guidelines for construction which describe cane railway engineering for
application to the Queensland sugar milling industry and these will be adhered to. Bundaberg Sugar operates under
the Code of Practice for Civil and Track Infrastructure that incorporates safety issues and is specifically designed for
the Queensland sugar milling industry. This code addresses AS4292 – Railway Safety Management.

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Ozone is produced by the Plant as required. This means that storage of ozone is negligible. It is, however, a strongly
oxidising chemical and fits within the pattern of chemical reactivity of other chemicals on site including oxygen and
peroxide. Hazards and risks associated with ozone will be addressed in the site emergency management plan. A copy
of the plan will be forwarded to relevant emergency services.

The potential for stockpile slip collapse etc. constitutes an element of training that will be applied to all areas of the
woodchip and bagasse stockpile systems. The woodchip stockpile will be managed with mobile equipment,
consequently mobile plant operators will be trained in ensuring that safety is foremost. For example, pre-
commissioning training will be carried out at other woodchip stockpile operations to provide experienced guidance
prior to commencement of operations.
12.5 Natural Hazards

12.5.1 Flooding
The Shire of Burnett has designated RL5m as the level below which development must not occur because of
unacceptable flood risk. The industrial site and stockpiles are located above this level. Individual elements of the
plant must also be designed to withstand inundation from floods. In line with acceptable design standards, the 1:100
year flood event will be adopted as the design standard in this regard. This standard is also acceptable to financial
backers of the Project.

Much of the equipment on the site is designed and constructed to withstand great internal pressure and constant
operation and is expected to be robust enough to withstand even larger flood events without any modifications.

Table 12-4 identifies flood hazards that are unique to the site and may result in releases to the environment.

Table 12-4 Flood Hazards

Event
Washing away of stockpiles of woodchips and bagasse
Damage or rupture of chemical storage tanks
Likely Impacts
Release of organic matter to flood waters
Contamination of waters
Management Measures
¨ Located above RL5m
¨ Site located above RL5m
¨ Chemical storage areas contained by bunds
¨ Tanks designed to relevant safety standards (as
determined by Shire of Burnett or other referral
agency and following hydraulic modelling to be
undertaken at detailed design stage)

The Probable Maximum Flood (PMF) event will be modelled during design of the proposed Burnett River Dam and
will be covered in a separate EIS. In the event that a PMF occurs during the life of the plant, or any significant flood
greater than the 1:100 year flood, the quantity of water that will be present is such that releases of the relatively small
volumes of chemicals stored on the site are considered insignificant. The flood waters will contain high levels of
organic matter from vegetation, animals and wooden structures that have been washed away in the flood waters and
release of additional organic matter from the stockpiles is also unlikely to be significant.

12.5.2 Earthquake
The risk of earthquake at the site is discussed in Section 5.1.4.2 of the EIS. Appropriate design standards exist (AS
1170.4) and these will ensure that structures can withstand likely earthquake activity in the area.

Earthquake damage could lead to the following impacts:

¨ release of chemicals from storage areas and process tanks into contained areas within the site
¨ release of odour from ruptured process tanks

Use of appropriate earthquake design standards is accepted as best practice for control of risks associated with
earthquakes. In the event that spills occur, there will be mortality and harm to plants and animals that come into
contact with the materials. Containment structures and the site’s stormwater collection system (which will contain all
stormwater on the site) will, even if partially ruptured by the earthquake, retard releases from the site and allow
emergency containment and clean up actions to be implemented before chemicals have spread significantly. Some
damage to local ecosystems can be expected in a worst case scenario, particularly if chemicals enter irrigation drains
near the site. Screening of all tanks and other structures containing chemicals will be carried out after any significant
earth tremor to detect any fractures or other damage that might lead to leaks or failure.

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Modern boilers are designed and independently verified to international standards such the ASME Boiler and Pressure
Vessel Code for Power Boilers, and the Australian Standard AS1200. These codes and standards specify design
methods which incorporate seismic design criteria aimed to withstand the expected levels of earthquake predicted for
the region where the plant is going to be constructed. This risk of an earthquake in Bundaberg is relatively low
compared to areas of the world such as Indonesia and New Zealand, but the boilers will still be designed to withstand
the predicted earthquake risk.

Lasting damage to the environment is considered unlikely on the basis that:

¨ The types of chemicals stored on the site are not persistent in the environment and will degrade quickly on release.
¨ the quantities of chemicals stored on the site are relatively low.

The closest residents to the site are far enough away (900m) that there would be adequate time for emergency
evacuation if required.
12.5.3 Cyclone
Cyclones have occurred in the Bundaberg area. The maximum recorded wind gust is reported to be 87.1 km/hr
(Bureau of Meteorology). Australian standards for resistance to wind pressures exist (AS404.2 and AS404.3) and
these will be used for design of all structures.

In the event of cyclone damage occurring to any of the structures containing chemicals, risk and impacts are
considered to be similar to those for earthquakes. It will be more difficult to respond to spills that occur during
cyclones due to the ongoing nature of such storms.
12.5.4 Bushfire
Small bushfires might occur in remnant woodlands surrounding the site. Due to the small area of the patches of
remnant bushland, a severe and uncontrollable bushfire is considered very unlikely. Fire fighting equipment will be
available on the site to protect the site from external bushfires.

Activities on the site are not expected to cause bushfires.

12.5.5 Counter Disaster Plan
The site operators will conduct a qualitative natural hazards risk assessment as part of the HAZOP studies to be
undertaken for the site. The results of this will be provided to Bundaberg City Council and other relevant agencies
involved in Counter Disaster planning and will also be input into the site’s emergency plan.

The site operators will request involvement of Bundaberg City Council’s Counter Disaster Committee and the
equivalent persons at Burnett Shire Council in development of emergency response plans relating to natural hazards.

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