With annual sales of $3.3 billion, Honeywell's Performance Polymers and Chemicals business is a world leader in the production of nylon, polyester, polyethylene, fluoropolymer, caprolactam and specialty and fine chemicals.
Based in Morristown, New Jersey, the business has approximately 10,000 employees and more than 50 manufacturing facilities worldwide.
The Geismar facility is located on the border of Ascension and Iberville Parishes, just south of St. Gabriel, near the Mississippi River. Established in 1967, the Geismar location was selected due to its easy access to river transportation and raw materials.
OUR PRODUCTS & PROCESSES
The Geismar Facility initially manufactured agricultural chemicals, ethylene and hydrofluoric acid. While the site operated relatively unchanged for several years, many upgrades were made to existing production units. In 1984 and 1985 the agricultural and ethylene manufacturing operations were divested. Production capabilities were also expanded in all areas.
In 1983, the hydrofluoric acid unit was expanded to become the world's largest hydrofluoric acid facility in the world with production capabilities of 95,000 tons per year. A year later, production capabilities of the hydrofluoric acid unit increased again when a unit to produce aqueous (70% HF) was constructed. As a result, hydrofluoric acid production capacity increased to 104,000 tons in 1990 and to 120,000 tons in 1992.Recently, significant advancements have been made at the Geismar site. In 1993, the multi-products plant (MPP) was built at the facility for manufacturing environmentally safer fluorocarbons marketed under the trade name Genetron. The unit, which produces either 120 series fluorocarbon products or 134a, is the only facility of its kind in the world. The plant has the annual capability to produce 30 million pounds of Genetron 134a or 32 million pounds of Genetron 123, Genetron 124 and Genetron 125.
In 1995, the Geismar site began producing electronic grade hydrofluoric acid (UHPHF), which is used in the manufacturing of electronics equipment and the cleaning of computer chips.
Today, the Fluorine Products division of Honeywell's Performance Polymers and Chemicals business is a world leader in fluorine technologies and is the largest global producer of hydrofluoric acid. It is also a leading producer of environmentally safer fluorocarbons used to replace ozone-depleting CFCs (chlorofluorocarbons) and HCFCs (hydrochlorofluorocarbons).
Honeywell has long been a leading supplier of films to the pharmaceutical packaging and healthcare markets. The company's Aclar® fluoropolymer films have been the standard bearers in blister packaging applications with very high moisture barrier demands. Aclar ® film, a proprietary fluoropolymer technology, is the only product able to deliver durability and a moisture barrier in a clear construction, which promotes safety. The film is primarily used as packaging for pharmaceutical products.
Earlier this year, the Geismar site expanded its operations once again with the construction of the Aclon ® resin facility. After being manufactured in Geismar, the resin is shipped to Honeywell's Pennsylvania facility, where it is used as a raw material for producing Aclar® film.
Additionally, a new world-scale hydrofluorocarbon (HFC) 245fa manufacturing facility is scheduled to be operational at the Geismar site by July 1, 2002. HFC-245fa is Honeywell's new non-ozone depleting blowing agent designed to replace HCFC-141b in a variety of foam-blowing applications essential to rigid polyurethane and polyisocyanurate foam insulation, including refrigerator and freezer insulation foam, boardstock foam used in construction for roofing and sheathing, and spray foam also used in construction applications. Approximately $250 million worth of HCFC-141b is used globally each year for foam-blowing applications.
As part of the Montreal Protocol on Substances that Deplete the Ozone Layer, the use of HCFC-141b is being phased out around the world due to its potential to deplete the earth's stratospheric ozone layer. The HFC-245fa product significantly strengthens Honeywell's position as the world's leading developer of the most suitable non-ozone-depleting alternative to HCFC-141b.
HEALTH, SAFETY & ENVIRONMENTAL EFFORTS
It is the worldwide policy of Honeywell to design, manufacture and distribute its products, and to handle and dispose of materials, throughout their life cycle in a manner that protects the environment and safeguards employees, customers and the public from unacceptable risk. Honeywell is committed to the guiding principles of Responsible Care, a program of the Chemical Manufacturers Association, dedicated to continuously improving health, safety and environmental performance and community outreach. Community Awareness and Emergency Response
In support of the Community Awareness and Emergency Response principle of the Responsible Care program, the Geismar Plant Manager meets with Ascension and Iberville Parish residents who serve as members of the Community Advisory Panels (CAPs). During the monthly meetings, CAP members have the opportunity to learn a lot about Honeywell's safety and environmental performance.
Honeywell representatives also participate in a number of community-wide programs, such as the Ascension Parish Community Awareness and Emergency Response Committee (CAER), established to reduce the impact of an emergency. Like other area manufacturing facilities, Honeywell also performs emergency drills, which are reviewed for potential improvements, and helps train emergency response teams.
Distribution
The Distribution principle of the Responsible Care program focuses on getting products from "here to there" safely. To support this, Honeywell takes precautions before product is ever loaded on a truck or railcar. In fact, alternative routes are evaluated using criteria such as population exposure, road conditions, speed limits, container type and more.
Process Safety
The safety of our employees and neighbors is Honeywell's top priority. Because the Geismar site produces potentially dangerous chemicals, all of our employees are acutely aware of the importance of safe processes. In an effort to reduce risk, the Geismar facility takes precautions through the implementation of safety devices and procedures, emergency controls, fire control systems and backup power supply.
As a further safety measure, Honeywell has a comprehensive Risk Management Plan (RMP) that complies with federal Clean Air Act regulations. The Geismar site's RMP, which is available to the public, includes information about potential chemical accidents and the emergency response action that would be taken should such an emergency occur.
Employee Health & Safety
Safe workers are essential to a safe workplace. The culture of Honeywell's Geismar site focuses on safety awareness and an individual commitment to safety. An employee led safety program, called "Safety Observations Achieve Results" or SOAR, encourages all workers to observe safe behaviors and provide feedback that will help identify problem areas and make improvements. On the basis of employee-hours worked, Honeywell's Geismar site has demonstrated world-class safety performance.
Product Stewardship
Product development is part of the Responsible Care initiative's Product Stewardship principle. At Honeywell, new fluorocarbon products are developed at the Buffalo Research Laboratory in New York. There, research and development employees host technical exchanges and trials with customers in order to promote safe and proper processing of materials.
Finally, to support the Product Stewardship principle, Honeywell has implemented a purchasing policy that encourages raw material suppliers to adopt practices as strict as those required by Responsible Care. Performance issues related to environmental, health and safety concerns are addressed immediately with all suppliers.
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