The Seveso Directive; the risk management of hazardous substances

In the small rural town of Seveso, to the north of Milan, 10 July 1976 is a date that will never be forgotten, as it was then that the ICMESA chemical plant experienced a serious accident that placed the Italian region of Lombardy among the world’s greatest environmental tragedies.

During an uncontrolled explosion in the manufacture of trichlorophenol, a chemical used to make synthetic herbicides, a fire broke out that released a cloud of gas into the atmosphere.

Among other toxic substances, it contained TCDD (2.3,7.8-tetrachlorodibenzo-p-dioxin), a highly toxic dioxin for living organisms. It is a hazardous organic waste chemical by-product when chlorinated organic compounds are burned at high temperatures.

It is a colourless and odourless dioxin that affects cognitive, learning and memory processes, and has a carcinogenic effect; it is also bioaccumulative, as it persists in air, water and soil. So dangerous is its effect on people and living beings that Seveso was called “Italy’s Hiroshima”. Immediately, the fire caused serious skin conditions (chloracne) due to exposure to dioxin, whose aerosol covered 18 square kilometres.

The dangerous effects of dioxin were hardly known then, but over time, scientific studies revealed that it caused a high incidence of cancer. It also caused immune, nervous and endocrine problems, in addition to affecting child health, with congenital malformations and developmental problems and altered the reproductive health of women exposed to it.

The presence of dioxin in the air forced the evacuation of 736 people living in areas bordering the chemical plant. In addition, many others were temporarily displaced due to the alarming level of air and soil pollution.

Dioxin also caused the instant death of many pets. Later, 80,000 farm animals had to be slaughtered to prevent the toxin from entering the food chain, because it had accumulated in the adipose tissue of animals intended for human consumption. The pets that were left to their fate also died from ingesting contaminated plants and water.

“This disaster, with all its environmental, economic and social impacts, has attracted attention to the production, processing, storage and transportation of chemical substances.” Tannous, S., et al. (2024).

At such a dramatic moment, the safety, risks and sustainability of industries in which hazardous substances that can become dangerous gases and aerosols are handled or produced became more important than ever before. Monitoring and managing said gaseous emissions that, during an accident, can pollute the atmosphere became a European-wide objective.

Introduction to the Seveso Directive

A fateful accident that led to the 10 Member States that at that time constituted the European Community to become aware of the risks involved in working with hazardous substances at an industrial level.

No accident has had greater “legislative repercussions” than Seveso: It was suddenly seen that current legislation had shortcomings and gaps in safety and risk management in activities with a risk of major accidents. Katerina S. et al. (2017).

This is how new safety regulations with legislative power were approved, in order to prevent accidents that, in the course of their activity, certain industries could cause by working with dangerous substances.

The Seveso Directive , or Directive 82/501/EEC, was created, based on strict regulations with measures to manage and prevent serious industrial accidents involving dangerous substances to ensure the safety of workers in the workplace, and to minimise, in the event of an accident, the consequences for the population and living organisms in the surrounding area.

Advanced technologies have been shown to be an efficient tool for measuring hazardous substances. They can also warn of the risk of pollution due to the presence of certain gaseous components, to ensure compliance with the Seveso Directive.  High-precision air quality sensors, chemical analysis techniques and data management systems fed by air quality sensors are essential tools to ensure that levels of hazardous substances are kept within safe limits.

Since then, the Seveso Directive has been updated several times to be more demanding. Largely because new instances of serious accidents involving hazardous substances have occurred, such as the case of the  pesticide disaster in Bhopal (India) and the derailment of a train loaded with chemicals in Ohio  (USA).

Therefore it has started to include new lessons learned and advances in industrial risk management. The most recent versions include:

Seveso II (1996)

This introduced improvements in risk management, soil control around these type of industrial facilities and emergency planning. Measures that help to prevent the danger posed by the proximity of industries working with hazardous substances to towns and residential areas.

Seveso III (2012)

This added new types of accidents such as those arising from mining storage and treatment activities, substances used in the manufacture of fertilisers and pyrotechnic and explosive compounds. In addition to adding new substances and activities, this new version of the directive is focused on harmonising with international legislation and improving transparency with the public and workers, as well as promoting public participation.

The Seveso Directive, since its enactment in 1982, has played a crucial role in improving industrial safety in the EU. The incidence of serious accidents has been reduced by monitoring the gaseous emissions of manufacturing processes, which allows the control of emitted gaseous pollutants and their proportion. Preparedness and response to potential industrial emergencies have also been improved.

In short, the Seveso Directive represents a comprehensive effort to control the risks associated with hazardous substances through systems that warn of pollution events by certain gaseous pollutants, promoting a culture of safety and responsibility in the industry.

What is the objective of the Seveso Directive?

The guidelines set out in the Seveso Directive have a common objective: To prevent serious accidents in industries that handle large quantities of dangerous substances. These can affect both the people who work and live in the area, as well as the ecosystems of the area where facilities are located.

The most important points of the directive are based on:

Identification of establishments:

• Industries and manufacturing activities that handle, store or could generate hazardous chemicals are subject to strict legislative compliance with the directive.
• A classification of factories and activities is established according to the quantity and type of hazardous substances present (high and low risk) in their facilities.
• New industries must undergo a thorough assessment before starting their operations, ensuring they meet all established safety requirements.

Emergency Plans:

• Obligation to develop and maintain internal (by the company) and external (by the local authorities) emergency plans.
• Regular review and testing of these plans to maintain their effectiveness.
• Obligation to inform the public about related risks and safety measures in place.
• Public participation in decision-making related to the installation of new industrial plants or the modification of existing ones.

Inspections and compliance:

• Regular inspections and audits by competent authorities are required to ensure compliance with the directive.
• Imposition of sanctions in the event of breaches.
• Safety reports:
  • Companies must submit detailed safety reports that include risk analyses, preventive measures and adequate emergency plans.
  • Periodic evaluation and updating of these reports.

Notification of accidents:

• Obligation to notify the competent authorities immediately in the event of an accident.
• Provision of detailed information about the accident and the measures taken to mitigate and prevent future incidents.

Assessment of urban planning impact and its control:

• Assessment of the impact of new industrial projects in terms of safety and proximity to residential areas.
• Strict control of urban planning near industries where hazardous substances are handled.

International cooperation:

• Promotion of cooperation and information exchange between Member States to improve prevention and response to major accidents for the protection of any living organism.

New substances:

• The directive also covers the management of new hazardous substances, ensuring that any newly introduced substance is properly assessed and controlled to prevent incidents.
• Existing industries are required to regularly review and update their safety protocols to adapt to regulatory changes and new threats that are identified concerning hazardous substances.
• The directive encourages research into and the development of new technologies and methods for the safe management of hazardous substances, as well as the continuous training of personnel involved in their handling.
• Through the inclusion of new hazardous substances in its scope, the directive adapts to scientific and technological advances, ensuring that industrial plants and their related manufacturing processes are always a prime focus in terms of safety and risk prevention.

Emergency plans

The implementation of the Seveso Directive involves close cooperation between industrial plant operators and regulatory authorities. In order to operate, factories must demonstrate their ability to measure and control their gaseous emissions.

In addition, they must be able to effectively manage any incident, whether indoor or outdoor, to minimise the impact of air pollution on human health and the environment.

“The fact that, despite the improvements still accidents happen is due to a number of factors, such as present methods do not guarantee perfect hazard identification and skip turn-arounds and other abnormal situations.” Laurent A., et al (2021).

Surveillance and enforcement are crucial to preventing serious accidents and protecting workers and surrounding communities alike. To determine whether a business can operate it is essential to take into account the multiple actors involved and the various possible scenarios. It is also necessary to establish a risk criteria evaluation that includes both qualitative and quantitative aspects.

However, these considerations are not sufficient to prevent accidents. It is also necessary to take into account other factors, such as changes introduced to promote energy savings, the technology used to automate industrial tasks and the ageing of facilities, among other factors.

In this sense, the Seveso Directive not only seeks to protect people and the environment from the devastating effects of a serious accident, but also to promote innovation and constant improvement in the industry.

Emergency plans focus on actions that must be carried out within the facility to control and minimise the effects of an incident.

These measures should include:

• Staff training.
• The installation of detection and alarm systems through constant air quality monitoring.
• Conducting regular drills to ensure that all employees are trained to act effectively in the event of an emergency.
• The provision of adequate personal protective equipment and clear procedures for evacuation and confinement, depending on the nature of the accident.
• In addition, external emergency plans are equally crucial and focus on coordination with local authorities and emergency services in order to manage the response outside facilities.

Said plans should include:

• Effective communication with the local community to inform people about potential risks and procedures to follow in the event of a serious accident.
• The identification of evacuation routes.
• The designation of secure meeting points.
• The preparation of the necessary resources to assist the affected population.
• The performance of joint drills between the facility and local authorities, in order to continuously assess and improve the effectiveness of external emergency plans.
• Close cooperation with local emergency services to prepare and keep these effective accident response plans up to date.

How do you know if the Seveso Directive affects you?

To determine whether the Seveso Directive affects your establishment, you must first identify whether hazardous substances are present and/or used in your facilities (plus any possible chemical combinations that could generate significant risks) in quantities included in the list of substances in the Seveso III Directive (Directive 2012/18/EU)detailed in its Annex I.

Its classification of hazardous substances is based on Regulation (EC) No. 1272/2008, known as the CLP (Classification, Labelling and Packaging) Regulation. It is implemented based on the criteria of the Globally Harmonised System of Classification and Labelling of Chemicals (GHS).

The GHS is an internationally agreed system of the United Nations (UN) that provides consistent criteria for the global classification and labelling of chemicals. It aims to ensure the protection of human health and the environment by providing consistent and clear global communication on the hazards of chemicals that threaten human health and living organisms in terrestrial and aquatic habitats.

It also simplifies international trade by facilitating the compatibility of chemicals regulations between countries. It also provides a common language for identifying potential hazards and for anyone to understand the risks of exposure to such hazardous substances.

Measuring hazardous substances

Measuring and controlling hazardous substances present in an industrial area is the fundamental task of the Seveso Directive. This analysis should not only consider the quantities stored, but also the characteristics of each substance, such as its toxicity, flammability and reactivity. The control should also be regularly updated to include new hazardous substances that may have been introduced.

Accurate measurement is essential, since an error in the identification or quantification of these substances could lead to a serious accident that could have catastrophic impacts on the health of living beings.

Similarly, the Seveso Directive establishes that these establishments must implement air quality monitoringControlling air quality is an essential task in order to enjoy optimal environmental conditions for healthy human development and to keep the environment i...
Read more systems continuously to detect possible leaks or accidental releases of these substances that alter the Air Quality Index. These advanced systems, such as those used in Kunak monitoring devices, are designed to alert operators in real time, thereby enabling informed action and a rapid and effective response to mitigate any potential risk.

Determining the level of hazardous substances in your establishment

The implementation of advanced technologies to measure hazardous substances is an essential component in order to comply with the Seveso Directive. High-precision air quality sensors, chemical analysis techniques and data management systems provided by air quality sensors are essential tools to ensure that levels of hazardous substances are kept under control and within safe limits.

Similarly, the directive also requires companies to conduct regular risk assessments, which must include simulations of major accident scenarios, in order to assess the effectiveness of the safety measures implemented.

The correct identification and classification of hazardous substances will allow us to determine whether they are classified as low or high level according to the Seveso Directive. This is a factor that in turn will determine the safety measures and emergency plans to be implemented in each case.

In short, measuring hazardous substances accurately and consistently is a fundamental pillar for the prevention of serious accidents and compliance with the Seveso Directive.

How can Kunak help you comply with Seveso Directive?

Kunak Technologies is a leader in environmental monitoring solutions and could be your partner for compliance with the Seveso Directive in any industrial activity that handles and generates hazardous substances that could alter air quality.

Our advanced environmental monitoring systems, based on innovative and reliable solutions , allow the identification and management of new hazardous substances, as well as detecting those already present in the air.  Our precision and efficiency are endorsed by international organisations, and by the recognition of the awards we have won.

By analysing the information provided by air quality sensors on an integrated platform, reports are generated that make it easier for managers of new and existing industrial plants to access critical information in real time. This is an essential factor for those who work with hazardous substances to make informed decisions and thereby implement effective corrective measures if irregularities are detected.

Kunak technology is highly adaptable, meeting the specific needs of every industry that could emit gases into the atmosphere when handling hazardous substances. This means that Kunak air quality monitoring devices can be easily integrated into existing environmental management systems in industries. This improves operational efficiency, as well as ensuring that all the requirements of the Seveso Directive are met without significant changes to existing infrastructures.

In conclusion, Kunak offers a comprehensive solution that not only helps compliance with the Seveso Directive, but also improves the safety and sustainability of industrial facilities handling hazardous substances.

References

Cárdenas, S.I., & Barba, X.G. (2019). Identificación, evaluación y control de riesgos y plan de emergencia para el tanque estacionario de Glp de la Escuela de Gastronomía de la ESPOCH, aplicando la normativa Seveso y método Probit. http://dspace.espoch.edu.ec/handle/123456789/11555

Motos, R., & Isabel, M. (2017). Los accidentes graves en la industria química: análisis de la normativa Seveso y nuevas propuestas. https://digitum.um.es/digitum/handle/10201/56106

Ochoa, M.S., & Trujillo, A. (2006). El análisis de riesgo medioambiental en el ámbito de la normativa Seveso. https://www.semanticscholar.org/paper/El-an%C3%A1lisis-de-riesgo-medioambiental-en-el-%C3%A1mbito-Ochoa-Trujillo/68b7af18815c37ac71e517badd8b107618d308e9

Katerina S. et al. (2017). Lessons learned from environmental risk assessment within the framework of Seveso Directive in Czech Republic and Italy. Journal of Loss Prevention in the Process Industries, Volume 49, Part A, 2017, Pages 47-60. https://doi.org/10.1016/j.jlp.2017.01.017

Laurent A., et al. (2021). A critical perspective on the implementation of the EU Council Seveso Directives in France, Germany, Italy and Spain. Process Safety and Environmental Protection, Volume 148, 2021, Pages 47-74. https://doi.org/10.1016/j.psep.2020.09.064

Tannous S., Merad M., Hayes J. (2024).  A comparative analysis of risk prevention policy tools and governance structures in Normandy (France) and Victoria (Australia): Assessing policies for high-risk sites, International Journal of Disaster Risk Reduction, Volume 110, 2024, 104600. https://www.sciencedirect.com/science/article/pii/S2212420924003625