29/04/2020 OCCUPATIONAL AND PROCESS SAFETY IN AMMONIA PLANTS – PITFALLS TO AVOID Harrie Duisters OCI N.V., Amsterdam, Netherlands 1 Content - Short OCI Company Introduction - Occupational Safety at OCI - Process Safety in Ammonia Plants - Conclusions 2
29/04/2020 OCI has 9 Production sites in 5 countries EBIC BioMCN OCI Nitrogen EFC OCI Beaumont Natgasoline Fertil UAE Iowa Fertilizer Company Sorfert Algérie 3 3 Leading Global Producer and Distributor of Nitrogen Products and Methanol Nitrogen Products Methanol % of Revenue 76% 24% Products Ammonia, urea, CAN, UAN, DEF and melamine Methanol # of Sites 6 3 3 rd largest global producer of nitrogen fertilizers 5 th largest global methanol producer 2 nd largest CAN producer in Europe Largest global bio-methanol producer Market position Largest global melamine producer Largest producer in Europe Largest seaborne nitrogen export platform globally 2 nd largest US producer Fast-growing presence in DEF Tightening supply for all products Positive production margins Natural gas costs expected to remain competitive in Europe Key trends Underlying long-term fundamentals of market and US remain strong Premium products growing fast Raw materials Natural gas Natural gas MTO, MTBE, fuel producers, industrial chemicals Customers Farmers, diesel vehicle owners, industrial chemicals producers producers 4 4
29/04/2020 OCI’s Occupational Safety Statistics Monthly LTI with Rolling LTIR All Sites All Workers 12 Months 4 0.25 0.2 3 LTIR Rolling Lost Time 0.15 Injury LTI 2 0.1 Rates 1 0.05 0 0 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar LTI LTIR R12 LTIR Target Monthly TRI with Rolling TRIR All Sites All Workers 12 Months 8 0.6 7 0.5 Total 6 TRIR Rolling 0.4 Recordable 5 TRI 4 0.3 Incident 3 0.2 Rates 2 0.1 1 0 0 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar TRI TRIR R12 TRIR Target Per 200,000 manhours 5 5 OCI’s Occupational Safety Statistics 6 6
29/04/2020 Ammonia Global Harmonised System labelling 7 7 Ammonia Personal Protective Equipment 8 8
29/04/2020 Benchmark: 2018 U.S. Bureau of Labor Statistics Total Recordable Lost Time Injury Industry Injury Rate (TRIR) Rate (LTIR) All industries including private, state and local government 3.1 1.0 Private industry 2.8 0.9 Construction 3.0 1.2 Manufacturing 3.4 0.9 Chemical manufacturing 1.9 0.6 Basic chemical manufacturing 1.3 0.5 Petroleum refineries 0.4 0.2 Industrial gas manufacturing 1.0 0.4 Other basic inorganic chemical manufacturing 1.3 0.5 Fertilizer manufacturing 3.3 0.7 Nitrogenous fertilizer manufacturing 1.9 0.3 OCI NV 2018 0.39 0.08 9 9 CONTINUOUS attention to improve on safety • Safety Tours and Observations in the plants • Contractors (LMRA) • Review Safe Work Practices and Procedures • Learning from Incidents, Incident Investigations, Flyers • Safety training program • Monthly safety teleconferences • Weekly HSE news articles • Quarterly publishing of an HSE newsletter • Corporate Standards • Site Audits • Annual Safety Award • Annual Safety Conference • Safety Awareness Programs; SafeStart: o Rushing o Frustration o Fatigue o Complacency • Etc. 10 10
29/04/2020 Occupational and Process Safety 11 11 Process Safety A process safety incident is the unexpected release of toxic, reactive, or flammable liquids and gases from our processes. Loss of Primary Containment “Keep the tiger in the cage”. 12 12
29/04/2020 Leak Preventing Rules 13 13 Process Safety in Ammonia Plants 14 14
29/04/2020 Over firing in furnace during start up 15 15 Explosion in Reformer furnace during start up 16 16
29/04/2020 High Temperature impact in furnace Overheating leading to bowing of catalyst tubes, increase in creep in coils and tubes; Tube leaks, fire inside the furnace and over pressure. 17 17 Secondary reformer dome failure Thermal expansion and thermal stress caused dome failure 18 18
29/04/2020 Waste Heat Boiler Wall Crack and Fire Human Error - Operator covered external surface 19 19 Waste Heat Boiler refractory failure causing crack in wall Refractory failure followed by overheating at inlet chamber 20 20
29/04/2020 NH 4 NO 2 formation in SCR impulse lines NOx and NH3 present in flue gas can form NH 4 NO 2 at low temperature. This can get deposited in the impulse lines which are far away from the reactor. 21 21 Rupture of Ammonia Storage Tank 22 22
29/04/2020 Risk of Stress Corrosion Cracking in ammonia tanks 23 23 Select the right material for H2 services 24 24
29/04/2020 Metal Dusting 25 25 Nitriding of metal Metal Nitride layer Flaking off of the nitride layer 26 26
29/04/2020 Corrosion under Insulation 27 27 Mechanical Integrity analysis 28 28
29/04/2020 Re-train personnel regularly 29 29 Conclusions • Ammonia is dangerous stuff and ammonia plants have a lot of safety risks that need to be managed well • Both Occupational and Process Safety are important • Knowledge on both aspects is of key importance 30 30
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