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Stream/Area:
-
Subject:
-
Paper ID:
IJSREM67709
Volume:
10 |
10 |
Oct 2026
Pages:
1-6
Publication Frequency:
Monthly (12 issues per year)
License:International Journal of Scientific Research in Engineering and Management follows the Creative Commons Attribution 4.0 (CC BY 4.0) License, allowing free use and distribution with proper attribution.
FIRE TECHNOLOGY & SAFETY ENGINEERING
VIKRANT UNIVERSITY, GWALIOR
FIRE TECHNOLOGY & SAFETY ENGINEERING
VIKRANT UNIVERSITY, GWALIOR
The fertilizer industry is a high-hazard process industry involving toxic, flammable, corrosive and high-pressure substances. Manufacturing processes for ammonia, urea and NPK fertilizers involve significant risks arising from chemical handling, high-temperature and high-pressure operations, rotating machinery, electrical systems, confined spaces, maintenance activities and material handling. Hazard Identification and Risk Assessment (HIRA) is an important systematic approach for identifying hazards, evaluating their likelihood and consequences, and establishing appropriate control measures. HIRA asks three fundamental questions: what can go wrong, how severe could the consequences be, and how likely is the event to occur. CCPS This paper examines the application of HIRA in fertilizer manufacturing, identifies major hazards associated with ammonia and urea production, and proposes control measures based on the hierarchy of controls. Particular attention is given to toxic ammonia releases, fire and explosion hazards, pressure-related incidents, chemical exposure, machinery hazards, electrical hazards, working at height and confined-space operations. The study demonstrates that systematic HIRA can support preventive safety management, prioritize high-risk activities and reduce the probability and consequences of industrial accidents.
KEYWORDS
The fertilizer industry contains significant chemical, mechanical, electrical, thermal and process-safety hazards. HIRA provides a systematic framework for identifying these hazards, assessing their likelihood and consequences, prioritizing risks and implementing appropriate controls. The most critical areas in ammonia and urea fertilizer plants generally require particular attention to loss of containment, toxic ammonia exposure, high-pressure equipment, chemical handling, fire and explosion potential, rotating machinery, electrical work, confined spaces and working at height. Effective engineering controls, operating procedures, maintenance, emergency preparedness and worker training are essential for reducing residual risk. HIRA is most effective when integrated with other process-safety techniques such as HAZOP, FMEA, LOPA, quantitative risk assessment and incident/near-miss analysis. AIChE's process-safety guidance similarly describes HIRA as a family of techniques whose depth should match the decision and lifecycle stage being assessed. CCPS
1. Khan, F. I., & Abbasi, S. A. Rapid risk assessment of a fertilizer industry using recently developed computer-automated tool TORAP. Journal of Loss Prevention in the Process Industries, 14, 413–427. ScienceDirect 2. AIChE Center for Chemical Process Safety. Introduction to Hazard Identification and Risk Analysis. CCPS 3. Darmawan, R., Ummi, N., & Umiyati, A. Identifikasi Risiko Kecelakaan Kerja dengan Metode Hazard Identification and Risk Assessment (HIRA). Jurnal Teknik Industri Untirta. Jurnal Untirta 4. Ferlania, D. A. F., & Rahadian, Y. R. Analisa Potensi Bahaya dengan Metode HIRA di Departemen Produksi. Industrial Management and Engineering Journal, 2023. Paperity 5. Bhagavathi Ana Labs/Bureau Veritas. Risk Assessment for Integrated Fertilizer Plant. Environment Clearance
Publication Date
10/6/2026
Peer Review Type
Double-Blind Peer Review
Review Rounds: 2
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Conflict of Interest
The authors declare no conflict of interest related to this research work.
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