BUNDELKHAND INSTITUTE OF ENGINEERING AND TECHNOLOGY

JHANSI , UTTAR PRADESH(284128)

Topic : Hazard and Risk Management in Chemical Industries

Submitted to : Submitted by :-
Dr. Ravindra Kumar Niranjan Sir Karunendra (2100430510004)

Department of Chemical Engineering BIET Jhansi

 CONTENTS

1. INTRODUCTION
2. RISK AND HAZARD
3. TYPES OF HAZARD IN CHEMICAL INDUSTRIES
4. DIFFERENCE BETWEENN RISK AND HAZARD
5. RISK ASSESSMENT IN CHEMICAL INDUSTRIES
6. RISK CONTROL AND MITIGATION MEASURES
7. CASE STUDIES
8. CONCLUSION
 INTRODUCTION

Chemical industries are responsible for the production of chemicals, petrochemicals, pharmaceuticals, and other
products that are integral to modern society. However, these industries operate in environments where the handling
of hazardous materials presents significant risks, including chemical leaks, fires, explosions, and exposure to toxic
substances.
The goal of risk and hazard management in chemical industries is to prevent such incidents, minimize their impact
when they occur, and ensure the safety of employees, the surrounding community, and the environment.

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 RISK AND HAZARD
Hazard: A hazard is an inherent physical, chemical, biological, or ergonomic condition or property that has the
potential to cause harm. It's an inherent characteristic of a substance, process, or activity, independent of the
probability of an incident occurring. Hazards exist regardless of whether controls are in place or not.
Risk: Risk is the likelihood or probability that a hazard will cause harm, combined with the severity of that harm.
It's a measure of the potential consequences of a hazardous event. Risk considers the probability of exposure to a
hazard and the severity of the resulting harm. Risk is dynamic, meaning it changes based on the controls in place
and other factors.

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 TYPES OF HAZARDS IN CHEMICAL INDUSTRIES
Chemical industries are exposed to various hazards that can have catastrophic consequences if not properly managed.
These hazards can be categorized into the following:
2.1 Chemical Hazards
•Toxic Chemicals: Exposure to hazardous chemicals can result in acute or chronic health effects such as poisoning,
respiratory problems, and cancer.
•Corrosive Substances: Chemicals that cause severe damage to living tissues or equipment.
•Reactive Chemicals: Chemicals that can react violently under certain conditions, leading to fires, explosions, or the
release of hazardous by-products.
2.2 Physical Hazards
•Fire and Explosion: Chemical reactions or the presence of flammable materials can lead to fire or explosions.
•Mechanical Hazards: Issues like equipment failure or improper maintenance leading to accidents.
•Pressure and Temperature Hazards: Equipment or systems operating under extreme conditions that could fail,
leading to accidents.

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 2.3 Environmental Hazards
•Pollution: Air, water, or soil contamination from accidental releases of toxic chemicals.
•Waste Management: Improper disposal of hazardous waste can result in environmental damage.
2.4 Human and Ergonomic Hazards
•Human Error: Accidents resulting from mistakes in handling chemicals or machinery.
•Ergonomic Issues: Poor workplace design leading to physical strain or injury to workers

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 DIFFERENCE BETWEEN RISK AND HAZARD

Example illustrating the difference between hazard and risk:

Hazard: A tank of flammable liquid propane.
Risk: The probability of a fire or explosion due to a leak in that propane tank, considering the size of the tank, the
presence of ignition sources, and the effectiveness of safety measures. The risk is low if appropriate safety
measures (pressure relief valves, fire suppression systems, emergency response plans) are in place and regularly
inspected. The risk is much higher if these controls are absent or deficient.
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 RISK ASSESSMENT IN CHEMICAL INDUSTRIES
Risk assessment is a systematic process to identify potential hazards, evaluate the risks associated with these hazards,
and implement measures to manage and mitigate these risks.
1. Steps in Risk Assessment
i. Hazard Identification: The first step is identifying potential hazards in the workplace. This can include
analyzing raw materials, processes, and equipment.
ii. Risk Analysis: Once hazards are identified, the likelihood and severity of each risk are assessed. This step
typically involves qualitative or quantitative analysis.
iii. Risk Evaluation: This involves comparing the level of risk with accepted risk levels or safety standards and
determining whether the risk is tolerable or needs mitigation.
iv. Risk Control: Identifying and implementing strategies to eliminate or reduce risks. This can involve engineering
controls, administrative controls, or personal protective equipment (PPE).

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 2. Hazard identification
 HAZOP (Hazard and Operability Study): A structured and systematic examination of a process to identify and
assess potential hazards. A team of experts systematically examines each part of the process, considering
deviations from the intended operating parameters.
 What-If Analysis: A brainstorming technique where a team explores potential scenarios by asking "What if...?"
questions about various aspects of the process or equipment.
 Fault Tree Analysis (FTA): A deductive technique that starts with an undesired event (top event) and works
backward to identify the underlying causes (faults) that could lead to that event. Uses a graphical representation
(fault tree) to show the relationships between faults.
 FMEA (Failure Modes and Effects Analysis): Identifies possible failure modes in a system and evaluates their
effects on system performance.
 Layer of Protection Analysis (LOPA): A quantitative technique that assesses the risk reduction provided by
different layers of protection (e.g., safety instrumented systems, alarms, procedures) to mitigate the consequences
of hazardous events.

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 RISK CONTROL AND MITIGATION MEASURES
Effective risk control involves reducing the likelihood and severity of potential hazards. Some common control
measures in chemical industries include:
1. Engineering Controls
•Ventilation Systems: To control exposure to harmful airborne chemicals.
•Process Containment: Using sealed systems or barriers to prevent spills or leaks of hazardous substances.
•Explosion-Proof Equipment: Equipment designed to withstand explosion pressure or prevent ignition of
flammable substances.
2. Administrative Controls
•Standard Operating Procedures (SOPs): Written protocols that define the proper handling of chemicals and
processes.
•Training and Education: Regular training sessions for employees on safety procedures, emergency response, and
chemical handling.
•Safety Audits: Regular audits to ensure compliance with safety standards and regulations.

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 3. Personal Protective Equipment (PPE)
•Gloves, goggles, and respiratory protection are essential to minimize direct exposure to chemicals and
hazardous environments.
4. Emergency Preparedness
•Emergency Response Plans (ERPs): Detailed procedures for responding to accidents, spills, fires, or explosions.
•Fire Suppression Systems: Systems like sprinklers, fire extinguishers, and foam for managing fire hazards.
•First Aid Training and Equipment: Immediate response kits and trained personnel to handle accidents.

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 CASE STUDIES
1. Bhopal Gas Tragedy (1984): One of the worst industrial disasters in history, where a toxic gas leak from a
Union Carbide pesticide plant in Bhopal, India, in 2-3 December,1984 resulted in thousands of deaths and
injuries. This disaster highlighted the importance of process safety management, emergency preparedness, and
the need for strict regulatory oversight.
2. Deepwater Horizon Oil Spill (2010): The Deepwater Horizon spill involved the release of hazardous
chemicals into the ocean. This incident emphasizes the importance of hazard assessments, safety measures, and
the need for robust risk management systems in industries handling chemicals and hydrocarbons.

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 CONCLUSION
Effective risk and hazard management is not merely a regulatory requirement in the chemical industry; it's a
fundamental pillar of responsible operation, ensuring worker safety, environmental protection, and business
sustainability. A comprehensive strategy encompasses a cyclical process of hazard identification, risk assessment,
control implementation, and continuous monitoring. This requires not only the adoption of established
methodologies like HAZOP and What-If analysis but also the cultivation of a strong safety culture that prioritizes
prevention, empowers employees, and encourages open communication.
The economic benefits of effective risk management are significant, minimizing the potential for costly accidents,
production downtime, legal liabilities, and reputational damage. The chemical industry is constantly evolving, with
new technologies, processes, and materials continually emerging. This necessitates a dynamic approach to risk and
hazard management, adapting strategies and incorporating best practices to stay ahead of emerging challenges and
ensure the ongoing protection of workers, the environment, and the public

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THANK YOU