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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

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OCCUPATIONAL AND PROCESS SAFETY IN AMMONIA PLANTS – PITFALLS TO AVOID Harrie Duisters

OCI N.V., Amsterdam, Netherlands

Content

  • Short OCI Company Introduction
  • Occupational Safety at OCI
  • Process Safety in Ammonia Plants
  • Conclusions

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OCI has 9 Production sites in 5 countries

3 OCI Nitrogen EFC OCI Beaumont EBIC Iowa Fertilizer Company Sorfert Algérie Natgasoline BioMCN Fertil UAE

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Leading Global Producer and Distributor of Nitrogen Products and Methanol

Nitrogen Products Methanol Key trends

  • Tightening supply for all products
  • Natural gas costs expected to remain competitive in Europe

and US

  • Premium products growing fast
  • Positive production margins
  • Underlying long-term fundamentals of market

remain strong Customers MTO, MTBE, fuel producers, industrial chemicals producers Raw materials Natural gas Natural gas Farmers, diesel vehicle owners, industrial chemicals producers Products Ammonia, urea, CAN, UAN, DEF and melamine Methanol Market position

  • 5th largest global methanol producer
  • Largest global bio-methanol producer
  • Largest producer in Europe
  • 2nd largest US producer

# of Sites 6 3

  • 3rd largest global producer of nitrogen fertilizers
  • 2nd largest CAN producer in Europe
  • Largest global melamine producer
  • Largest seaborne nitrogen export platform globally
  • Fast-growing presence in DEF

% of Revenue 76% 24%

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OCI’s Occupational Safety Statistics

Lost Time Injury Rates Total Recordable Incident Rates

0.05 0.1 0.15 0.2 0.25 1 2 3 4 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar LTIR Rolling LTI

Monthly LTI with Rolling LTIR

All Sites All Workers 12 Months LTI LTIR R12 LTIR Target 0.1 0.2 0.3 0.4 0.5 0.6 1 2 3 4 5 6 7 8 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar TRIR Rolling TRI

Monthly TRI with Rolling TRIR

All Sites All Workers 12 Months TRI TRIR R12 TRIR Target

Per 200,000 manhours

OCI’s Occupational Safety Statistics

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Ammonia Global Harmonised System labelling

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Ammonia Personal Protective Equipment

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Benchmark: 2018 U.S. Bureau of Labor Statistics

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Industry Total Recordable Injury Rate (TRIR) Lost Time Injury 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

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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:
  • Rushing
  • Frustration
  • Fatigue
  • Complacency
  • Etc.

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Occupational and Process Safety

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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”.

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Leak Preventing Rules

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Process Safety in Ammonia Plants

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29/04/2020 Over firing in furnace during start up

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Explosion in Reformer furnace during start up

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Overheating leading to bowing of catalyst tubes, increase in creep in coils and tubes; Tube leaks, fire inside the furnace and over pressure.

High Temperature impact in furnace

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Secondary reformer dome failure

Thermal expansion and thermal stress caused dome failure 17 18

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29/04/2020 Waste Heat Boiler Wall Crack and Fire

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Human Error - Operator covered external surface

Waste Heat Boiler refractory failure causing crack in wall

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Refractory failure followed by

  • verheating at

inlet chamber

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29/04/2020 NH4NO2 formation in SCR impulse lines

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NOx and NH3 present in flue gas can form NH4NO2 at low temperature. This can get deposited in the impulse lines which are far away from the reactor.

Rupture of Ammonia Storage Tank

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29/04/2020 Risk of Stress Corrosion Cracking in ammonia tanks

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Select the right material for H2 services

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Metal Dusting

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Nitriding of metal

Metal Nitride layer Flaking off of the nitride layer

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Corrosion under Insulation

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Mechanical Integrity analysis

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29/04/2020 Re-train personnel regularly

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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

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