With the rapid advancement of science and technology, the variety and quantity of chemicals used in industrial facilities have increased. Chemicals are used in the production of many materials we use in our daily lives. These products include cleaning agents, cosmetics, pharmaceuticals, food additives, manufacturing, construction and energy sector products, and agricultural pesticides. While this optimizes production processes and makes our lives easier, it also brings serious risks.
Prof. Dr. Didem Saloğlu Dertli
Istanbul Technical University, Institute of Disaster Management, Department of Disaster and Emergency
Fire and Explosion Risks in the Chemical Industry
Management Faculty Member
With the rapid advancement of science and technology, the variety and quantity of chemicals used in industrial facilities have increased. Chemicals are used in the production of many materials we use in our daily lives. These products include cleaning agents, cosmetics, pharmaceuticals, food additives, manufacturing, construction and energy sector products, and agricultural pesticides. While this optimizes production processes and makes our lives easier, it also brings serious risks. These dangers and risks include human health, environmental impacts, accidents, and explosions.
Hazardous chemicals are substances and mixtures with various dangerous properties such as explosive, oxidizing, highly flammable, toxic, corrosive, and irritating. These substances have the potential to affect not only the individuals who come into direct contact with them but also the environment and large populations.
Chemicals can cause major disasters such as fires and explosions due to their physical properties like explosiveness, flammability, and oxidizing characteristics. They also pose significant health risks, such as toxicity, carcinogenicity, and mutagenicity, which can severely threaten human health. Additionally, chemicals can lead to irreversible environmental damage by contaminating water sources, poisoning the soil, and threatening biodiversity. Furthermore, industrial accidents can result in substantial economic losses due to production stoppages and cleanup operations.
Combustion and fire are two concepts we frequently encounter in daily life and are of vital importance. Combustion is a type of chemical reaction. It occurs when a flammable substance (fuel) combines with oxygen at a specific temperature, and this reaction continues spontaneously. During this process, heat and light energy are released, and combustion is essentially a rapid oxidation event. Fire, on the other hand, is the uncontrolled occurrence of combustion that causes damage to the surroundings.
For a fire to occur, three essential elements are required: a combustible material, an oxidizer, and an ignition source. When a combustible material is sufficiently heated by an ignition source, it vaporizes or turns into gas. At this stage, known as ignition, the vaporized or gaseous combustible material combines with oxygen, initiating the combustion reaction. The heat released during combustion causes more material to vaporize and burn, thus feeding the flame. Combustion ceases when the combustible material, oxygen, or heat source is exhausted.
A fire is not just a threat created by flames. Fires are complex events that arise from the combination of many different factors, and these factors play a significant role in the size, duration, and impact of the fire.
In industrial facilities, there are numerous hazards associated with fires, some of which include:
“Regular risk assessments should be conducted in facilities to identify potential hazards and necessary precautions should be taken. Automatic fire detection and suppression systems should be installed in facilities and regularly maintained.”
Fire Growth Rate: The rate at which a fire grows determines the time required to bring it under control and the extent of damage it can cause. Factors such as the type and quantity of combustible materials and the ventilation of the environment affect the fire's growth rate.
High Temperature Hazard: Fires can reach very high temperatures, leading to the collapse of structures, ignition of flammable materials, and spread of the fire. Additionally, high temperatures pose a significant burn risk to individuals.
Impact of Fire Components on Fire Spread: The different components within a fire (combustible materials, smoke, heat, etc.) influence the speed and manner of its spread. For instance, flammable liquids can cause the fire to spread more rapidly, while smoke can hinder visibility and complicate evacuation efforts.
Hazards at Different Stages of a Fire: Different hazards emerge at various stages of a fire. While a fire may be more controllable in its initial stage, it becomes a greater threat in its advanced stages.
Toxic Gas Hazard: Many different toxic gases can be released during a fire, leading to respiratory diseases, suffocation, and even death.
Explosion Hazard: Some combustible materials can explode under certain conditions, increasing the fire's intensity and causing greater damage.
Collapse Hazard: High temperatures can weaken structural support systems, leading to collapses. Collapsing buildings pose a significant threat to individuals trapped underneath.
Electrical Hazard: During a fire, electrical installations can be damaged, posing a risk of electric shock.
Chemical Hazards: Some chemicals can vaporize or burn during a fire, producing toxic gases that pose serious threats to both humans and the environment.
Explosion is defined as a chemical reaction that creates a shock wave due to the rapid combustion of a flammable substance either completely or in large part. Flammable substances can be in the form of gas, vapor, mist, or dust. Explosions can occur due to chemical as well as physical reasons. These types of explosions generally occur due to an increase in pressure. Explosions can happen as a result of a fire, and fires can also be triggered by explosions. Additionally, gases released from combustion reactions can have suffocating, toxic, and other harmful effects. Combustion in the form of a flash and explosion can be seen in substances that ignite easily.
Substances that combust suddenly can transform into various gases, causing a significant volume expansion and resulting in explosions that exert pressure on their surroundings. The term "explosion" is potentially associated with a wide range of scenarios. These include the release of pressurized gas stored in a container without undergoing a reaction, the production of energy through a chemical reaction that causes an increase in pressure, the rapid transfer of heat resulting in the violent expansion of a liquid and the subsequent increase in pressure, and the violent expansion due to the loss of containment of a pressurized liquid stored at a temperature higher than its normal boiling point.
In today's world, industrial facilities in the chemical industry, especially chemical industry plants, frequently face fire and explosion risks. This situation poses serious threats both in terms of occupational health and safety as well as to the environment and the economy. Fires not only cause material losses but can also lead to fatalities and environmental disasters. As is known, a significant portion of raw materials, intermediate products, and final products used in the chemical industry are flammable and explosive. Improper storage, handling, or use of these substances increases the risk of fire. Similarly, faulty electrical installations in the facility, spark formation, and overheating can lead to fires. Improperly used or poorly maintained heating systems can elevate the risk of fire. Alongside this, equipment failures such as those of pumps and compressors also increase fire risk. In dusty and dry environments, static electricity can cause explosions. One of the significant causes of fires and explosions in a chemical plant is human error. Operational mistakes, negligence, and lack of awareness are among the most important factors contributing to fires.
To minimize fire and explosion risks in industrial facilities within the chemical industry, it is crucial to implement various preventive measures. Regular risk assessments should be conducted at the facilities to identify potential hazards and take necessary precautions. Automatic fire detection and suppression systems should be installed and maintained regularly. Detailed emergency plans should be prepared for fire or explosion scenarios, and all personnel should be informed about these plans. Regular training on fire safety should be provided to all staff, and they should learn how to use fire extinguishing equipment. Business procedures should be developed to reduce fire risks and adherence to these procedures should be ensured. All equipment in the facilities should be regularly maintained and repaired, fire-resistant coverings and barriers should be used in areas where flammable and explosive materials are stored, and electrical installations should be regularly inspected and secured.
“Activities such as risk assessment, fire safety training, disaster and emergency planning, and regular maintenance are crucial for preventing fires and minimizing potential damage.”
Additionally, measures should be taken to prevent static electricity formation in dusty and dry environments.
On the other hand, under the Regulation on the Fire Protection of Buildings, measures should be taken to prevent the spread of heat and smoke during a fire. Fire-resistant doors, walls, ceilings, and floors, as well as escape routes, should be prepared. Emergency exit doors, emergency lighting, fire detection and alarm systems, sirens and announcement systems, automatic suppression systems, fire water infrastructure, water tanks, pumps, hose cabinets, hydrants, and extinguishers should be acquired.
Additionally, the fire-fighting team should receive detailed, practical training using all fire-fighting devices and equipment available at the facility. This training should be repeated periodically, and fire drills involving all staff should be conducted more than once a year. Drill scenarios should be prepared and communicated to all personnel. It is also important to prepare a post-drill evaluation report and develop an action plan for areas needing improvement.
Although it is not possible to completely eliminate fire and explosion risks in industrial facilities, these risks can be significantly reduced by taking the necessary precautions. Activities such as risk assessment, fire safety training, disaster and emergency planning, and regular maintenance are crucial for preventing fires and minimizing potential damage.
An Overview of Disaster Management
Disaster and emergency management, which is particularly important for industrial facilities in the chemical industry, is a struc-ture that encompasses the entire process of organizing resources for risk and damage reduction, preparation, response, and recovery activities against all types of hazards. This includes the analysis, planning, decision-making, and evaluation processes involved. The fundamental components of disaster management are illustrated in Figure 1.
The primary objectives and goals of the four main phases of disaster management are briefly as follows:
Mitigation: The first phase of disaster management involves iden-tifying steps to reduce the risk of injury and loss due to structural and non-structural causes before a disaster occurs.
Preparedness: This phase provides checklists to evaluate current practices and capabilities. Its aim is to highlight areas where your workplace needs to be better equipped and trained to handle disasters such as earthquakes.
Response: This phase offers guidance on what employees should do both individually and as teams during and immediately after disasters.
Recovery: This phase focuses on assessing the workplace’s capabilities for recovery and returning to normal operations after a disaster, and planning for improvement activities post-disaster.
Effective planning in risk and damage reduction, preparedness, response, and recovery can minimize the adverse effects of disasters and prevent the occurrence of secondary disasters and emergencies.
Whether dealing with natural or human-made threats and risks, institutions that do not take preventive and protective measures or are unprepared will not have the chance to respond to incidents in a timely, efficient, and effective manner, thereby reducing the chances of minimizing damage and loss during disasters.
In this context, the primary goal of Disaster and Emergency Management Planning is to:
Before Disasters and Emergencies: Identify potential hazards and risks, reduce risks to manageable levels, manage risks, prevent them if possible, or mitigate their potential impacts, and ensure preparedness for disasters.
During Disasters and Emergencies: Implement the principles of rescue, first aid, and evacuation using the correct behaviors acquired through training and exercises without interruptions.
After Disasters and Emergencies: Use the lessons learned to ensure timely, rapid, and effective response to the incident, minimize losses, and determine and implement the necessary actions to ensure business continuity.
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