Risk analysis report of chemical fertilizer production process
Key words: fertilizer, regulation, discipline and measures: the technical management of production process safety is an important part of enterprise safety management and a key monitoring link of safety management, especially the control of key safety process indicators is very important. If the safety management of the production process is done well, other accidents will be reduced accordingly, which can ensure the continuous and stable operation of various production devices, and then we can talk about economic benefits, social benefits and the survival and development of enterprises. The process characteristics of modern large chemical fertilizer plant are advanced process flow, large material circulation, high reaction pressure and temperature, fast rotating speed of rotating machinery and strict control of process parameters. The production process is carried out at high temperature, high pressure, low temperature and negative pressure. The raw materials, intermediate products and products used in production have many dangerous factors such as flammability, explosion, poisoning and corrosion, especially the production of synthetic ammonia and sulfuric acid, especially the start-up and shutdown time of synthetic ammonia is long and the consumption is large. In addition, some enterprises are backward in technology, have incomplete or defective safety facilities, lack the most basic control and support capabilities, and have defects and hidden dangers in design and equipment to varying degrees, which brings certain difficulties to process safety management. In the actual production process, operational accidents (process accidents) caused by poor management of process safety technology or operational errors are common, which have caused huge economic losses to enterprises. In the process of chemical fertilizer production, there are many hidden dangers due to various reasons. Eliminating hidden dangers of accidents and preventing all kinds of accidents is a major event in production. Therefore, in view of the key points of chemical fertilizer safety management, the countermeasures of strengthening chemical fertilizer safety production management, preventing accidents, strengthening training and education and improving operation level are put forward. Carry out safety training from team to individual, and everyone must pass the safety barrier. First of all, we should pay attention to the training object. When many senior managers mention training and education, they often only think of post operators. In fact, this idea is one-sided, and the training and education of post operators is absolutely indispensable. But more importantly, managers, technicians and production commanders at all levels should also receive comprehensive education and training in strict safety technology and process technology, so as to achieve "three understandings and four skills". Be familiar with all aspects of the production process, find existing problems or hidden dangers in time during inspection, and put forward solutions and preventive measures. Risk factors exist with production, which is the premise of risk factors. Without production, these risk factors will naturally disappear. In the production process, if we can identify and control the dangerous factors, we can avoid or reduce accidents, that is, minimize the injuries and losses, so as to achieve the expected goal of safe and civilized production and bring vitality, vitality and benefits to enterprises. Secondly, the ability to deal with emergencies or emergencies is also an essential training content. Before the factory is put into production, the enterprise shall prepare an emergency plan for chemical accidents and train personnel at all levels. Conditional units should also conduct simulation drills to let personnel at all levels know how to deal with emergencies, and gradually improve the emergency response ability of personnel at all levels through training. Thirdly, we should pay attention to the training methods, which should be flexible and diverse, that is, centralized teaching, on-site operation training, "send out and please come in", after-class meeting, posting answer sheets and other forms. No matter how the training is conducted, we should pay attention to the effect. As a training manager, you should have a high sense of responsibility, be responsible for the company, be responsible for the operators, never go through the motions, and carefully organize the training, so as to achieve the training effect. Managers' understanding of the purpose and significance of training will affect the quality of training. If the operator arranges to operate independently without training, it will not only violate the provisions of relevant laws and regulations such as Labor Law, Safety Production Law and Occupational Disease Prevention Law, but also be prone to accidents due to unskilled operation and lack of the most basic safety knowledge. Therefore, strengthening training and education is the basic premise and important link to improve the safety management of fertilizer production process. 2. Formulate scientific and strict process regulations, post operation methods and safety technical regulations. Before each production device is put into trial production, corresponding process regulations, post operation methods and safety technical regulations must be formulated to meet the production requirements and ensure the safety requirements. When introducing new technology or changing process conditions, it must be reviewed and approved by the person in charge of technical management department (or chief process engineer), and it is required to revise operation methods and other regulations, and timely issue effective versions to all production posts to guide production operations. Without approval, no one is allowed to change the process index, let alone carry out experimental operation on the equipment. We must strictly abide by the process regulations, otherwise it will be difficult to ensure safe and civilized production. 3, strict artistic discipline, to ensure safety in production. Strengthen the supervision and inspection of the implementation of process indicators, strictly enforce process discipline, be strict with operators, strengthen ideological education of process discipline, and gradually improve the consciousness of observing discipline. In the production process, the operation is carefully carried out in strict accordance with the process regulations and operation methods, and the changes of temperature, pressure, flow rate, trace elements and other indicators in production are strictly monitored. At the same time, strengthen the cooperation between posts, and the process indicators should not fluctuate greatly, let alone run over temperature, pressure and load. Once the important safety process parameters are out of control, it will lead to irreparable consequences. Therefore, production commanders and post operators at all levels are required to stick to their posts and strengthen the monitoring of process index changes. Once there is an abnormality, it is necessary to adjust it in time and take effective measures decisively to save the day. 4. Take intrinsic safety measures to ensure the safe operation of the equipment. Modern large chemical fertilizer plants are equipped with automatic instruments, such as Tianji Coal Chemical Industry Group, which are mainly used in thermal power plants, power plants, synthetic ammonia plants, nitric acid plants, compound fertilizer plants and ammonium nitrate plants. Their automatic control features are: many kinds of detection, many detection points, high precision requirements, many centralized control systems, and many alarms and interlocks. In addition to testing or controlling common chemical measurement parameters, such as pressure, temperature, liquid level and composition, it also tests or controls parameters, such as speed, vibration, displacement, density, flame, program operation and pump stroke. The layout principle of automatic instruments is to set up detection, control or alarm interlocking devices according to the main links of the process and the characteristics of the main equipment, so as to ensure the safe and stable operation of large chemical fertilizer plants. At ordinary times, it is necessary to strengthen maintenance and regular inspection, eliminate abnormal faults in time, and ensure good, effective and sensitive state. 5. Evaluate the safety of process indicators. There are many technological indexes in the production process, and each index is difficult to control. Therefore, all process indicators are classified and managed, and according to the size of accidents or dangers that may be caused by out-of-control process indicators, they are divided into safety process indicators, and general process indicators are managed in a targeted manner. Because not every out-of-control process index will lead to accidents, some out-of-control process indexes will only affect product quality and will not involve personal equipment safety, while some out-of-control process indexes will lead to major accidents, such as equipment damage, production stoppage or casualties. Key safety process indicators like this should be listed as key monitoring targets. Thirdly, the control range of process indicators is divided into three areas, such as normal operation control area A-B, danger control area C-D and accident control area E and above. In the production process, once it is found that the safety process index fluctuates into the dangerous area, it should be adjusted decisively in time, otherwise it may lead to an accident if it enters the accident area. In addition, the risk analysis and evaluation of important safety process indicators are carried out, which indicators have a high probability of losing control and which indicators have a low probability of losing control; Which indicators are at greater risk of losing control and which indicators are at lower or general risk of losing control; Through careful analysis and evaluation of safety process indicators, the key or weak link of process safety management is found out, and effective measures are taken to ensure the safe operation of the device. 6. Evaluate and analyze process (operation) accidents. Because there are many accidents caused by poor process safety management or operation errors, the accident losses can't be compared with personal injury accidents. Therefore, according to the principle of "four don't let go" in accident handling, the process (operation) accidents are analyzed and evaluated, the causes of accidents are found out, and accident prevention measures are formulated to prevent or reduce accident losses. As the production management department is the centralized management department of process (operation) accidents, once a process (operation) accident occurs, it should promptly organize relevant department personnel to investigate, analyze and deal with it, and evaluate the harmfulness of the accident, that is, what is the direct economic loss caused by the accident? What is the indirect loss, which production devices are affected, the scope and personnel involved, etc. If the accident expands, what is the severity of the consequences? If any abnormality is found, decisive measures shall be taken in time, and careful analysis and evaluation shall be made. Chemical fertilizer branch should always take enterprise safety production as the maximum benefit, strengthen the management of potential safety hazards, make a fuss about the word "small" and work hard on the word "fine" to ensure the stable and long-term operation of the device. While increasing the management of hidden dangers, the company has established rules and regulations to strengthen the management of key positions and key departments. Production process safety technology management is an important part of enterprise safety management and a key monitoring link of safety management, especially the control of key safety process indicators is very important. Reference 1, Liu Huazhang. Industrial application of A30 1 low temperature and low pressure ammonia synthesis catalyst and discussion on several problems [J]. Fertilizer industry,1999,26 (2):16-20.2, Zhejiang Institute of Chemical Technology. ZA-65438+。