fertilizer plants defined 101

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Fertilizer Plants101

So What Does a Fertilizer

Plant Look Like?

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ExamplesFertilizer Plants

• NAICS 325311 Nitrogenous Fertilizer Mfg.• NAICS 325312 Phosphatic Fertilizer Mfg.• NAICS 325314 Fertilizer (Mixing Only) Mfg.

North American Industry Classification System (NAICS)

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Fertilizer Plant

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Fertilizer Plant

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Fertilizer Plant

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OSHA Process Safety Management (PSM)

Violations-07/28/2011 (Fertilizer Plant)

• 1910.119(d) Process safety information. • 1910.119(e) Process hazard analysis.• 1910.119(f) Operating procedures• 1910.119(j) Mechanical integrity• 1910.119(k) Hot work permit.• 1910.119(l) Management of change.• 1910.119(o) Compliance Audits

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Grain and Field Bean Merchant Wholesalers

Adair Grain Inc.AKA, West Fertilizer

West, Texas

EPARisk Management Plan (RMP)

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Anhydrous Ammonia

DOT-Nonflammable EPA Toxic Inhalation Hazard

Anhydrous Ammonia On-Site Process Safety Controls:

•Pressure Relief Valves•Excess Flow Valves•Check Valves•Manual Shutoff Source:

West Fertilizer EPA Risk Management Plan

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DOT NonflammableAnhydrous Ammonia

• Sprinklers -No

• Water Deluge Systems-No

• Blast Walls-No

• Fire Walls-No

These engineering control measures not required for nonflammables

Source:West Fertilizer EPA Risk Management Plan

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Ammonium Nitrate

• Hazard Class Division 5.1: Oxidizers• Not an EPA-RMP Highly Hazardous Chemical • Not an OSHA-PSM Highly Hazardous Chemical• As a result not listed in EPA Risk Management Plan

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Merchant Wholesalers Process Safety Management (PSM)

Exempt

PSM does not apply to a retail facility when more than half (>50%) of the income is from sales of a PSM-covered chemical to end users (farmers) such as anhydrous ammonia.

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PSM Exemption Example

Businesses primarily engaged in the merchant distribution of farm supplies, such as:

• Animal feeds, • Fertilizers • Agricultural chemicals • Pesticides

• Plant seeds and plant bulbs

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Establishments

Fertilizer Plants Agriculture SuppliersHealth Care Products

Mining Suppliers Concrete & AggregatesChemical Wholesalers

44 facilities in Texas reported having at least 10,000 pounds ammonium nitrate. 

http://www.dallasnews.com/news/local-news/20130503-find-ammonium-nitrate-sites-near-you.ece

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Texas Agriculture & Farm SuppliersGoogle Map Examples

• Adair Grain, Inc. Dba West Fertilizer Co• Helena Chemical Company• Lawrence Farm And Ranch Supply

• Riggs' Feed & Fertilizer, Inc.

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• Buddy‘s Plant Plus• Gavilon Fertilizer, Llc

Texas Fertilizer PlantsGoogle Map Examples

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The Problem

Referring to agricultural wholesale/retail establishments as fertilizer plants

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Result

Stakeholders not believing they have anything in the magnitude of the West, Texas facility, since they’re not a fertilizer manufacturer, yet have businesses supplying fertilizer in bulk for agricultural entities.

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Farm Supplies Merchant Wholesalers

EPA Risk Management Plan

• 3,645 facilities • 138 five-year accidents

• 3 deaths from 5-year accidents • 191 injuries from 5-year accidents

• $209, 774 property damage from 5-year accidents

Source: EPA Risk Management Plans

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Alternative Solution

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Offsite Consequence Analysis&

Worst-Case Release Scenario Analysis

Flammables. Endpoints for flammables (Scenarios)

(i) Explosion. Overpressure of 1 psi.(ii) Radiant heat/exposure time.

(iii) Lower flammability limit.

Source:CFR Title 40: Protection of Environment PART 68—CHEMICAL ACCIDENT PREVENTION PROVISIONS Subpart B—Hazard Assessment

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So What Do You Think?

Thank You

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