Fertilizer Plants Defined 101

Combustible Dust Policy Institute 1

Fertilizer Plants101

So What Does a Fertilizer

Plant Look Like?


ExamplesFertilizer Plants

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

North American Industry Classification System (NAICS)


Fertilizer Plant


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


Grain and Field Bean Merchant Wholesalers

Adair Grain Inc.AKA, West Fertilizer

West, Texas

EPARisk Management Plan (RMP)


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


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


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


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.


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


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

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


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.


• Buddy‘s Plant Plus• Gavilon Fertilizer, Llc

Texas Fertilizer PlantsGoogle Map Examples


The Problem

Referring to agricultural wholesale/retail establishments as fertilizer plants


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.


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


Alternative Solution


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


So What Do You Think?

Thank You

Support your Local Emergency Planning Committee (LEPC)

Fertilizer Plants Defined 101

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