Journal of Health and Safety at Work

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Introduction: Being aware of the explosion, fire radius, and their damages, has an important role in accident prevention methods. Therefore, the aim of this study was modeling and evaluation of the consequences of propylene oxide spill in a petrochemical company.
 

Material and Method: The QRA method including seven steps was used in this study. In the present study, in order to examine and modeling of the propagation propylene oxide, first a familiarization with the process information of the unit was done then, a risk assessment was carried out adopting HAZOP technique to identify existing hazards. Consequence analysis in a process unit includes: selecting important scenarios, characterizing scenario, modeling the consequences of scenarios, analyzing the results and determining the percentage of mortality. PHAST software version 6.51 was used for modeling of outcomes and assessment propylene leak.
 

Result: urves of the firing zones of sudden release of propylene oxide showed that the influence puts are included up to radius of 0.15 meters in the scenario of leakage 5 mm, in scenarios with leaks 25 mm to a radius of 1.1 meters and in scenarios with leakage of 100 mm to a radius of 39 meters. The maximum intensity of flash fire in the initial point Scenario 5 mm was 4.2 kW/m2, in the scenario of radiation leakage was 25 mm at the distance to 5 meters from the fire intensity up to maximum of 9 kW/m2, and also in the scenario with 100 mm flash fire radiation leak at an earlier point fire was 14 kW/m2. The maximum intensity of thermal radiation at the distance to 5 meters up to 16.5 kW/m2, and maximum distance of 80 meters around the reservoir affected. The mortality rate of flash fire has exposed employees, was 50 percent.
 

Conclusion: Many accidents caused by leakage and explosion were due to corrosion, spoil tanks and equipment, and the majority of such accidents can be prevented by technical inspections and continuous audits.

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Introduction: Industrial units, such as oil refineries, face significant hazards due to the release of toxic and flammable gases. Hydrogen sulfide (H₂S), due to its high toxicity and environmental impact, is among the most dangerous pollutants. This study aimed to model and assess the consequences of H₂S release in the Sulfur Recovery Unit (SRU) of Abadan Refinery using PHAST software to support safety planning and risk reduction strategies.
Material and Methods: Consequence modeling was conducted using PHAST version 8.4. Process data, including temperature, pressure, flow rate, and feed composition, along with meteorological conditions (average temperature, relative humidity, and wind speed based on Pasquill stability classification), were used to define probable scenarios. Scenarios included partial pipeline rupture, variable leak flow, short pipe release, and catastrophic reactor tank rupture. Key damage criteria, including thermal radiation threshold, explosion overpressure, and toxic dose, were used to determine hazard zones.
Results: Thermal radiation up to 71.027 kW/m² can cause instant death within a 70-meter radius, while overpressure exceeding 0.206 bar can destroy equipment and structures up to 35 meters in summer conditions. The H₂S cloud can spread up to 120 meters downwind, causing immediate fatalities among exposed personnel. These findings identify high-risk zones in and around the SRU, emphasizing the need to relocate shelters, install gas monitoring systems, and provide protective equipment. Results are limited to the defined scenarios and PHAST assumptions.
Conclusion: Due to the lack of risk assessment studies in early phases and during operation, identifying safe points and high-risk zones, along with prioritizing risk reduction, is essential to ensure workplace and public safety. Comprehensive risk assessment, including probability analysis (using software such as SAFETI) and application of advanced models (CFD and AI-based methods), is recommended for future research.