How can nitrogen fertilizer companies ensure safe production?

Safety responsibilities must be truly implemented； Safety management is not relaxed ； Safety inspections should not be a mere formality ； Continuous identification of safety hazards ； Talk about safety at all times, and focus on safety in everything.

1. It is essential to ensure that the equipment is used in a safe condition. 2. Any abnormalities in the device must be addressed promptly and correctly; if they cannot be resolved, the operation should be stopped immediately. 3. Safety risk assessments need to be strengthened. 4. Employees should improve their operational skills, carry out inspections carefully and thoroughly, and ensure that inspections are completed properly. 5. Managers should stay informed about the safety status of the devices and make decisions in a timely manner. 6. Safety officers must carry out their duties effectively

Safety is not just an empty slogan; it must be put into practice, and doing a good job in safety is extremely difficult.

As for specific measures, there are many of them. What was said on the 3rd floor is already quite good, but the key lies in corporate culture – fostering a sense of pride in and belonging to the company. To enable employees to achieve this, company leaders need to make more efforts. To put it simply, corporate development should benefit its employees. The primary responsibility for ensuring safe production in a company lies with its leadership. It is important to focus on production and the economy, but safety must come first.

Whether it is a state-owned enterprise or a private enterprise, priority should be given to the legal entity; funds and human resources should be allocated accordingly. Even in difficult times, companies must not cut corners on safety!

1. Ammonia is a colorless substance with a strong, pungent odor and high volatility (boiling point: -33.5°C). When liquid ammonia comes into contact with the skin, it causes frostbite immediately due to the heat absorbed during vaporization; a 1% concentration of liquid ammonia can already irritate the skin. Reaching over 3% can cause burns and blisters. A concentration of 0.1% can burn moist skin. Working in an environment with an ammonia concentration of 0.2 milligrams per liter for a certain period of time can cause poisoning and lead to emphysema. To prevent ammonia poisoning, workers must use protective equipment properly when going to work, and protective personnel should be on site for supervision if necessary. First aid measures: 1. Quickly move the poisoned person to an area with fresh air. 2. Loosen the collar to keep breathing easy. 3. In severe cases, notify the safety personnel promptly and transport the affected person to the hospital for emergency treatment. **The health standard for ammonia content in the air within workshops stipulates a limit of ≤30 mg/m3; an ammonia concentration of 0.49 milligrams per liter (approximately 0.06%) can cause eye burns. 1.1 When the eyes are burned, it is necessary to adhere to the principle of \"treatment on the spot, immediately, and by oneself\". Immediately lift the eyelids and rinse the upper part of the eye socket with water continuously, but avoid letting the water flow directly onto the eyeballs. It is absolutely forbidden to use a cloth to wipe them in order to prevent further damage. 1.2 Ammonia easily forms explosive gases in air, with an explosion range of 15.5–27% (by volume); an explosion can occur within this range in the presence of an open flame or spark. Ammonia leakage and the presence of ammonia gas are possible at all stages of the production process in the workshop; therefore, smoking is strictly prohibited there. Before carrying out any welding or heating operations, analyses must be conducted and the necessary procedures must be followed as per relevant regulations. 1.3 Gaseous ammonia has a high solubility in water; at normal pressure and 0°C, its solubility in water is 0.90 g/ml. Taking advantage of this property, once there is a large leak of liquid or gaseous ammonia, water can be sprayed at the site of the leak to absorb the ammonia and suppress the ammonia mist. To prevent widespread damage from spreading, when dealing with such accidents, one should stand upwind and wear the necessary protective equipment. If surrounded by ammonia of unknown origin and there is no gas mask available, cover your mouth and nose with a wet cloth and leave the area quickly. 2. Carbon dioxide: Carbon dioxide is a colorless gas with a boiling point of -78.5°C. It is non-toxic at low concentrations, but at high concentrations it has significant toxic effects, causing asphyxiation and other adverse effects. When the CO2 concentration in the air is between 4.6% and 6% (by volume), it can be fatal within an hour; when the concentration exceeds 18% (by volume), death from asphyxiation occurs immediately. **The established health standard for the maximum CO2 concentration in workplace air is 10% (by volume).** Since CO2 is heavier than air, it tends to accumulate in low-lying areas or at the bottom of containers. Therefore, before entering such places, a safety and hygiene assessment must be conducted; entry is not permitted unless the standards are met. If measures taken still do not meet the requirements, it is necessary to wear a self-contained breathing apparatus or a long-tube mask before entering the area, and there must be someone to supervise the work. In the event that an employee suffers an accident, the supervisor should immediately remove them from the toxic environment to provide first aid, such as performing artificial respiration or supplying oxygen. 3. Ammonium carbamate: Ammonium carbamate is an intermediate product in the urea production process; it exists only under certain pressures and not at normal pressure. It decomposes into NH3 and CO2 at atmospheric pressure; therefore, it should be treated as NH3 and CO2. In production, if it comes into contact with methylamine, it should be rinsed with water as soon as possible. 4. Urea/melted urea: In production, urea solutions, and especially melted urea, are at high temperatures; skin contact with them will cause rapid crystallization, releasing heat that can burn the skin and simultaneously leading to the formation of a hard urea crust. In this case, it must never be wiped; it should only be rinsed with water, as otherwise the skin could be wiped away. If melted urea gets into the eyes, they must be rinsed thoroughly with water for at least 15 minutes. Therefore, gloves and safety glasses must be worn during emission or clogging treatment. 5. Risk of explosion from emitted exhaust gases: To prevent corrosion of the stainless steel components in the high-pressure system of this device, some air and hydrogen peroxide are added. Therefore, in order to make the oxygen content in the exhaust gases 5% (by volume), turning it into a safe, non-explosive gas. Note: Mont Edison’s safety principle: “A N2-H2-NH3 mixture with an O2 content of ≤5% (by volume) is never explosive, regardless of the amounts of H2 and NH3 present in the mixture.” 6. Properties of auxiliary materials 6.1 Hydrogen peroxide (H2O2): Melting point –0.43°C, boiling point 150.2°C, specific gravity 1.54 (at 20°C). It has redox properties, is acidic, and can be decomposed under the action of a catalyst when exposed to light. Commercially available hydrogen peroxide is an aqueous solution with a concentration of 27-30%. The concentration of hydrogen peroxide used in the workshop is 2.5-4%. Frequent exposure to hydrogen peroxide may cause dermatitis or irritation of the mucous membranes. Ingesting high-concentration hydrogen peroxide can lead to poisoning, with symptoms such as abdominal pain, chest pain, difficulty breathing, vomiting, temporary difficulty in moving or sensory disturbances, as well as an increase in body temperature. When handling hydrogen peroxide, it is necessary to wear acid- and alkali-resistant rubber gloves as well as protective transparent goggles made of polymer materials. 6.2 Steam and Condensate The steam used in the workshop comes in the following grades: A. Superheated steam at 3.6 MPa (absolute), at 435°C; B. Saturated steam and condensate at 2.6 MPa (absolute); C. Saturated steam and condensate at 0.7 MPa (absolute); D. Saturated steam and condensate at 0.35 MPa (absolute). The steam and liquids in these grades have very high temperatures, and direct contact with them or with exposed pipes in contact with these substances can cause burns. When using steam or condensate to clear blocked pipes, it is essential to ensure that the hose connections are secure, and gloves must be worn during operation. II. Safety Features of the Production Environment: This facility features a three-dimensional layout; the new framework is as tall as 53 meters, with various material pipelines crisscrossing throughout it. There are thousands of sealing points, and operation points for different tasks are located on all floors (from 0 to 53 meters). In case of emergencies such as NH3 leaks, it is difficult to evacuate the area; therefore, when conducting inspections, performing operations, and dealing with accidents, it is necessary to wear gas-proof and protective equipment. When working on high floors, be careful not to drop tools or other items, to avoid injuring people below. The communication phones on each floor must remain functional at all times, and those working on site should report their location to the relevant personnel in the control room promptly. III. Safety features of gamma-ray level gauges: Both E1 and E2 in my workshop are equipped with gamma-ray level gauges. These radiation sources have been approved by the relevant authorities for production, use, and installation; therefore, it is safe to work around their protective lead shields. Precautions: 1. Do not enter inside the lead plate protective layer. 2. If these devices need to be repaired, the relevant instrumentation staff must be notified to turn off the radiation source before it is possible to enter the lead plate area for work. 3. Protect the source transmitter, receiver, and converter; avoid impacts and exposure to water. 4. The operator on duty shall monitor the safe operation of the radiation source during inspections, and report any abnormalities promptly. IV. General precautions in safe production 1. Work permit – Personnel must pass safety and production technology examinations before taking up their posts, and must work with the corresponding certificates. For each maintenance task, a maintenance work order must be prepared in accordance with the company’s relevant regulations first. 2. Hot work permit – Before carrying out hot work, it is necessary to obtain a hot work permit in accordance with the company’s relevant regulations. 3. Flushing of blocked pipes – When flushing pipes blocked by crystals with steam or condensate, it should be started from the outlet end; heating at a location far from the outlet may generate high pressure that could cause the pipes to burst. 4. Smoking is prohibited — Smoking at the production site can cause severe fires and explosions, so it must be banned. 5. Unrelated personnel are not allowed to enter the production area without permission. 6. Strictly enforce the inspection regulations during the safety production process. 7. Strictly implement the safety measures for work at heights. 8. Strictly comply with the safety procedures for operating on the ground belt and overhead belt. 9. Strict maintenance and management of the safety facilities in production units (safety valves, level gauges, explosion-proof plates, guards, interlock switches, alarms, etc.). 10. Strictly enforce the safety regulations for elevator use. 11. Strictly comply with the safety management regulations for hazardous chemicals. 12. When conducting inspections in high areas, tight spaces, or edge zones, two people must work together, wear appropriate protective equipment, and inform the team leader. V. Common fire extinguishing agents and extinguishers Chemical enterprises must adhere to the fire safety principle of \"prevention first, suppression second\" in their fire prevention efforts; taking proactive measures for prevention and suppression is essential to ensure safe production and minimize fire-related losses. 1. Common fire extinguishing agents: The common fire extinguishing agents used in workshops include water, CO2, steam, and nitrogen; in addition, there are also newer types such as 1211, CO2, and dry powder fire extinguishers. Water is non-flammable and has a wide range of applications in fire extinguishing; it can be used to put out many types of fires. However, there are some fires that cannot be extinguished with water (such as those involving metals like sodium and potassium, strong acids, flammable liquids that are lighter than water or insoluble in water, as well as electrical equipment). CO2 is a compressed liquid stored in steel cylinders, with a water content of no more than 0.01% and an oil content of no more than 10PPM. Nitrogen is one of the commonly used fire extinguishing agents; it has a wide range of applications, is readily available, and is a practical fire extinguishing agent. Steam is also a commonly used fire extinguishing agent; saturated steam is more effective in extinguishing fires than superheated steam. To be effective, steam fire extinguishing requires not only a certain volume of steam but also appropriate pressure. The duration of steam fire suppression can be up to 3 minutes. 2. Fire extinguishers 2.1 Portable CO2 fire extinguishers are used to extinguish fires involving valuable equipment, archival materials, instruments, electrical devices with voltages below 600 volts, as well as oils and greases in areas of limited size. It can be used to extinguish fires without leaving any traces, and it has no corrosive or damaging effects; it is an excellent type of fire extinguisher. When in use, first remove the seal, take out the safety box, then hold the wooden handle on the firing nozzle with one hand and press the trigger with the other; high-pressure gas will then be ejected automatically. When extinguishing a fire, one should stand upwind and hold the handle of the nozzle to avoid frostbite. 2.2 The 1211 fire extinguisher is a multi-effect, low-toxicity fire suppressant with good insulating properties, and it leaves no residue after extinguishing a fire. It can be stored for a long time without deteriorating, its fire-extinguishing efficiency is 3.5 times higher than that of CO2, and it is a relatively advanced fire extinguishing agent at present. When in use, first remove the safety pin, point it at the source of fire, then grasp the push button; the push rod causes the seal valve to open, and as a result, the \"1211\" fire extinguishing agent is ejected from the nozzle through a siphon tube under the pressure of nitrogen. When the pressure handle is released, the pressure rod returns to its original position under the action of the spring, the valve closes, and the spraying stops. 2.3 Portable dry powder fire extinguishers are used to extinguish incipient fires involving flammable liquids, flammable gases, and electrical equipment. To use it, first pull out the safety pin, press the handle and sweep it back and forth at the base of the flame, staying on the upwind side. VI. Gas Masks and Their Proper Use 1. Filter-type gas masks primarily remove toxic and harmful substances from the air through filter media. A chemical agent can only be used against specified types of toxins, and it is effective only under certain conditions; it cannot be utilized for work inside tanks or for maintenance tasks in complex environments. Usage rules: 1.1 Filter-type gas masks can only be used when the concentration of toxic gases in the air is 18% (wt). 1.2 Various filter-type gas masks must be used for their specific intended purposes only; filters of different types can only protect against the corresponding toxic gases, in order to prevent misuse. (The type 4 masks used in the workshop are gray in color and resistant to NH3, while type 3 masks are red in color and resistant to organic gases.) 1.3 When using filter-type gas masks, it is necessary to strictly follow the rules of “open first, check second, put on third”. First, open the rubber stopper at the bottom of the gas filter canister ； Second, check that the gas filter canister and mask are free of defects ； Wear the mask three times; ensure smooth breathing and that everything is in order before using it. 1.4 If you experience difficulty breathing, smell a toxic odor, or feel unwell while using it, you should immediately leave the toxic area and replace your gas mask; it is strictly prohibited to remove the mask inside the toxic area. 1.5 Filter-type gas masks are prohibited from being used in enclosed equipment such as towers, tanks, and containers. 2. Isolated gas mask: An isolated gas mask relies on its own supply of oxygen or air, and is suitable for working environments with low oxygen levels, unknown toxic gas components, or high concentrations of such gases. The duration of use and the range of movement are limited by the available oxygen supply; it is primarily used for emergency rescue purposes. It has a complex structure and is relatively heavy; personnel must be trained in advance and master the operating skills before they can use it. Mastering proper wearing through training is a basic skill that employees in chemical enterprises must possess. The isolation-type gas masks currently available in the workshop are as follows: 2.1 Oxygen respirators – Usage regulations: a. Oxygen respirators are used by workers to prevent poisoning and suffocation in case of production emergencies; they are stored in dedicated emergency cabinets, with the cabinet doors sealed with lead seals. Unless there is an urgent need related to production, no one is allowed to damage these seals. b. When using an oxygen respirator, it is necessary to strictly follow the rule of “open first, check second, put on third”. First, open the valve of the oxygen cylinder ； Secondly, check that the oxygen pressure is above 10 MPa and there are no leaks ； Wear the mask, take a few deep breaths, and ensure it is in good condition before use. c. When in use, put on the mask first before entering the toxic area; do not remove the mask while inside. If you feel unwell, exit the toxic area immediately. d. If automatic supply (of gas) fails to function during use, immediately switch to manual supply (of gas) and exit the toxic area. When the oxygen pressure drops to 3 MPa, the toxic area should be evacuated. e. When in use, care should be taken to avoid contact with oils and sources of fire; it is prohibited to operate the oxygen cylinder valves while wearing oil-stained gloves. f. When working with an oxygen respirator, two persons or a dedicated supervisor must be present for supervision. For tasks with poor monitoring or rescue conditions, two persons must work in a team and monitor each other; it is forbidden for anyone to enter the toxic area alone. g. Each shift must strengthen the maintenance and management of mask cabinets and oxygen respirators, keeping the mask cabinets clean and tidy. Inspections of mask cabinets and oxygen respirators, as well as their use, must be included in the shift handover procedures. If the lead seals on the mask cabinet doors are damaged or if an oxygen respirator has been used, the personnel on duty must immediately inform the gas protection station to conduct an inspection, replace the gas cylinders, and re-seal them. 2.2 Usage regulations for air respirators: a. First, open the valve on the air tank (turn it at least two full turns), and check the pressure gauge (the device can be used only if the pressure indicated is 25 Mpa or higher). b. Extend the shoulder straps and wear the air respirator on the back (with the cylinder valve facing downward). c. Tighten the shoulder straps; use both thumbs to grasp the loops on either side of the straps and pull them backward until the back frame is in comfortable contact with the back of the body. d. Use both hands to grasp the belt buckle of the air respirator and insert it into the buckle. e. Hang the mask around the neck, pull apart the head strap, first put the lower part of the mask over the chin, then pull the head strap back to cover the head ； At the same time, use your hands to even out the headband and tighten it gradually around the neck, temples, forehead, and other areas. f. Mask airtightness test (method): Cover the connector inlet with the palm and take a deep breath; it is considered successful if no air leaks into the mask; otherwise, adjust the head strap again before attempting the test. g. Connect the air supply valve to the mask inlet; when a \"click\" sound is heard, it indicates that the connection is complete and the air supply valve begins to supply air properly. h. During use, regularly check the tightness of the connection between the pressure reducing valve and the mask, as well as the cylinder pressure indicated by the pressure gauge. If the pressure in the gas cylinder drops to the level that triggers the alarm (the red zone), the alarm will emit a whistle sound (an evacuation signal), and the user must immediately leave the work area and move to an area with fresh air. i. Remove the air supply valve from the mask: Use two fingers (thumb and middle finger) to press the yellow buttons on either side of the air supply valve while pulling it outward; this will disconnect the air supply valve from the mask. j. Remove the mask: Use your fingers to push the clasp forward to loosen the headband, then grasp the joint of the mask and pull it toward the back of the head to remove it (note: keep the mirror side facing up). k. Press the button at the belt connector of the self-contained breathing apparatus with the finger, and the belt will release on its own. m. Pull up the buckles on both sides of the SCBA strap to release the shoulder straps, then remove the respirator (Note: Do not throw it away carelessly; place it down gently). n. After removing the air respirator, first close the cylinder valve, then press the yellow supply button on the supply valve to release any remaining air in the system. o. Check the pressure on the gauge, place the used air respirator in the accident cabinet, and inform the gas protection team to inspect it, replace it, and apply a seal.

Agree with the opinion from the third floor: three of these points are the most important. 1. It is essential to ensure that the equipment is used in a safe condition. 2. Managers need to stay informed about the safety status of the equipment and make decisions promptly. 3. Employees should improve their operational skills, carry out inspections carefully and thoroughly, and ensure that inspections are done properly

First, responsibilities must be properly implemented; second, regulations must be enforced strictly; third, adequate funding must be ensured. By achieving these, unsafe human behaviors can be controlled and unsafe conditions of equipment can be eliminated, thus ensuring safety.