(21c) Management of Hazardous Materials Risks for New Project | AIChE

(21c) Management of Hazardous Materials Risks for New Project


KEMYA is a manufacturing company located in Saudi Arabia, Jubail City. In 2016, KEMYA introduced four new plants (Halo-butyl, Polybutadiene, EPDM rubber and Carbon Black) to the site with a lot of associated hazards chemicals such as toxic, flammable and corrosive materials. Introducing new plants to the site required many process safety precautions and studies to manage and control the potential risk and to mitigate any process safety incident. These hazardous materials were managed through the life cycle of the project up to the initial startup. Starting from the inherent safety review and implementing the principle up to the pre startup HAZOP a lot of work was done specially for the high consequence hazardous materials such as Hydrofluoric Acid (HF), Bromine (Br2), Hydrochloric Acid (HCL), Methyl Chloride (MeCl) and Alkyls.

In my paper, I will show how KEMYA managed those hazardous chemicals in each stage of the project up to the startup by highlighting the following studies:

    • Inherent Safety Review: how the inherent safety principle was implemented to minimize the inventory, moderate the operating conditions and simplifying the design.
    • HAZOP: to identify the risk and what kind of mitigations and recommendations were implemented to prevent the risk of those hazardous chemicals.
    • Facility Siting Study: to identify the explosion and toxic releases zones in the plant associated to those hazardous materials.
    • Hazardous area classifications study: to classify the hazardous areas inside the plant.
    • Process Safety Management System Implementation: new project needs a lot of work to implement the process safety management system and the culture.
    • High Potential Hazard Review: to identify the high potential hazard.
    • Emergency Response Plan: to develop an emergency response plan for the high risk scenarios and to test the effectiveness of plan.
    • Health Risk Assessment: to identify, assess and mitigate the health risk associated to those hazardous materials.


This paper has an Extended Abstract file available; you must purchase the conference proceedings to access it.


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