The production, handling, commercialization, transportation and disposal of chemical substances are activities with a high fire risk. Prevention is the most effective solution, along with a comprehensive emergency plan that includes cutting-edge fire protection solutions tailored to each specific process type.

The current regulations categorize a broad range of production processes as part of the chemical industry. These processes are based on the transformation of raw materials (such as water, metals, minerals, petroleum, natural gas, etc.) into products with different chemical-physical properties than the original raw materials. This category includes (but is not limited to) the following:

• Plants where the following are produced, used or stored: flammable and/or oxidizing gases; flammable and/or combustible liquids; explosive substances; ammonium nitrates; alkali and alkaline earth metal nitrates; lead nitrate; inorganic peroxides; spontaneously combustible substances, and/or substances that produce flammable gases when in contact with water; hydrogen peroxide; phosphorus and its derivatives; magnesium, elektron and other magnesium-containing alloys
• Plants for the compression/decompression of flammable and/or oxidizing gases
• Plants for the preparation of lubricating oils, heat transfer fluids, and similar products
• Plants for extraction using flammable solvents and refining of vegetable and animal oils and fats
• Storage facilities and/or retail outlets for alcohols
• Storage, filling, and retail outlets for flammable gases
• Storage of compressed and/or liquefied oxidizing gases in fixed and/or mobile tanks

The chemical industry also encompasses a wide range of production activities, including, for example, the manufacturing of cosmetics, pharmaceuticals, paints, synthetic materials, fuels, additives, food dyes and more.

The processes involved in these activities are often hazardous, making the chemical industry a critical sector for workplace accidents. This is confirmed by a recent study published by INAIL, which examines workplace accidents involving exposure to chemical agents and those involving toxicological agents over a ten-year period (2002-2012).

 

Outlining the scope of risks

Specifically, when discussing fatal accidents, the INAIL report states that 44.7% of them are due to fires/explosions with flames, 14.4% due to fires/explosions without flames, and the remaining portion to contact with chemical agents. Upon further analysis, 55% of accidents related to fire or explosion are attributable to inadequate work equipment, workplaces lacking necessary safety requirements, improper or missing use of PPE, and the hazardous nature of the chemical agents involved. Among the sectors with the highest incidence of accidents are the metalworking and chemical industries. Regarding the location of accidents, 29% occur in confined or potentially contaminated spaces, while around 60% take place in production, maintenance, and storage areas. Finally, focusing on the size of the companies that reported accidents, the most affected are those with fewer than 10 employees, accounting for 53% of the cases.

 

What the regulations require

An incident at one of the aforementioned facilities can result in medium-to-severe injuries to personnel and a high risk of environmental pollution. Given this dual threat, fire safety regulations for chemical plants are among the most stringent and detailed. To simplify what is, in reality, a complex network of laws, regulations, and decrees—often tailored specifically to certain production processes—the approach to fire safety is predominantly preventative. This approach directly stems from the chemical risk assessment mandatory in workplaces where there is potential exposure to hazardous agents, which subsequently leads to the development, drafting, and implementation of an emergency plan. This plan must include:

1. The provision of safe, clearly marked escape routes that are always free of obstacles
2. Assurance of building stability in the event of a fire, at least for the time necessary for evacuation and rescue operations
3. Adequate compartmentalization of work environments
4. Limitation of the presence or use of highly flammable substances
5. Proper installation of technical systems, including regular maintenance
6. Installation of technologically safe work equipment
7. Installation and functionality of appropriate fire detection and alarm systems
8. Installation and periodic maintenance of firefighting equipment and systems
9. Clear safety instructions and signage for fire protection
10. A plan outlining procedures to follow in the event of a fire
11. Proper maintenance of work environments through constant monitoring to prevent the outbreak of fires
12. Adequate training and education of personnel on fire risks, the measures in place to prevent them, and the procedures to follow in case of a fire
13. The use of collective protection systems and, where not applicable, the use of suitable PPE.

 

How to proceed

The first step involves understanding the company’s production category and the associated processes, as deviations in these areas are often the source of incidents. It also involves identifying all substances/mixtures present, determining their state of aggregation, and the pressure and temperature parameters under which they are managed, both during storage and production phases. Equally essential is identifying the critical components of the plant, whose failure or abnormal behavior could lead to an incident, as well as all supply and loading/unloading methods.

Once the hazards have been identified, the next step is to conduct a risk analysis to determine the level of vulnerability to fire. This information, combined with a study of the regulatory framework applicable to fire prevention, allows for the correct identification of the most appropriate mitigating barriers to reduce the risk of fire.