Integrated Fire and Explosion Risk Assessment Using HIRAC and Dow F&EI in a Nickel Smelter Electric Furnace

Abstract

Introduction: Nickel smelting using Rotary Kiln Electric Furnace technology involves substantial fire and explosion risks from high temperatures, coal, carbon monoxide, and molten metal. Objective: This study aimed to evaluate fire and explosion risks in the Electric Furnace area of a nickel smelter by integrating the Hazard Identification, Risk Assessment, and Control method with the Dow Fire and Explosion Index. Method: The Hazard Identification, Risk Assessment, and Control method identified hazards, assessed risks, and determined controls, while the Dow Fire and Explosion Index quantified fire and explosion potential. Result and Discussion: The Hazard Identification, Risk Assessment, and Control assessment identified several high and extreme occupational risks related to molten metal handling, oxygen-related tapping operations, hydraulic oil systems, combustible dust, refractory furnace failure, and other fire and explosion scenarios. The Dow Fire and Explosion Index produced a value of 229.06, showing that the Electric Furnace was classified as a severe hazard process unit with substantial potential for fire and explosion losses. Conclusion: Integrating both methods provides a practical basis for prioritizing fire and explosion controls and improving process safety in nickel smelting operations