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CF Industries Donaldsonville Nitrogen Complex

Parent Companies:
CF Industries Holdings, Inc.
EPA Facility ID:
100000126446
Other ID:
70346CFNDSHWY30
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
39018 Highway 3089
Donaldsonville, LA 70346
County:
ASCENSION
Lat / Long:
30.087, -90.958 (Get map)
Method:
GPS Carrier Phase Kinematic Relative Positioning Technique
Description:
Plant Entrance (General)
Horizonal accuracy:
1 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
CF Industries Nitrogen, LLC
Phone:
(225) 473-8291
Address:
P.O. Box 468
Donaldsonville, LA 70346 -0468
Foreign Address:

Person responsible for RMP implementation:

Name:
Morris Johnson
Title:
General Manager

Emergency contact:

Name:
Scott Rodrigue
Title:
Production Manager, Urea/UAN
Phone:
(225) 473-8291
24-hour phone:
(225) 473-8291
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Ascension Parish LEPC
Full-Time Equivalent Employees:
459
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0180-00004-V14
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
April 7, 2016
Inspecting Agency:
U.S. Coast Guard
Using Predictive Filing:
No

Processes:

Nitrogen Fertilizer Manf
RMP ID:
1000072893
CBI claimed:
No
Program Level:
3
NAICS:
Nitrogenous Fertilizer Manufacturing (325311)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
460,000
No
Flammable Mixture
00-11-11
22,000
No
Ammonia (anhydrous)
7664-41-7
330,000,000
No
Chlorine
7782-50-5
100,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Larry Dunn
Address:
P.O. Box 468
Donaldsonville, LA 70346 -0468
Foreign Address:

Phone:
(225) 473-8291

Latest RMP Submission:

Date:
June 17, 2016
Type:
Resubmission
Reason:
Revised PHA / Hazard Review due to process change (40 CFR 68.190(b)(5))
Registered:
Yes
RMP ID:
1000058364

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Nitrogen Fertilizer Manf)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by refrigeration
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
1807.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • Enclosures
  • Berms
  • Drains
  • Sumps
Public OCA Chemical (in Nitrogen Fertilizer Manf)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by refrigeration
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
1980.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Nitrogen Fertilizer Manf)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
HGSYSTEM
Wind speed (meters per sec):
2.50
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Nitrogen Fertilizer Manf)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Nitrogen Fertilizer Manf)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls

5. Flammables: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Nitrogen Fertilizer Manf)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

March 10, 2016 at 21:30
ID:
1000044921
NAICS:
Nitrogenous Fertilizer Manufacturing (325311)
Duration:
1 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
5.69999981 miles/h N
Temperature:
71.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
1
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Improper procedure
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Revised operating procedures
  • An alternative for chlorine will be implimented
Jan. 22, 2015 at 02:30
ID:
1000044920
NAICS:
Nitrogenous Fertilizer Manufacturing (325311)
Duration:
1 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
9.0 NNE
Temperature:
71.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
1
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Maintenance activity/inactivity
  • Process design failure
  • Training misunderstood
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised training
April 24, 2013 at 11:45
ID:
1000044919
NAICS:
Nitrogenous Fertilizer Manufacturing (325311)
Duration:
1 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
8.80000019 miles/h W
Temperature:
69.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
1
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • An alternative for chlorine will be implemented.

7. Prevention: Program level 3

Nitrogen Fertilizer Manf, Nitrogenous Fertilizer Manufacturing (325311)
Prevention Program ID:
1000061078
Safety Review Date
April 21, 2016, since latest RMP submission
PHA Update Date
March 9, 2016, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • Increased Inventory
  • Process Controls
  • Process Detection
  • Mitigation Systems
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
May 6, 2016, since latest RMP submission
Training Review Date
May 10, 2016, since latest RMP submission
Maintenance Review Date
April 6, 2016, since latest RMP submission
Maintenance Inspection Date
April 14, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 21, 2016
Management of Change Review Date
Sept. 23, 2015
Pre-startup Review Date
April 21, 2016
Compliance Audit Date
Oct. 17, 2014
Compliance Audit Change Completion Date
Dec. 31, 2021
Incident Investigation Date
March 10, 2016
Incident Invest. Change Completion Date
March 31, 2016
Participation Plan Review Date
Jan. 8, 2014
Hot Work Review Date
Nov. 30, 2015
Contractor Safety Review Date
May 19, 2015, since latest RMP submission
Contractor Safety Eval. Date
May 12, 2016, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
April 28, 2016
Local Response Agency:
Local Response Agency Phone:
(225) 621-8360
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

CF Industries Holdings, Inc., headquartered in Deerfield, Illinois, through its subsidiaries is a global leader in the manufacturing and distribution of nitrogen products, serving both agricultural and industrial customers. CF Industries operates nitrogen manufacturing complexes in the central United States, Canada, and the United Kingdom and distributes plant nutrients through a system of terminals, warehouses, and associated transportation equipment located primarily in the Midwestern United States. The company also owns a 50% interest in an ammonia facility in The Republic of Trinidad and Tobago. CF Industries adheres to stringent safety and environmental stewardship standards at all of its operations.



What are fertilizers?



Fertilizers are plant nutrients. Nutrients exist naturally in the earth's soil and atmosphere, and in animal manure. However, naturally occurring nutrients are not always available in the forms that plants can use. Therefore, man-made fertilizer is vital to food production. Man-made and natural fertilizers contain the same ingredients, but man-made fertilizers act more quickly and are less susceptible to weather changes. Farmers, ranchers, and gardeners add these fertilizers directly to the soil, where they can be absorbed by plants for healthy growth. Incorporated into a program of best management practices, which includes soil testing, man-made fertilizer use leads to higher crop yields and greater environment protection. Man-made fertilizers have made a tremendous difference in farm productivity and the wellbeing of the world's people.



CF Industries Donaldsonville Nitrogen Complex



CF Industries' nitrogen complex at Donaldsonville, LA is North America's largest and, in many respects, it's most flexible nitrogen operation. It can produce and ship approximately 5 million tons of nitrogen for agricultural and industrial uses each year. Donaldsonville's location provides numerous advantages, including access to low-cost river an
d other transportation modes, abundant supplies of natural gas (the primary raw material used to produce ammonia, the basic nitrogen product), and availability of a committed, trained work force. The complex is more than just a manufacturing complex. With five docks on the Mississippi River and extensive product handling and storage capabilities, it has a unique "make versus buy" capability. As a result, CF Industries can respond quickly to market conditions by supplementing or replacing a portion of its manufacturing capacity with purchased product.



Description of Manufacturing Units and Regulated Substances Handled







Manufacturing activity at Donaldsonville begins with the production of ammonia. Ammonia is in turn utilized in the production of urea, nitric acid, and UAN solution. The complex has six ammonia plants, one urea solution plant, four granular urea plants, four nitric acid plants, and three UAN blending units. The primary RMP regulated substance at the facility is ammonia that is manufactured, shipped as a product (via railcars, tanker trucks, barges, ships, and pipeline), and used as feedstock for other products. Chlorine is also present in excess of threshold quantities. Chlorine is used as a biocide in water treatment. The flammable substances hydrogen, methane, and ethane also qualify for regulation under the rule. A flammable mixture (hydrogen and methane), referred to as syngas, is produced from natural gas and water in the ammonia process and trace quantities present in by-product carbon dioxide are a concern in the urea process. Natural gas (a flammable mixture containing methane and ethane) is used as feedstock for the ammonia process and as a fuel throughout the facility.



Environment, Health and Safety Philosophy



It is the philosophy of CF Industries to conduct its business and operate its facilities in a safe and secure manner designed to protect the environment and the health and safety of its employees. CF Industries i
s committed to complying with all applicable environmental laws, rules and regulations and will promote environmental concern and education among its employees and with the communities in which it operates. CF Industries is equally committed to protecting the safety and health of its employees and will take all practical steps to eliminate or reduce the exposure of employees to conditions adversely affecting their safety or health while on the job. It encourages off-the-job employee safety and health awareness as well. Additionally, all facilities, where CF Industries has operating control, will have appropriate security measures in place to protect employees, surrounding communities, facilities, property, and products from persons intending to do harm or cause damage. The corporation will not hesitate to go beyond legal requirements if, in its prudent judgment, a higher level of performance is in order. Management at each facility is directly responsible for the development and implementation of programs and procedures to ensure conformance with this philosophy. These programs and procedures will be reviewed and updated continually, and each facility is audited periodically by our Corporate EHS Group to assure compliance.



General Accidental Release Prevention Program and Chemical Specific Prevention Steps



The Donaldsonville Nitrogen Complex is subject to the U.S. Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) standards 29 CFR 1910.119. According to EPA, PSM standards form the basis for the Agency's RMP prevention program component. In addition to the required prevention program elements, each area where the regulated substances mentioned above are handled has specific safety features such as remote Isolation valves, control systems and alarms. These chemical specific prevention steps are all managed under our PSM program.



Emergency Response Program



The facility's emergency response plan meets the OSHA requiremen
ts of 29CFR1910.120 (q). The Incident Command System method of establishing an appropriate organization for response to emergency situations is the basis of the plan. Incident Commanders, Medical First Responders, Hazardous Materials Technicians, Firefighters, Rescue Team Members, Building Wardens, and other support personnel are trained and available. Facility personnel participate in Community Awareness Emergency Response Committee meetings where representatives of chemical companies and the Ascension Parish Office of Homeland Security and Emergency Preparedness formulate, implement, and maintain up-to-date community emergency response plans.



Five-year Accident History



Three accidents have occurred in the past 5 years that meet the RMP rule reporting requirements. Two involve a release of chlorine that resulted in an onsite injury but had no offsite or environmental impacts. The other involved a release of ammonia that resulted in an onsite injury but had no offsite or environmental impacts.



Planned Changes to Improve Safety



The facility has a goal of continuous improvement and uses total quality management techniques to define and address issues. Continued pursuit of the improvement goal is planned to improve safety.