Limitation of Ammonia Exposure among Workers in Fertilizers Industry Using Modern Modified Technology Towards Sustainability

Background: Fertilizer production is a worldwide industry. Workers in the production process area may be exposed to mineral dust, water-soluble and insoluble compounds, nitric acid, nitrogen dioxide, nitrogen monoxide, ammonia (NH ₃₎ , and hydrogen fluoride which might be emitted into the work environment in the different departments . Subjects and methods: The study was conducted in one of the modern nitrogenous fertilizer companies in Alexandria, Egypt. The company specializes in producing high quality nitrogenous fertilizers, mainly Granular Urea (46%) as a final product and Anhydrous NH ₃ as an intermediate product using advanced technology. The study involved descriptive research adopts a quantitative and case study approach . Pre-designed and pre- tested structured two questionnaires for workers' data were used. The first questionnaire (A) was used for professional characters and occupational hygiene profile. The second questionnaire (B) was an optimal symptom score for employees’ complaints and their awareness about the occupational exposure to NH _3. NH ₃ gas was measured in the ten different working areas in the factory. A direct reading- infrared spectrophotometry method was used. Results: The NH ₃ synthesis factory is based on reliable and proven process steps controlled through automated operation of plants and machines. In the urea plant, the possible and available emission reduction techniques were used. All workers are males (100%). Current position includes specifications as technicians (n=125, 74.4 %) and engineers (n=43, 25.6%). The technicians' job duties are operation (n=77, 61.6%), production (n=2, 1.6%), maintenance (n=32, 25.6%) and inspection (n=14, 11.2%). Otherwise, the engineers ' job duties are operation (n=33, 76.7%), production (n=1, 2.3%), and maintenance (n=9, 20.9%). Work regime is day shift (n=119, 70.8%), and night shift (n=49, 29.2%). The total number of working hours/week ranges from 24-48 hours with a mean of 47.68±1.85 and a median of 48 hours. Considering the availability and usage of personal protective equipment (PPE) (n=167, 99.4%) and no smoking habits (n=168,100%), this reflects the increased knowledge and awareness, and the promoted safety culture of both the management and the employees. There is a statistically significant difference between the years of employment and the median for eyes, nose and sinuses symptoms (P = 0.001, 0.019 and 0.009 respectively ) . Regarding the mean concentration of NH ₃ in the different working stations, it was found to be lower than the Threshold Limit Value- Time weighted average (TLV-TWA) of NH ₃ which is 25 ppm. Conclusion: The current study highlighted the role of applying modern modified industry in limiting exposure to potential occupational hazards, improving the health of the workers, and achieving sustainability.