In 2017, AmmoniaKnowHow.com and UreaKnowHow.com introduced global open source risk registers for ammonia and urea plants. On January 1, 2018, the Risk Register Safety Risks in Urea Plants contained its first 100 safety risks. This paper provides the detailed analysis of these risks: In which plant sections and during which project phase do these safety risks occur, which safety risks occur most frequent, and which risks have the highest risk factor. This paper describes the most critical safety risks and recommends its prevention and mitigation measures.

A surprising conclusion is that most safety risks may lead to a sudden release of toxic ammonia. The paper provides suggestions on how to safely behave in a urea plant, and how to identify a maximum number of safety risks.