The process safety management (PSM) system was introduced in South Korea in 1996, wherein a company voluntarily organizes and manages a chemical accident prevention system, which contributes to reducing chemical accidents. However, large- and small-scale chemical accidents occur frequently. This trend necessitates analysis and improvement of the PSM systems. This study aimed to analyze the correlation between major industrial accidents, their main causes, the status of accidents by company size and industry, and the PSM evaluation grade through an analysis of 130 accidents that occurred in the past 17 years (2005–2021). The results showed that small- and medium-sized enterprises (SMEs) with fewer than 100 employees accounted for 36% of all accidents, indicating a higher occurrence rate than large companies. Additionally, the proportion of companies with inadequate PSM levels, rated as M-grade (M+, and M−), were 67.0%, suggesting a high probability of major industrial accidents. The results of this study show that a company’s voluntary safety management can be induced by an improved PSM system and management plan, which is expected to prevent major industrial accidents.

The Chemical Substances Control Act emphasizes the importance of proactive planning for chemical accident prevention and response, requiring facilities handling hazardous chemicals to develop and submit comprehensive plans in compliance with regulatory standards. Among these measures, the designation of chemical accident evacuation sites is considered a critical step to protect local residents and mitigate the impact of accidents. Despite the significance of evacuation site planning, existing research has primarily focused on the general conditions and locations of evacuation sites, with limited attention to their selection process and safety evaluation. This study aims to bridge this gap by evaluating the suitability of evacuation site locations through detailed risk assessments. Using tools such as KORA and ALOHA, the study analyzes the impact range under seasonal meteorological conditions. The limitations of current evacuation sites were assessed, and additional sites were proposed, considering the number of evacuees able to travel on foot during emergencies. The study highlights the importance of selecting evacuation sites based on seasonal weather conditions and provides actionable recommendations to improve public safety and minimize risks during chemical accidents. The findings of this study are expected to contribute to the advancement of emergency response systems, promoting a safer and more resilient environment for both local communities and industrial facilities.

This study analyzes the risks posed by high-temperature summer conditions to atmospheric storage tanks containing acrylic acid and proposes mitigation measures. Recent increases in heat waves and tropical nights have led to an increase in the temperatures of acrylic acid storage tanks. This temperature increase results in higher vapor pressure and promotes spontaneous polymerization, thereby increasing the risk of explosions in atmospheric storage tanks. Hazard and operability (HAZOP) analysis identified explosions due to pressure buildup as a major risk scenario. To mitigate this risk, a spray-tower system was introduced through a layer of protection analysis (LOPA), which effectively reduced the hazards associated with atmospheric storage tanks. Additionally, the removal of flame-arrester replacement operations not only achieves economic benefits, such as reduced replacement costs and labor time, but also enhances safety by eliminating worker exposure to hazardous chemicals. These findings have significant implications for improving safety at industrial sites and highlight the potential economic benefits of preventing chemical accidents.