Limitation of Ammonia Exposure Among Workers in Fertilizers Industry using Modern Modified Technology Towards Sustainability

Background: Fertilizer production is a global industry, and workers in the processing areas may be exposed to various airborne contaminants, including mineral dust, water-soluble and insoluble compounds, as well as gases such as nitric acid, nitrogen dioxide, nitrogen monoxide, ammonia, and hydrogen fluoride, which can be released into the work environment across different departments.Subjects and methods: This study took place at a modern nitrogen fertilizer company in Alexandria, Egypt. The company mainly produces high-quality granular urea (46%) and anhydrous ammonia using advanced technology. The research used a descriptive, quantitative, case study approach. Two structured and pre-tested questionnaires were used to collect data from workers. Questionnaire A gathered information about the workers’ job roles and workplace hygiene conditions. Questionnaire B focused on symptoms reported by employees and their awareness of ammonia exposure. Ammonia levels were measured in ten different areas of the factory using a direct-reading infrared spectrophotometer.Results: The study involved 168 male workers, comprising 74.4% technicians and 25.6% engineers. Most technicians were engaged in operation (61.6%) and maintenance (25.6%), while engineers primarily worked in operation (76.7%). A majority of workers (70.8%) were on day shifts, with an average workweek of 47.68 ± 1.85 hours. Personal protective equipment (PPE) usage was reported by 99.4% of workers, and 100% were non-smokers, reflecting a strong safety culture and high awareness of occupational hazards. A statistically significant association was observed between years of employment and the prevalence of symptoms affecting the ocular/nasal symptoms (p = 0.001, 0.019, and 0.009, respectively).Ammonia concentrations measured at various factory locations were consistently below the TLV-TWA of 25 ppm, indicating effective environmental and occupational exposure control within the facility.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.