Application of the Functional Resonance Analysis Method to Identify Emerging Risks and Model Consequences in a Direct Reduction Iron Unit of the Steel Industry

Authors

  • Somayeh Kheirandish Sarabi Department of Occupational Health Engineering, School of Health, Iran University of Medical Sciences, Tehran, Iran.
  • Shahram Vosooghi Occupational Health Research Center, Department of Occupational Health Engineering, School of Health, Iran University of Medical Sciences, Tehran, Iran
  • Hossein Ebrahimi Department of Occupational Health Engineering, School of Health and Safety, Shahid Beheshti University of Medical Sciences, Tehran, Iran.
  • Hamidreza Azimi Department of Occupational Health Engineering, School of Health and Safety, Shahid Beheshti University of Medical Sciences, Tehran, Iran.
  • MohammadHossein Keyvani Boroujeni Student Research Committee, School of Health, Iran University of Medical Sciences, Tehran, Iran.
  • Saber Moradi Hanifi Occupational Health Research Center, Department of Occupational Health Engineering, School of Health, Iran University of Medical Sciences, Tehran, Iran.

DOI:

https://doi.org/10.18502/jhsw.v16i2.22917

Keywords:

Risk, Steel industry, Systems theory, The functional resonance analysis method, Socio-technical Systems

Abstract

Introduction: Steel industry socio-technical systems involve non-linear human, technological, and organizational interactions. As traditional risk assessments often fail to capture emergent risks, this research employs the Functional Resonance Analysis Method (FRAM) to analyze operational variability. Additionally, PHAST 8.4 software models the consequences of accidents triggered by functional fluctuations, providing a comprehensive assessment of hazard zones.

Material and Methods: Conducted in 2025 at a Direct Reduction Iron (DRI) plant, this study used a two- phase approach. First, FRAM analysis utilized expert panels, interviews, and observations to map 14 systemic functions. After identifying functional variability, PHAST (v8.4) simulated catastrophic scenarios, translating abstract functional misalignments into concrete physical impact data.

Results: Using the FRAM method, a total of 14 functions and 42 interactions were identified within the direct reduction unit, among which 6 functions and 9 interactions were determined as critical points. The results indicated that certain organizational and human functions, including maintenance (F12), inspection (F13), and training (F14), act as essential preconditions for key technical functions such as the direct reduction furnace (F2) and the reformer (F6). Evaluation of time and accuracy variability showed that performance fluctuations in the reformer can lead to catastrophic scenarios, such as gas leakage and explosion. PHAST 8.4 modeling results for the reformer unit revealed that in the event of an accident, the 100% fatality radius could reach 15 meters, while under winter meteorological conditions, the thermal radiation impact zone could extend up to 16 meters along the gas pipelines.

Conclusion: This paper provides a practical framework for transitioning from a reactive to a proactive approach. By identifying hidden critical points arising from functional resonance, the findings can support managers in more targeted resource allocation. Furthermore, integrating FRAM with consequence modeling enables a more accurate understanding of accident-scenario propagation and supports the determination of safety boundaries in complex industrial systems.

Published

2026-10-07

Issue

Volume (16) issue (2)

Section

Articles