Purpose This paper aims to propose a process optimization approach showing how organizations are able to achieve sustainable and efficient process optimization, based on integrated process-risk analysis using several criteria to a better decision-making. Design/methodology/approach Several approaches are used (functional/dysfunctional) to analyze how processes work and how to deal with risks forming multi-criteria decision-making. In addition, a risk factor is integrated into the structured analysis and design techniques (SADT) method forming a novel graphical view SADT-RISK; it identifies process’s failures using the traditional failure modes, effects and criticality analysis (FMECA) and economic consideration “failure mode and effect, criticality analysis-cost FMECA-C” making a multi-criterion matrix for better decision-making. Subsequently, some recommendations are proposed to overcome the failure. Findings This paper illustrates a methodology with a case study in a company, which has a leading brand in the market in Algeria. The authors are integrating a varied portfolio of approaches linking with each other to analyze, improve and optimize the processes in terms of reliability and safety to deal with risks; reduce the complexity of the systems; increase the performance; and achieve a safer process. However, the proposed method can be readily used in practice. Originality/value The paper provides a new approach based on integrated management using new elements as an innovative contribution, forming a novel graphical view SADT-RISK; it identifies process’s failures using the traditional FMECA and economic consideration “a new multi-criterion matrix for better decision-making and using the SWOT analysis – Strengths, Weaknesses, Opportunities, Threats – as a balance to decide about the process improvement”. The authors conclude that this methodology is oriented and applicable to different types of companies such as financial, health and industrial as illustrated by this case study.

Purpose The purpose of this paper is to employ lessons learned from the industrial accidents in Skikda refinery during the period from 2005 to 2016 as input data for the numerical simulation of risk consequences to identify the exposed areas to the various effects of industrial accidents. Design/methodology/approach In order to assess how the lessons learned can contribute to modeling the accidents effects in the refining activities, this paper presents a combined statistical/dynamic approach that combines two main tools, namely, lessons learned from petroleum refining in Algeria and Areal Locations of Hazardous Atmospheres software. Findings The results showed that fire is the most frequent accident at Skikda refinery that is mainly caused by equipment failures with a frequent involvement of crude oil and LNG. The NO2 toxic effects are unacceptable. This means that in the case of a similar accident, the entire population will be exposed to an intolerable concentration of NO2. Therefore, people must be relocated to a safer place. The results indicate that the concentration threshold can be met beyond the distance of 1 km. Research limitations/implications Due to the economic importance of Skikda refinery and the absence of data related to the accidents in the refineries of Algiers, Arzew and Hassi Messaoud, this study is limited to the statistical analysis of accidents related to Skikda refinery. Practical implications This approach makes the risk assessment more practical and effective for the appropriate utilization of safety barriers and for the whole decision-making process. Originality/value This work presents a review paper of accidents that occurred in the oil-refining sector in Algeria, whose objective is learning lessons from past accidents history, by identifying their immediate causes and effects on personnel, equipment and environment in order to propose prevention measures. The novelty of this work is highlighted by the fact that this statistical analysis of oil and gas refining accident is realized for the first time in Algeria. This is due to the difficulty of obtaining data on accidents in the Algerian refining sector; for this reason, the authors have limited the study to the Skikda refinery.

This paper presents a statistical analysis of reported accidents related to the Skikda’s Oil and Gas Refinery that led to a major explosion and loss of life. A historical review of fire, explosion and toxic release incidents that occurred during the period between 2002 and 2013 is presented. A brief description of each accident/incident is provided with the fatalities and personal injuries that resulted being described. These case studies have been analyzed with a view to understand the common causes including errors, which have led to catastrophic events. Accident frequency analysis has been applied to various types of primary accidental events such as fire, explosion and toxic gas releases to assess the potential damage of such events and the likelihood of such damage occurring. The basic principles of such analysis is to utilize the available information and use the most detailed elements to illustrate what the industry should learn from these accidents so that it can learn from them and hopefully prevent future major accidents.