Abstract Nowadays, the need for using newer technologies that assure a secure environment for people to live

in has reached a climax. Therefore, scientists develop software that comes to satisfy this need. In this paper, using several quantitative and qualitative analyses, the authors take into consideration the hypothetical case study of a leakage from a TNT producing plant. The plant consists of a chemical reactor that produces TNT in the presence of sulfuric acid as catalyst. ALOHA (Areal Location of Hazardous Atmospheres) is the software used hereby to model the supposed area affected and by which extent. Two qualitative and two quantitative methods have been used to study the possible accidents and their effects. Hazard and Operability Study (HAZOP) and Failure Modes and Effects Analysis (FMEA) exemplifying the causes and effects of certain failures due to varying parameters in the process such as temperature, pressure or due to a certain trouble that occurs within the installation. The quantitative methods resume to The Tree of Faults and The Tree of Events which are meant to estimate the probability by which a certain event/fault may happen during the process. The results that follow are a series of different types of explosions and/or fires that may logically succeed one another if a leak may happen (this being the top event, the leak). ALOHA was also used for generating a visual graph over the potential perimeter affected in case the top event should happen. Therefore, using the information and data gathered to this point and also the MSDS (Material Safety Data Sheets) of each substance involved in the process (toluene, nitric acid, sulfuric acid, trinitrotoluene) together with ALOHA modeling we got to the conclusion that:
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a safety perimeter of 324m (worst case scenario) should be implemented between the plant and any inhabited area; the employees ought to be good professionals in order to avoid human mistakes leading to accidents; plant employees should be well trained how to act in case of an accident and aware of the hazards that they are exposed to.