<p>This review examines the safety, reliability, and failure mechanisms associated with hazardous Direct Air Capture (DAC) plants through a systematic synthesis of existing research, industrial experience, and lessons learned from related high-risk sectors such as carbon capture, oil and gas, and chemical processing. DAC systems handle corrosive chemicals, high temperatures, pressurized equipment, and complex mechanical subsystems, yet the literature lacks a consolidated engineering review of their failure modes and prevention strategies. This article compiles and categorizes the major mechanical, process, and human-factor failures that can occur across DAC units, including absorber columns, fans, blowers, valves, piping networks, rotating equipment, and thermal regeneration systems. Special attention is given to corrosion, degradation, fire and explosion hazards, and potential loss-of-containment scenarios involving hazardous solvents. The review also summarizes methods for hazard identification, operational risk reduction, and engineering controls applicable to DAC facilities. Finally, key gaps in the current knowledge base are identified to support future research and safe large-scale deployment of DAC.</p>