CDB4623/CEB4523

Designs for Process Safety

Lecture Week 4A_Sept 2021

Measuring ISD Conflicts/Alternatives
Thursday (30/9/2021)
11.00 A.M. - 1.00 P.M.
 At the end of the lecture, you should be able to:

Course Learning Understand the ISD conflicts or tradeoffs

Outcomes Identify suitable ISD measurement tools for

process lifecycle
 Inherent Safety Conflicts/Trade-Offs

Inherent Safety Measurement

Techniques
Topic 4A Outline Qualitative

Quantitative
Example of Inherent Safety Conflicts/Trade-
Offs

Solvent A - non-flammable, but

toxic
Solvent B - flammable but low
toxicity

Which one is InherentlySafer?

Mode of
transportation
Measurement of inherent safety

Must consider all hazards

Aspects which involve judgment of the relative importance of different

hazards must be transparent to the decision maker

Decision maker must be able to change relative importance of different

hazards to meet the specific requirements of the situation
Questions designers should ask when they
have identified a hazard
Ask, in this order:

Can I eliminate this hazard?

If not, can I reduce the magnitude of the hazard?

Do the alternatives identified in questions 1 and 2 increase the magnitude of

any other hazards, or create new hazards? If so, consider all hazards in
selecting the best alternative

At this point, what technical and management systems (passive, active,

procedural) are required to manage the hazards which inevitably will remain?
Inherent Safety Measurement Techniques

Qualitative Quantitative

Consequence Inherent Safety

PHA Tools
Analysis Index

Prototype Index of
HAZOP FMEA INSET Toolkit
Inherent Safety
(INherent SHE
(PIIS)
Evaluation Tool)
What If
Analysis
/Checklist Dow FEI & Dow
Other Indices
CEI
Qualitative - PHA Analysis - HAZOP
Qualitative - PHA Analysis - FMEA
Qualitative - PHA Analysis - What If Analysis
Quantitative - Consequence Analysis

IS Strategy Description Consequence

Chlorine transfer line rupture 2 inch - 3.4 miles

Minimize
(distance to 20ppm) 1 inch - 1.2 miles
Consequece Analysis using Phast
Methanol -
Atmospheric concentration
Substitute 1000ppm
500 ft from tank spill
Butanol - 130 ppm

Distance to 500ppm 10C - 1.2 miles

Moderate atmospheric concentration, 3C - 0,7 miles
large monomethylamine spill -6C - 0.4 miles

Consequece Analysis using Aloha

Quantitative - Prototype Index of Inherent
Safety (PIIS), (Edwards & Lawrence,1993)

Factors Considered PIIS for Alternate Processes for Methyl Methacrylate

Inventory Process Route Index Value

Flammability
Explosiveness Acetone Cyanohydrin 120
Toxicity
Ethylene based/propionaldehyde 75
Temperature
Pressure Propylene based 70
Process Yield
Quantitative - Inherent Safety Index (ISI),
(Heikkilӓ & Hurme, 1996)
 Quantitative - Inherent Safety Index (ISI) :
Chemical Inherent Safety Index : Reaction
Hazard

Can be used for both ;

main reaction & side reaction
Quantitative - Inherent Safety Index (ISI) :
Chemical Inherent Safety Index : Hazardous
Substances
Quantitative - Inherent Safety Index (ISI) :
Process Inherent Safety Index : Process
Conditions
Quantitative - Inherent Safety Index (ISI) :
Process Inherent Safety Index : Process
System
ISBL

OSBL
Class Activity
Process alternative of anthraquinone process for the production of hydrogen peroxide is shown as below.
The overall process involves hydrogenation, oxidation, extraction, regeneration and finishing to produce
high-quality hydrogen peroxide. In the conventional technology, the oxidation reactor is a bubble column
for gas-liquid reaction, with air as the oxygen source. A tubular reactor is introduced in the intensified
process, where the air is replaced by pure oxygen introduced via direct injection to the working fluid.
Several injection points at different locations are required to fulfill the reaction needs. Rapid mixing in the
tubular reactor gives a very high mass transfer rate with improved selectivity. Conduct safety
assessment using ISI.
Quantitative - Inherent Safety Index - INSET
Toolkit (INherent SHE Evaluation Tool, 1997)

Fire and explosion hazards index

Developed by the INSIDE Project,
sponsored by the Commission of the
European Community to encourage
inherently safer process design
considering safety, health &
environment aspects
Eighteen (18) tools for identifying and
evaluating inherently safer process
options at four (4) stages
Acute toxic hazards index
Health hazards index
Acute environmental incident index
Transport hazards index
Gaseous emissions index
Aqueous emissions index
Solid wastes index
Energy consumption index
Reaction hazards index
Process complexity index
 Quantitative - Inherent Safety Index - INSET
Toolkit (INherent SHE Evaluation Tool, 1997)
Stage I : Chemistry route selection
This stage is where potential chemistry routes to manufacture the
product are sought; for some products there could be hundreds of
routes available. Some simple screening is carried out on these to
see which (say five) should be evaluated further
Stage III: Process design optimization
The selected route(s) from INSET Stage II are assessed to
optimize the conditions and take account of the practicalities of
industrial scale processing and the implications of
using particular processing equipment.
Stage II: Chemistry route detailed evaluation
This stage involves taking a few potential chemistry routes,
gathering the relevant chemical data, and assessing the routes in
detail. A final selection of the best route, or perhaps two routes, to
be further optimized/developed or to be used directly as the basis
of the plant process should result. It is particularly applicable
where the available options have many conflicting aspects and
there is no immediately obvious route alternative
Stage IV: Process plant design
The initial process design is developed and "challenged" to
identify further changes in sequencing, feed profiles, conditions,
unit operations and equipment selection in order to improve the
performance. The detailed aspects of equipment sizing and
pipework fittings are subsequently evaluated to try to identify
means of reducing the process inventories and eliminating
complexity and hence the possible leak points
Other IS Measuring Tools

Mond Index (ICI, 1979)

i Safe ( Palaniappan ,

Inherent Safety Index Based on Fuzzy Logic, (Gentile et al, 2003)

Integrated Risk Estimation tool ( iRET ), (Shariff et al, 2006)

Process Route Index (PRI), (Leong & Shariff, 2009)

Inherent Risk Design Index (IRDI), (Risza & Shariff, 2011)

 Self Check
Thank you

Question? Are you able to explain ISD

conflicts and trade-off

Are you able to differentiate

and conduct IS assessment
using qualitative & quantitative
IS measuring tools?
 Learning Materials Distribution
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