Approach and application of life cycle screening in early phases of process design: case study of supercritical water gasification

Process design can be influenced most in the early phases. Here, screening methods play a major role, as they reduce the complexity of a system studied by making a pre-selection from a set of alternatives available. The remaining alternatives can be analyzed in more detail in the subsequent design process, which increases design efficiency. The present paper focuses on a multi-stage screening approach for use in the early process development phase in particular. This approach is based on the use of non-compensatory decision support methods that are transferred to life cycle assessment. It may be divided into a first stage, in which the decision matrix used is developed on the basis of decision analysis principles, and a second stage, in which the decision matrix developed is further processed using non-compensatory decision support methods. An example of such a method is the pareto-dominance analysis applied here. The approach proposed is validated by application to the process of biomass gasification in supercritical water, which is being developed at the moment. Here, screening is performed to identify those life cycles, the potential environmental impacts of which contribute most to the total impacts. Attributes are selected in line with the requirement of a simple, but still sufficient modeling of these environmental impacts. By pareto-dominance analysis, emissions from the gasification of sewage sludge, the pre-chain of natural gas production, and from the construction of the supercritical gasification plant are identified to dominate over the remaining life cycles studied. Apart from the predominating alternatives, it is of particular importance to know the dominated alternatives. Due to their small shares in the result, no or only a small expenditure is needed to identify improvement potentials of these alternatives.     

A multivariable model for estimation of vapor cloud explosion occurrence possibility based on a Fuzzy logic approach for flammable materials

In this paper, a new method based on Fuzzy theory is presented to estimate the occurrence possibility of vapor cloud explosion (VCE) of flammable materials. This new method helps the analyst to overcome some uncertainties associated with estimating VCE possibility with the Event Tree (ET) technique. In this multi-variable model, the physical properties of the released material and the characteristics of the surrounding environment are used as the parameters specifying the occurrence possibility of intermediate events leading to a VCE. Factors such as area classification, degree of congestion of a plant and release rate are notably affecting the output results. Moreover, the proposed method benefits from experts' opinions in the estimation of the VCE possibility. A refrigeration cycle is used as the case study and the probability of VCE occurrence is determined for different scenarios. In this study, sensitivity analysis is performed on the model parameters to assess their effect on the final values of the VCE possibility. Furthermore, the results are compared with the results obtained using other existing models.     

A critique of the Hazard and Operability (HAZOP) study

Conventional wisdom holds that the Hazard and Operability (HAZOP) study is the most thorough and complete process hazard analysis (PHA) method. Arguably, it is the most commonly-used PHA method in the world today. However, the HAZOP study is not without its weaknesses, many of which are not generally recognized. This article provides a critique of the method to assist study teams in compensating for them to the extent possible and to help guide the development of improved methods.     

锦州市农村饮用水水源地环境评估

为了研究锦州市农村饮用水水源地基础环境状况综合评估工作,从环境禀赋、污染状况、环境监管和环境风险四个领域入手,分析农村饮用水水源地存在的主要环境问题和原因。有以下几点:水文地质参数匮乏,上游来水水质较差;由于地质因素及当地人民生活、牲畜饲养所排废物以及长期施用化肥导致总硬度及高锰酸盐指数超标;基本没有开展保护区的划分,也没有进行勘界、树立水源保护区标志、污染源搬迁等工作。     

复合生物法处理炼化污水厂恶臭气体

介绍了“生物洗涤+生物滴滤”的复合生物法在某炼化企业污水处理厂治理恶臭污染的工艺原理、技术流程、过程控制和实践效果,分析讨论生物处理装置运行影响因素。实践结果表明,复合生物技术对炼化企业污水处理厂恶臭治理具有较为理想的恶臭净化效果,其中硫化氢处理效率可达到98%,非甲烷总烃处理效率可达到94%,且运行操作简便、成本低廉、无二次污染。     

基于灰色层次分析的灭火救援实兵演习效果评估

灭火救援实兵演习是消防训练工作的重要组成部分,是高级的、贴近实战的消防战术训练方式。为了使演习评估结果真实地反映参演消防部队的战斗力,加强消防部队技战术训练的针对性,介绍了一种基于灰色层次分析的灭火救援实兵演习效果评估方法,确定了指标体系,构建了评估模型。以某市举办的地震救援实兵演习为对象,进行了评估,结果显示该演习处于"较好"水平,但应加强现场通信和警戒保障的训练。该实例验算的结果证明了这种评估方法的可行性,为消防部队灭火救援实兵演习效果评估提供了理论依据。     

Safety-based process plant layout using genetic algorithm

This paper presents a method based on a genetic algorithm for optimizing process plant layout. The relative location of main process units is determined to minimize an annual cost function including the cost of material transfer between process units (piping and pumping costs), land cost, and the expected annual loss resulting from damage to each secondary unit caused by primary accidents occurring in nearby process units. This method is an improvement over previous attempts using genetic algorithms or mathematical programming techniques to optimize plant layout, which neglected pumping costs and included safety issues by evaluating the infringement of predefined safety distances only. In this approach the operating cost of material transfer is included and the likelihood of accidents is taken into account thus providing good practical solutions to the plant layout problem incorporating more realistic cost functions and constraints. In the paper, after discussing the structure of the annual cost function and describing the working logic of the layout generating algorithm, a case study is described to demonstrate the effectiveness of the proposed methodology.     

An extension to Fuzzy Fault Tree Analysis (FFTA) application in petrochemical process industry

Fault Tree Analysis (FTA) is an established technique in risk management associated with identified hazards specific to focused fields. It is a comprehensive, structured and logical analysis method aimed at identifying and assessing hazards of complex systems. To conduct a quantitative FTA, it is essential to have sufficient data. By considering the fact that sufficient data is not always available, the FTA method can be adopted into the problems under fuzzy environment, so called as Fuzzy Fault Tree Analysis (FFTA). This research extends FFTA methodology to petrochemical process industry in which fire, explosion and toxic gas releases are recognized as potential hazards. Specifically, the case study focuses on Deethanizer failure in petrochemical plant operations to demonstrate the proposed methodology. Consequently, the study has provided theoretical and practical values to challenge with operational data shortage in risk assessment.     

Reaction mechanism and process safety assessment of acid-catalyzed synthesis of tert-butyl peracetate

Esterification during the synthesis of tert-butyl peracetate (TBPA) is highly exothermic. Since peroxides (tert-butyl hydroperoxide TBHP and TBPA) are intrinsically thermosensitive, this synthesis process is potentially dangerous. In this work, the exothermic process and mechanism of TBPA synthesis using acetic anhydride (Ac₂O) and TBHP under the catalysis of sulphuric acid (H₂SO₄) were clarified by calorimetry, infrared spectroscopy, and high-performance liquid chromatography. To substantially alleviate the thermal risk of the reaction, and to feasibly select appropriate synthesis conditions for ensuring the process safety of the synthesized products, several sets of isothermal and isoperibol experiments were performed using calorimetry. The intermediates formed and concentration changes during the reaction were monitored using in-situ Fourier-transform infrared spectroscopy. Differential scanning calorimetry and adiabatic calorimetry were used to assess the thermal hazard of the materials during the synthesis process. The reaction mechanism was verified using density functional theory calculations. The results revealed that a controlled increase in exothermicity could be achieved by adding aqueous TBHP to Ac₂O in semi-batch experiments in isothermal mode, and accordingly, the highest yield was 95.71%. Experiments combined with theoretical calculations revealed that the primary exothermic event was the TBPA formation reaction, and the removal of a large amount of water from TBHP prior to this is favourable for the reaction. The criticality classes of this reaction were of Grade 2.     

Improved management practice and process hazard analysis techniques for minimizing likelihood of process safety incidents in Taiwan

In Taiwan, process safety accidents often occur despite the prior implementation of process hazard analysis (PHA). One of the main reasons for this is the poor quality of the PHA process; with the main hazards not being properly identified, or properly controlled. Accordingly, based on the findings of 86 process safety management (PSM) audits, dozens of post-accident site resumption review meetings, and hundreds of PSM review sessions, this study examines the main deficiencies of management practice and PHA implementation in Taiwan, and presents several recommendations for improved PHA assessment techniques and procedures. The study additionally examines the feasibility for using PSM-related information, such as process safety information and process incident information, as a tool for further enhancing the PHA quality. Overall, the study suggests that, in addition to following the basic rules of PHA and requirements of OSHA (1992),management in Taiwan should also provide training in the enhanced assessment techniques proposed herein and take active steps to incorporate PSM information into the PHA framework in order to improve the general quality of PHA and reduce the likelihood of process safety accidents accordingly.