Thermal risk in batch reactors: Theoretical framework for runaway and accident |
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| Institution: | 1. Jiangsu Key Laboratory of Hazardous Chemicals Safety and Control, College of Safety Science and Engineering, Nanjing Tech University, Nanjing, 210009, China;2. University Paris-Est, Laboratoire Modelisation et Simulation Multi Echelle, MSME, UMR 8208 CNRS, 5 bd Descartes – Bat. Lavoisier, 77454, Marne-la-Vallee, Cedex 2, France;1. Department of Health and Nutrition Biotechnology, Asia University, 500, Lioufeng Rd., Wufeng, Taichung, 41354, Taiwan;2. Department of Occupational Safety and Health, China Medical University, 91, Hsueh-Shih Rd., Taichung 40402, Taiwan;3. Department of Chemical and Materials Engineering, National Defense University, 75, Shiyuan Rd., Dasi, Taoyuan 33551, Taiwan;4. Department of Safety, Health, and Environmental Engineering, Central Taiwan University of Science and Technology, 666, Buzih Rd., Taichung, 40601, Taiwan;5. Chemical Engineering, Texas A&M University, USA;1. Normandie Université LSPC-Laboratoire de Sécurité des Procédés Chimiques (LSPC), EA4704, INSA/Université Rouen, 685 Avenue de l’université, BP 08, 76801 Saint-Etienne-du-Rouvray, France;2. Laboratory of Industrial Chemistry and Reaction Engineering, Johan Gadolin Process Chemistry Centre, Åbo Akademi University, Biskopsgatan 8, FI-20500 Åbo/Turku, Finland;1. Jiangsu Key Laboratory of Hazardous Chemicals Safety and Control, College of Safety Science and Engineering, Nanjing Tech University, Nanjing, 210009, China;2. University Paris-Est, Laboratoire Modelisation et Simulation Multi Echelle, MSME (UMR 8208 CNRS), 5 bd Descartes – Bat. Lavoisier, 77454 Marne-la-Vallee Cedex 2, France |
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| Abstract: | Thermal safety and risk of accidents are still challenging topics in the case of batch reactors carrying exothermic reactions. In the present paper, the authors develop an integrated framework focusing on defining the governing parameters for the thermal runaway and evaluating the subsequent risk of accident. A relevant set of criteria are identified in order to find the prior conditions for a thermal runaway: failure of the cooling system, critical temperature threshold, successive derivatives of the temperature (first and second namely) vs. time and no detection in due time (reaction time) of the runaway initiation. For illustrative purposes, the synthesis of peracetic acid (PAA) with hydrogen peroxide (HP) and acetic acid (AA) is considered as case study. The critical and threshold values for the runaway accident are identified for selected sets of input data. Under the conditional probability of prior cooling system failure, Monte Carlo simulations are performed in order to estimate the risk of thermal runaway accident in batch reactors. It becomes then possible to predict the ratio of reactors, within an industrial plant, potentially subject to thermal runaway accident. |
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| Keywords: | Thermal runaway Batch reactor Chemical synthesis Accident Risk Critical temperature Critical duration Cooler failure |
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