The integration of Dow's fire and explosion index (F&EI) into process design and optimization to achieve inherently safer design

For the processing industries, it is critically to have an economically optimum and inherently safer design and operation. The basic concept is to achieve the best design based on technical and business performance criteria while performing within acceptable safety levels. Commonly, safety is examined and incorporated typically as an after-thought to design. Therefore, systematic and structured procedure for integrating safety into process design and optimization that is compatible with currently available optimization and safety analysis methodology must be available.The objective of this paper is to develop a systematic procedure for the incorporation of safety into the conceptual design and optimization stage. We propose the inclusion of the Dow fire and explosion index (F&EI) as the safety metric in the design and optimization framework by incorporating F&EI within the design and optimization framework. We first develop the F&EI computer program to calculate the F&EI value and to generate the mathematical expression of F&EI as a function of material inventory and operating pressure. The proposed procedure is applied to a case study involving reaction and separation. Then, the design and optimization of the system are compared for the cases with and without safety as the optimization constraint. The final result is the optimum economic and inherently safer design for the reactor and distillation column system.     

A New Safety Risk Index for Use in Petrochemical Planning

Risk analysis is being used to evaluate and manage the potential of unwanted events in the chemical processing industry. The risk in this study is the risk posed by chemical plant accidents and it is presented in a simple quantitative form. A safety risk index is formulated that represents the maximum number of people that might be affected if an accident occurred that caused the release of all the plant inventory of a chemical. The index has four terms: frequency of accidents; hazardous effect of the chemical; inventory of the chemical released; size of the plant. The overall unit of the index is expressed as the number of people affected per year from the plant operation and is formed in a particularly simple manner so as to be suitable for the comparison of safety risk within a model for planning the development of the petrochemical industry.     

PTA生产火灾爆炸危险性分析与评价

采用道化学公司的火灾、爆炸危险指数法对PTA生产工艺进行了分析与评价。首先分析了PTA具体的生产工艺流程,其次对其生产原料、生产流程中的高温氧化反应、加氢反应阶段的火灾危险性以及PTA装置的包装工段的火灾危险性进行了具体的分析。接着运用道化学公司的火灾、爆炸危险指数法,系统地对PTA生产装置的火灾爆炸危险性进行了评估。文章选取该装置中火灾爆炸危险性较大的高温氧化单元以及加氢精制单元为评价单元。并依照火灾爆炸指数法的评价程序进行评价,确定物质系数、单元危险系数、火灾爆炸指数、安全措施补偿系数、危害系数等一系列参数。最后就评价结果及各单元补偿前后危险程度进行详细的分析并提出了防止PTA生产装置燃烧爆炸的安全对策措施,文章为后期系统深入地研究PTA安全生产提供了一定的参考。     

小氮肥生产装置火灾爆炸危险性分析与评价

结合小氮肥生产工艺的特点及企业实际情况,在分析小氮肥生产过程中火灾爆炸危险因素的基础上,应用道化学法对小氮肥生产工艺中的煤气发生炉、煤气柜、脱硫、变换、铜洗和合成等6个单元进行了固有危险指数和安全补偿措施后的危险指数的计算,同时对评价单元的火灾爆炸危险度进行了研讨。分析评价结果表明,合成单元和煤气发生炉的固有危险度最大,生产过程中极易发生火灾爆炸危险,小氮肥企业应特别重视。笔者建议,小氮肥企业应设法改进监控和操作手段,降低相应的工艺危险系数或加强安全防范,提高整个系统的安全性。     

基于FAHP的危化品企业安全标准化评价体系研究

当前危险化学品从业单位安全标准化考评工作中存在针对性不足、标准分值难把握等缺点,结合我国危化品生产储运及安全监管现状,为合理地评价危化品企业的安全标准化等级,参考现有的法律法规、技术标准和规范,提出了采用10个一级指标和44个二级指标来评价危化品企业安全管理水平,将层次分析法和模糊综合评判法有机结合,确定具有针对性的各级指标权重值,创建了一套危化品企业安全标准化评价体系.最后以某涂料企业作为该评价体系的应用实例,并对比现场考评结果进行分析.结果表明,该评价体系可行、有效,指标权重可信度高,更能真实、客观地反映不同危化品企业的安全管理水平,可为评价危化品企业的安全标准化等级提供科学、准确的参考依据.     

Comparison of inherent safety indices in process concept evaluation

In conceptual design, process routes can be compared and ranked by using inherent safety indices. In this paper, some inherent safety index methods presented in literature are compared and their properties and limitations discussed. As a case study, an inherent safety evaluation of methyl methacrylate process routes is presented. Three index based inherent safety evaluation methods are compared with expert evaluations on methyl methacrylate process routes and their subprocesses. Also the index based inherent safety ranking of process routes is compared with an expert ranking.     

火灾爆炸危险指数评价法在催化裂化装置中的安全运用

以大庆石化总厂140万吨/年重油催化裂化装置为例,运用美国道化学公司火灾、爆炸危险指数评价法对该装置进行安全性评价,分析装置各单元固有的火灾爆炸危险性。根据火灾爆炸危险指数大小给工艺单元划分危险等级,评价其潜在的火灾爆炸危险,确定安全补偿系数。通过量化其危险性因素,从生产设备、工艺操作、安全管理等方面综合分析该装置的危险性、生产过程存在的火灾爆炸危险性和发生事故的可能性,评价发生事故的严重程度,找出主要危险因素力求从技术、工艺、设备、原材料、安全管理等方面采取措施,以减少火灾爆炸事故的发生或降低事故损失。本文为石化企业采取有针对性的火灾爆炸预防措施,从而降低事故的发生概率,提高装置运行的稳定性和可靠性,减少损失,保证生产安全进行提供了科学依据。     

催化裂解装置火灾爆炸危险性评价

道氏方法是对石化装置风险性进行量化评价的一种行之有效的方法,尤其是对装置的系统和单元的固有危险性及安全设施降低危险性的安全补偿作用进行认识和评价,采用道化学公司的火灾、爆炸危险指数法,对安庆石化炼油厂65×104t/a催化裂解装置的潜在火灾爆炸和反应危险性进行评价和分析,得到“严重”以上程度的单元有:加热炉、丙烷塔、丙烯塔、液化气储罐和汽油柴油储罐、反应器、瓦斯发生器、乙烷塔和稳定器,同时给出单元的危险等级和薄弱环节,为工厂的风险管理和安全管理决策提供了科学依据,并为降低装置风险提出了建议。     

Fire and Explosion Index calculation method incorporating classified safety measure credits

Based on an analysis of two methods for the modification of the F&EI for the DOW Guide, it is found that the effects of safety measures are not classified. Moreover, the efficiency of the measures is magnified to various degrees, as the positive impact of the loss reduction measures are applied to the rate reduction of the intrinsic hazard in the evaluated unit. For this reason, a modification method using classified safety measures is proposed, in which safety measures are classified into process protection measures and loss reduction measures. The calculation of the modified F&EI involves the credit factors of process protection measures, whereas the determination of the maximum probable property damage incorporates the loss reduction measures. This method could provide more reasonable reference data for hazard units because of its more objective and reasonable evaluation results.     

原油稳定装置的风险评价

运用美国道化学公司的火灾爆炸危险指数评价方法,对大庆油田天然气分公司正压原油稳定装置的火灾爆炸危险性进行了定量计算和评价,介绍了火灾爆炸指数评价法的评价程序和计算步骤,定量计算火灾爆炸可能导致的危害程度和最大可能财产损失,根据实际情况确定了单元的危险系数和安全措施补偿系数,最后得出单元危险分析的安全评价结果.     

火电机组氢冷系统安全评价

国外已经对火电厂的安全评价工作进行了一定的研究,但是国内对此项工作的研究还是比较匮乏,尤其对火电厂危险化学品更缺乏相关的安全评价方法及研究。在火力发电厂实际生产中,需使用到大量易燃、易爆危险化学品,由于使用、存储不当,极易造成重大事故。根据某火电厂实际情况,结合安全评价的基本程序,运用道(DOW)化学火灾、爆炸危险指数评价法对火电机组氢冷系统(GRH)单元进行了评价。结果显示,GRH单元的本质危险性很大,经过安全措施补偿后危险性较轻,说明利用道氏法对火电厂危险化学品使用状况进行评价,能够比较准确地反映被评价单位的实际情况,根据评价结果和存在的问题提出有针对性的对策措施,进一步改善火电机组运行环境的安全。评价结果可为火电厂提高安全管理水平提供有价值的参考。     

基于模糊综合评价的化工工艺本质安全指数研究

建立化工工艺的本质安全评价指标体系,包括可燃性、爆炸性、毒性、反应性、温度、压力、储量等7个指标。为解决前人指数法中的边界波动效应,采用模糊综合评价建立化工工艺本质安全评价指数模型,确定各指标的权重、危险分级及对各分级的隶属函数。以甲基丙烯酸甲酯的5条工艺路线为例进行分析,结论与前人提出的指数方法的评价结果相吻合,表明该指数方法可以用来进行化工工艺的本质安全评价,以指导设计初期的本质安全型工艺路线选择。     

Risk assessment and risk reduction of an acrylonitrile production plant

Reducing accident occurrence in petrochemical plants is crucial, thus appropriately allocating management resources to safety investment is a vital issue for corporate management as international competition intensifies. Understanding the priority of safety investment in a rational way helps achieve this objective.In this study, we targeted an acrylonitrile plant. First, Dow Chemical's Fire and Explosion Index (F&EI) identified the reaction process as having the greatest physical risk. We evaluated the severity of accidents in the reaction process using the Process Safety Metrics advocated by the Center for Chemical Process Safety (CCPS); however, this index does not express damages a company actually experience. To solve this problem, we proposed a new metric that adds indirect cost to CCPS metrics. We adopted fault tree analysis (FTA) as a risk assessment method. In identifying top events and basic events, we attempted to improve the completeness of risk identification by considering accidents from the past, actual plant operation and equipment characteristics, natural disasters, and cyber-attacks and terrorist attacks. Consequently, we identified the top events with high priority in handling because of serious accidents as fire/explosion outside the reactor, fire/explosion inside the reactor, and reactor destruction. The new CCPS evaluation index proposed in this study found that fire and explosion outside the reactor has the highest severity. We considered the creation of the fault tree (FT) diagram of the top event, estimating the occurrence probability, and identifying the risk reduction part and capital investment aimed at risk reduction. As an economically feasible selection method for risk reduction investment, using the difference in loss amounts before and after safety investments indicated investment priority.     

Calculation of Fire and Explosion Index (F&EI) value for the Dow Guide taking credit for the loss control measures

The Dow Fire and Explosion Index (F&EI) is universally used in evaluating the hazard category of a process plant, area of exposure, expected losses in case of fire and explosion, etc. In the current procedure, the effects of the loss control measures (LCMs) on the F&EI value are not taken into account. This makes the plant look more hazardous, makes it more spread out, requires more elaborate emergency measures and alarms the public and the civil administration more than is necessary. It also affects the insurance premium.We suggest taking the effects of the LCMs into account in the F&EI value. We call this the ‘Offset F&EI’ value. It favorably affects all the above items, and other related ones. To do this, we have developed the relevant equations and have proved the efficacy of the Offset F&EI by means of an example.     

Using process stream index (PSI) to assess inherent safety level during preliminary design stage

In the current practice, safety assessment is conducted once the process design has been completed. At this stage of design, the freedom to change the conceptual design is very limited and whatever strategies to be implemented will only control the hazard. This paper reports on the development of inherent safety index known as a process stream index (PSI) for inherent safety level assessment at preliminary design stage from the perspective of an explosion. The aim for PSI is to calculate, compare and prioritize the level of inherent safety of process streams during simulation work that influences the explosion. By prioritizing the streams based on the potential for the explosion, the design engineers can easily identify the critical streams to be considered for improvement in order to avoid or minimize explosion hazards. An enhancement technique to reflect the contribution of the individual components in the mixture is introduced, which provide significant contribution to the ranking of inherent safety level of process streams. The assessment of inherent safety level using PSI is demonstrated by case studies of HYSYS simulation for Acrylic Acid Plant and Natural Gas Liquid (NGL) plant.     

基于道化学法的大型合成氨装置安全评价

根据道化学公司火灾、爆炸危险指数的基本原理。用VH6．0开发的安全评价软件DowSE1．0，对某大型合成氨装置进行安全评价，得出其安全措施补偿前后的火灾、爆炸指数F＆EI以及危险暴露面积，危害系数，危险等级，实际可能财产损失程度等指数。结果表明。合成氨装置中实际最大可能财产损失值都没有超过200万美元，气化系统在合成氨装置中实际最大可能财产损失值占损失替换值比例高达53％，超过了10％的相对危险值界限。说明在引进国外技术时应注重其安全防范配套措施消化吸收，并结合实际采取切实可行的安全措施，降低合成氨装置的风险程度。     

危险品道路运输风险分级指数法研究

危险品道路运输过程风险影响因素多,随机性和不确定性大,定量风险评价比较复杂,至今没有统一的风险评估模型.为了有效预防危险品运输事故和进行快速风险评估,基于运输危险品本身特性和相关的风险影响因素探讨了运输危险品现实风险分级指数法.该方法由危险品风险分级指数、路线影响因素和安全措施补偿因子3部分构成.危险品风险分级指数由危险品加权平均风险等级和运输危险品量、泄漏点与居民区距离以及危险品扩散因子等级确定.危险品加权平均风险等级涉及其健康危害性、可燃性、化学反应活性以及特殊危险性(氧化性和与水反应性)等级的确定.路线影响因素包含运输道路特征、气象条件、交通状况和影响人员分布4类.安全措施补偿因子为车辆、设备、容器、包装因子,人员素质因子和安全管理因子3类.该方法可对运输危险品的潜在风险进行快速分级,有利于采取有效的安全预防和控制措施,降低运输事故概率和沿线影响人员风险.     

道化学火灾、爆炸危险指数法在1,3丁二烯聚合安全性评价中的应用

道化学火灾、爆炸危险指数法是在化工领域中广泛应用的一种评价方法,根据该法制定的指数选取规则,可对工艺单元火灾爆炸危险性进行量化和分级.以某化工厂3000t/a三聚体生产项目为背景,从工艺过程、危险物质、安全设施设计等方面,对1,3丁二烯聚合过程火灾、爆炸危险性进行分析;定量评价工艺装置及所含物料潜在危险性,得出主装置区、储罐区固有危险等级,分析不同状态下安全补偿系数对降低危险等级的影响,提出相应安全对策措施.     

基于本质安全的化学工艺风险评价方法研究

基于本质安全原理对化学工艺进行风险评价,以易燃性、易爆性、毒性、腐蚀性、反应热、化学活性、工艺温度、工艺压力和存储量9个指标,建立化学工艺的本质安全评价指标体系。采用基于遗传算法的Shepard插值算法对本质安全进行评价,以甲基丙烯酸甲酯的合成工艺路线为例进行分析,结果表明该方法适用于化学工艺本质安全评价,相对传统方法更加科学,能够有效对危险工艺进行选择,为政府监管部门和化工企业提供工艺选择决策技术。