Safer management of process changes in chemical reactors

Nowadays many chemical industries are SMEs where multi-purpose batch or semi-batch reactors are commonly used. Vent sizing for realistic runaway scenario is not an easy task for such enterprises since they have usually few resources and use multi-purpose reactors with fast process turnovers. As a consequence these batch and semi-batch reactors are usually equipped with emergency relief systems sized once forever when the reactor is designed. This can lead to a large underestimation of the vent area in case of runaway reactions occurring when processes different from the ones considered for originally sizing the vent are carried out.The approach proposed in this work aims to identify the maximum reactor load leading to safe conditions even in case of runaway phenomena to be handled with the emergency relief system already installed (or even with a smaller vent area). This approach allows avoiding the change of the emergency relief system with a larger vent area (as required every time a new more hazardous process has to be carried out on existing reactors) at the price of lower plant productivity.     

Biodiesel Reaction Screening Using Oscillatory Flow Meso Reactors

This paper is concerned with performing laboratory scale alkali-catalyst transesterification for biodiesel reaction and ranking conversion and performance between a stirred tank reactor, and oscillatory flow meso reactors in both batch and continuous mode. The results show that a comparative conversion can be achieved for the same reaction conditions, thereby demonstrating that batch and continuous meso reactor configurations can be used for a high throughput screening biodiesel reactions.     

The multi-energy critical separation distance

Devastating vapour cloud explosions can only develop under appropriate (boundary) conditions. The record of vapour cloud explosion incidents from the past demonstrates that these conditions are readily met by the congestion by process equipment at (petro-) chemical plant sites. Therefore, the possibility of an accidental release of a flammable and a subsequent vapour cloud explosion is a major hazardous scenario considered in any risk assessment with regard to the process industries.If an extended flammable vapour cloud at a chemical plant site extends over more than one process unit, which are separated by lanes of sufficient width, the vapour cloud explosion on ignition develops the same number of separate blasts. If, on the other hand, the separation between the units is insufficient, the vapour cloud explosion develops one big blast. The critical separation distance (SD) is the criterion that allows discriminating in this matter for blast modelling purposes.This paper summarises some major results of an experimental research programme with the objective to develop practical guidelines with regard to the critical SD. To this end, a series of small-scale explosion experiments have been performed with vapour clouds containing two separate configurations of obstacles. Blast overpressures at various stations around have been recorded while the SD between the two configurations of obstacles was varied.The experimental programme resulted in some clear indications for the extent of the critical SD between separate areas of congestion. On the basis of safety and conservatism, these indications have been rendered into a concrete guideline. Application of this guideline would allow a greater accuracy in the modelling of blast from vapour cloud explosions.     

Assessing safety culture in the Spanish nuclear industry through the use of working groups

This paper presents the design and the implementation of a methodology for measuring and improving safety culture at a nuclear power plant (NPP). The study has involved the completion of a pilot project aimed at seeing how to make use of the RADAR logic (Results, Approach, Deployment, Assessment and Review) of the EFQM model as a tool for the self assessment of safety culture in a nuclear power plant. The work was aimed at finding evidence of the safety culture that was in place at the plant and at identifying both the strengths of that culture and any areas in which it could be improved. The score obtained from an analysis of those strengths and areas for improvement has made it possible to prioritise the actions to be taken. The identification of perceptions and evidence, the agreement on the strong points and areas for improvement and the quantification of the safety culture have been performed by groups comprising volunteers who work at the NPP. The advantages of this methodology are assessed in the paper.     

Thermal risk in batch reactors: Theoretical framework for runaway and accident

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.     

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。     

Probe into effect of the initiator on the thermal runaway hazards of methyl methacrylate bulk polymerization

The bulk polymerization of methyl methacrylate (MMA) is of great importance in chemical industry, but the polymerization process is highly hazardous, and few reports have focused on the effect of initiators on its thermal hazards. In this work, to thoroughly explore the thermal hazard characteristics, the runaway behavior of MMA bulk polymerization is investigated by a combination of thermodynamics experimental and kinetics theoretical methods. The results indicate that the presence of initiator exhibits an undesirable thermal hazard to the MMA bulk polymerization, and its exothermic behavior is also greatly influenced by the type and concentration of initiator. For azobisisoheptanenitrile (ABVN), azodiisobutyronitrile (AIBN) and dibenzoyl peroxide (BPO) initiators as examples, the AIBN-initiated reaction has the shortest adiabatic induction period (39.51 min), whereas the BPO-initiated polymerization exhibits the strongest maximum temperature-rising rate and maximum pressure-rising rate. Under adiabatic runaway, the temperature and pressure change significantly with increasing AIBN concentration, revealing a great potential risk of thermal runaway. Kinetic parameters are calculated to further understand the thermal runaway mechanisms, showing a strong agreement with the adiabatic experimental data. Finally, based on the cooling failure scenario, severity grading is determined by the evaluation criteria. The current work provides extensive data as a reference and guidance for the process design and optimization of MMA bulk polymerization from the perspective of safety.     

Team crystallization (SIO2): Dynamic model of team effectiveness evaluation under the dynamic and tactical environment at nuclear installation

Accident management activities at nuclear power plants require concurrent communication, information sharing, team based decision-making and collective actions under tactical and dynamic environments. Team effectiveness under such environments can be characterized as the performance of team situation awareness with hierarchically distributed information and knowledge susceptible to organizational characteristics and communication quality. This paper proposes a team performance model, called a team crystallization model comprising of four elements: state, information, organization, and orientation and its quantification method using a communication process model based on a receding horizon control approach. The team crystallization model is a holistic approach for evaluating team effectiveness in conjunction with team situation awareness considering physical system dynamics and team behavioural dynamics for a tactical and dynamic task at a nuclear power plant. This model provides a systematic measure to evaluate time-dependent team effectiveness or performance affected by multi-agents such as plant states, communication quality in terms of transferring situation-specific information and strategies for achieving the team task goal at a given time, and organizational factors. To demonstrate the applicability of the proposed model and its quantification method, a case study was carried out using the data obtained from a full-scope power plant simulator for 1000 MW(e) pressurized water reactors with four on-the-job operating groups and one expert group who knew accident sequences.     

A hybrid approach to faults detection and diagnosis in batch and semi-batch reactors by using EKF and neural network classifier

This work deals with a new hybrid approach for the detection and diagnosis of faults in different parts of fed-batch and batch reactors. In this paper, the fault detection method is based on the using of Extended Kalman Filter (EKF) and statistical test. The EKF is used to estimate on-line in added to the state of reactor the overall heat transfer coefficient (U). The diagnosis method is based on a probabilistic neural network classifier. The Inputs of the probabilistic classifier are the input–output measurements of reactor and the parameter U estimated by EKF, while the outputs of the classifier are fault types in reactor. This new approach is illustrated for simulated as well as experimental data sets using two cases of reactions: the first is the oxidation of sodium thiosulfate by hydrogen peroxide and the second is alkaline hydrolyse of ethyl benzoate in homogeneous hydro-alcoholic. Finally, the combination of the estimated parameter U using EKF and probabilistic neural network classifier provided the best results. These results show the performance of the proposed approach to monitoring the semi-batch and batch reactors.     

An examination of shared leadership configurations and their effectiveness in teams

A key challenge in the shared leadership literature has been a limited understanding of how multiple leadership activities are shared across team members and roles. We address this issue by conceptualizing and operationalizing shared leadership using both its content (i.e., what leadership roles are shared) and distribution (i.e., how leadership is shared across members and roles). In an exploratory study comprised of 129 work teams, we use latent profile analysis (LPA) to identify multiple shared leadership configurations that vary in the extent of sharing. Our second study of 103 MBA teams supports these findings and further (a) considers what shared leadership configurations have the greatest influence on team effectiveness, (b) examines the mediating role of teamwork processes, and (c) investigates the moderating role of temporal dispersion. We advance current research by demonstrating that shared leadership typically manifests in collective (i.e., members share all leadership roles) and distributed configurations (i.e., members hold one leadership role while other members hold other leadership roles), which has implications for team processes and effectiveness. Specifically, we show that collective configurations have higher team effectiveness (compared to distributed configurations) owing to improved teamwork processes and observe that these effects are more pronounced when temporal dispersion is high.     

Application of the TNO multi-energy and Baker-Strehlow-Tang methods to predict hydrogen explosion effects from small-scale experiments

Analytical models or abacus are of importance to predict explosion effects in open and congested areas for industrial safety reasons. The goal of this work is to compare overpressure and flame speed values of small-scale deflagration experiments to predicted values from the TNO multi-energy (TNO ME) method and the Baker-Strehlow-Tang (BST) method. Experiments were performed in cylindrical congested volumes of hydrogen – air mixtures varying from 1.77 L to 7.07 L. The reactivity was controlled by the equivalence ratio of hydrogen-air mixtures, ranging from 0.5 to 2.5. The congestion was realized with varying numbers of grid layers and configurations. The influence of the obstacle density and the importance of the mixture reactivity to choose the strength index in order to predict the effects of an explosion has been highlighted for the TNO ME method. Predictive flame speed values from the BST method are in accordance with almost half of the experimental results and the method is conservative in most tested configurations. The use of the TNO ME method has been validated on a small-scale experiment to predict maximal overpressures generated by the deflagration of medium and large-scale H₂/air clouds.     

Influence of parameter uncertainty on modeling of industrial ammonia reactor for safety and operability analysis

Chemical reactors represent probably the most hazardous units of chemical industry. Safety analysis of a chemical reactor requires basic knowledge of all particular processes which can be described by mathematical models. Most of the model parameters involved in the prediction of reactor behavior are uncertain. These uncertainties can cause discrepancies mainly in the prediction by models with nonlinear behavior and they can be the source of confusion in the design of chemical reactors and consequently also in the safety and operability analysis.The main aim of this work was to analyze the influence of uncertainties in the model parameters on the prediction of operating quantities by mathematical models with nonlinear behavior. Such analysis can be used for safety and operability analysis of an industrial catalytic ammonia reactor. The industrial fixed-bed reactor was used by a mathematical model with nine parameters. Analyses of the influence of uncertainty in a single model parameter and their combination were carried out by the Monte Carlo approach. It is shown that even a small uncertainty in one of the key parameters or in a combination of these key parameters can result in several steady states results of the operating quantities and can be the source of confusion in the design and consequently also in the safety and operability analysis.     

Parametric sensitivity analysis for thermal runaway in semi-batch reactors: Application to cyclohexanone peroxide reactions

The semi-batch reactors (SBRs) system, which is widely used in industrial processes, possesses an intrinsic parametric sensitivity, in which infinitesimal disturbances of input parameters can result in large variations in output variables. In this work, local parametric sensitivity analysis (PSA) was used to understand parameter variations and global PSA was conducted to examine the interaction of input parameters. The effects of these parameters on the output of the system model were analyzed based on the Monte Carlo method with Latin hypercube sampling and the extended Fourier amplitude sensitivity test model. The results showed that the evolution of thermal behaviors in SBRs were observed: marginal ignition; thermal runaway; and the quick onset, fair conversion, and smooth temperature profile. The threshold point of transition from marginal ignition to thermal runaway was at the maximal value of local sensitivity, for which the slope with respect to cooling temperature equaled zero. Moreover, the sequence of the global sensitivity of six common input parameters was computed and evaluated. The reliability of the numerical models was verified by using our previous experimental results of cyclohexanone peroxide reaction. This comprehensive sensitivity analysis could provide valuable operating information to improve chemical process safety.     

Fire and explosion disasters occurred due to the Great East Japan Earthquake (March 11, 2011)

The Great East Japan Earthquake (magnitude 9.0 Mw: the moment magnitude scale, based on the seismic moment of the earthquake) occurred at 14:46, March 11, 2011. It triggered huge tsunami waves (seismic sea waves) that reached heights of up to about 20 m. In this paper, the fire and explosion disasters occurred due to the Great East Japan Earthquake are reported shortly. Some fires occurred in seacoast areas after tsunami attacks and some of them were spreading very widely to the tsunami flooded areas. It is important to study the mechanisms of such fires (tsunami fires) for preparing huge tsunami. After the earthquake, a very severe accident happened in the Fukushima Daiichi nuclear power plant. Three reactors experienced full meltdown. During this disaster, hydrogen explosions occurred and made the situation more serious. It has to be realized once again that the countermeasures for hydrogen explosions is indispensable. Also Large scale BLEVEs (Boiling Liquid Expanding Vapor Explosions) happened at LPG storage area in an oil refinery in Chiba Prefecture. This accident started from the falling down of an LPG storage tank by earthquake motions. The tank was heavier than usual, as it was filled with water (1.7 times heavier than LPG) for periodic inspection. Considering these disasters, we have to think about how we prepare the accident of low probability and of very severe consequence. Recently, the risk based approach is widely utilized. However, for such disasters it seems not enough to perform safety management only by risk based approach. Not only probabilistic approach (Risk), but also deterministic approach (Emergency plan, Mitigation technique) should be taken in account.     

Using retro-reflective cloth to enhance drivers’ judgment of pedestrian walking direction at night-time

Purpose: Fatal pedestrian collisions are over-represented at night and poor conspicuity is believed to be a leading causative factor. Retro-reflective clothing enhances pedestrian conspicuity, particularly when placed in a biological motion or “biomotion” configuration. In this study, we explored how various retro-reflective clothing configurations affected the ability to judge the direction of a pedestrian walking across the road, which has important implications for collision avoidance. Methods: Participants included 21 young drivers (mean age 21.6 ± 2.0 years) with normal vision. A closed-road circuit was used to assess the accuracy of drivers’ judgement of the direction of walking of a pedestrian at night-time wearing one of five different clothing configurations: four with retro-reflective materials placed in different locations (Biomotion, Legs + Torso, Torso Only, Legs Only), and a control wearing only black clothing (Street). Participants were seated in a stationary vehicle with low beam headlamps, 135 m from a pedestrian, who walked across the road from both sides, in different directions (towards the car, straight across the road, or away from the car). Outcome measures included drivers’ response accuracy and confidence ratings for judging pedestrian walking direction. Results: Accuracy in judging pedestrian walking direction differed significantly across the clothing configurations (p < 0.001). Response accuracy was significantly higher for the Biomotion configuration (80% correct), compared to the other retro-reflective (Legs + Torso 64%; Torso Only 53%; Legs Only 50%) and Street configurations (33%). Similar trends were noted for confidence ratings across the clothing conditions, yet the relationship between confidence ratings and response accuracy within each clothing configurations was poor. Conclusions: The use of retro-reflective clothing in a biomotion configuration facilitated the highest accuracy and confidence in drivers’ judgment of pedestrian walking direction, compared to other configurations. These findings highlight the importance of using biomotion clothing for pedestrians at night, to not only facilitate drivers’ earlier recognition of pedestrians, but also increase their accuracy in determining the walking direction of pedestrians as they cross the road. Practical applications: The use of clothing incorporating retro-reflective material in a biomotion configuration for pedestrians crossing roads at night provides enhanced cues for drivers regarding the presence and walking direction of pedestrians.     

Usability of non-standard lower anchor configurations for child restraint system (CRS) installation

Abstract

Objectives: The objective of this study was to determine whether the amount of tension required for proper child restraint system (CRS) installation varies with lower anchor spacing and to determine whether nonexperts can produce adequate tension on wider-than-standard lower anchor configurations.

Methods: CRSs were installed by certified child passenger safety technicians (CPSTs; n?=?6 subjects, n?=?72 installations) and nonexperts (n?=?30 subjects, n?=?120 installations) on a mock-up vehicle seat fixture with lower anchors set at 11 (standard), 15, 19, and 23 in. apart from one another. Each CPST installed a rear-facing (RF) infant base, RF convertible, and forward-facing (FF) convertible into each of the 4 spacing configurations in random order. The CPSTs were instructed to tighten the lower connector strap until the tension was exactly at the threshold between passing and failing the 1-in. test. Each nonexpert installed one CRS model into all 4 spacing conditions in random order. Nonexperts were instructed to install the CRS to the best of their ability. The tension produced on the lower connector strap was recorded via load cell in the lower anchor assembly of the vehicle seat. Resultant tension magnitudes were compared across spacing conditions using matched pair t-tests. The CPSTs’ mean 1-in. test threshold values were compared to tensions produced by nonexperts. Installations were visually evaluated for errors and qualitative usability feedback was collected via survey.

Results: CPSTs installed the infant base with higher tensions in the 15-, 19-, and 23-in. configurations compared to the standard 11-in. configuration (P = .034, .032, and .003, respectively). The nonexperts installed the infant base with higher tension in the 15- and 23-in. configurations compared to the 11-in. configuration (P = .004 and .026, respectively). The RF convertible and FF convertible installations showed no significant differences in tension among any of the spacing configurations for either group. Only 19% of the nonexperts’ installations were tight enough to pass CPST thresholds, and the pass rate did not vary with respect to lower anchor spacing. In feedback surveys, the nonexpert group did not show a consistent preference for either standard or wider-than-standard lower anchor configurations.

Conclusions: The amount of tension required to pass the 1-in. rule did not vary with lower anchor spacing configurations for the RF and FF convertible CRS, but the infant base required more tension in wider anchor configurations. Nonexperts tended to produce less than ideal tension in all configurations, although their tension magnitudes increased for the infant base in wider configurations.     

The effect of job and environmental factors on job satisfaction in automotive industries.

A methodology was developed for diagnosing industrial work, which includes questionnaire, observation, measurements, data collection and statistical analysis. A survey was conducted to investigate the relationship between job satisfaction and factors that affect work design in 2 automotives manufacturing companies in Malaysia. A basic work design model was proposed. The aim of this model was to determine the factors that influence employees' perception towards their work. A set of multiple-choice questionnaires was developed and data was collected by interviewing employees at a production plant. The survey focused on job and environmental factors. The results supported the proposed model and showed that job and environmental factors were significantly related to job satisfaction. They highlighted the significant influence of age, work experience and marital status on job satisfaction. Further, environmental factors, especially the surroundings, context dependence and the building's function, also had a significant impact on job satisfaction.     

Analysis of the self-heating process of tetrafluoroethylene in a 100-dm3-reactor

There is a lack of data on the self-ignition behaviour of tetrafluoroethylene in industrial sized equipment. Therefore, a facility was designed and constructed for the determination of the Minimum Ignition Temperature of Decomposition of tetrafluoroethylene in a cylindrical reactor with a volume of 100 dm³. Tests with initial pressures of 5 and 10 bar(a) were performed. The Minimum Ignition Temperature of Decomposition of tetrafluoroethylene was observed to decrease with the initial pressure, in agreement with previous experiments with small scale cylindrical vessels. This paper describes the test set-up und gives an overview of the achieved experimental results. In particular the effect of the reactor orientation (vertical or horizontal) is discussed. Furthermore, simplified equations from the Semenov thermal explosion theory are used to attempt extrapolations of previous and current data on the Minimum Ignition Temperature of Decomposition of tetrafluoroethylene to other vessel volumes or initial pressures. Moreover, the experimental data are plotted together against the heated volume to heated surface ratio, which should provide a better extrapolation to other vessel dimensions by taking into account that the efficiency of the dispersion of the heat generated by the reaction is different for two reactors with the same volume but different diameter. Finally, simplified methods for predicting the Minimum Ignition Temperature of Decomposition of tetrafluoroethylene presented previously by the authors are validated for large scale reactors with the experimental data collected within the current work.     

On the operator action analysis to reduce operational risk in research reactors

Human errors during operation and the resulting increase in operational risk are major concerns for nuclear reactors, just as they are for all industries. Additionally, human reliability analysis together with probabilistic risk analysis is a key element in reducing operational risk. The purpose of this paper is to analyze human reliability using appropriate methods for the probabilistic representation and calculation of human error to be used alongside probabilistic risk analysis in order to reduce the operational risk of the reactor operation. We present a technique for human error rate prediction and standardized plant analysis risk. Human reliability methods have been utilized to quantify different categories of human errors, which have been applied extensively to nuclear power plants. The Tehran research reactor is selected here as a case study, and after consultation with reactor operators and engineers human errors have been identified and adequate performance shaping factors assigned in order to calculate accurate probabilities of human failure.     

The Effect of Job and Environmental Factors on Job Satisfaction in Automotive Industries

A methodology was developed for diagnosing industrial work, which includes questionnaire, observation, measurements, data collection and statistical analysis. A survey was conducted to investigate the relationship between job satisfaction and factors that affect work design in 2 automotives manufacturing companies in Malaysia. A basic work design model was proposed. The aim of this model was to determine the factors that influence employees’ perception towards their work. A set of multiple-choice questionnaires was developed and data was collected by interviewing employees at a production plant. The survey focused on job and environmental factors. The results supported the proposed model and showed that job and environmental factors were significantly related to job satisfaction. They highlighted the significant influence of age, work experience and marital status on job satisfaction. Further, environmental factors, especially the surroundings, context dependence and the building’s function, also had a significant impact on job satisfaction.