A semi-quantitative methodology for risk assessment of university chemical laboratory

University chemical laboratory is a high-risk place for teaching and scientific research due to the presence of various physical and chemical hazards. In recent years, university chemical laboratory accidents occur frequently. This urges the need to enhance university chemical lab safety. A semi-quantitative methodology comprising Matter-Element Extension Theory (MEET) implemented with Combination Ordered Weighted Averaging (C-OWA) operator is proposed to assess the risk of a university chemical laboratory. First, an index-based risk assessment system of university chemical laboratory is built by identifying various risk factors from a system perspective. Then, C-OWA operator is used to calculate the weight of assessment indices, whereas MEET is employed to determine the correlation degree of assessment indices. Finally, the comprehensive risk of university chemical laboratories is assessed, and some safety measures are proposed to reduce the risk of university chemical laboratories. The applicability of the proposed methodology is tested using a practical case. It is observed that the methodology can be a useful tool for risk assessment and management of university chemical laboratories.     

An integrated methodology to manage risk factors of aging urban oil and gas pipelines

Aging urban oil and gas pipelines have a high failure probability due to their structural degradation and external interference. The operational safety of the aging urban oil and gas pipeline is challenged by different hazards. This paper proposes a novel methodology by integrating an index-based risk evaluation system and fuzzy TOPSIS model for risk management of aging urban oil and gas pipelines, and it is carried out by evaluating the priority of hazards affecting pipeline safety. Firstly, the hazard factors of aging urban oil and gas pipelines are identified to establish an index-based risk evaluation system. Subsequently, the fuzzy TOPSIS model is employed to evaluate the importance of these hazard factors and to decide which factors should be managed with priority. This work measures the importance of a hazard factor from three aspects, i.e. occurrence (O), severity (S) and detectability (D), and the weights of these three parameters are determined by a combination weight method. Eventually, the proposed methodology is tested by an industrial case to illustrate its effectiveness, and some safety strategies to reduce the operational risk of the pipeline are presented. The proposed methodology is a useful tool to implement more efficient risk management of aging urban oil and gas pipelines.     

Engineering for Sustainable Development (ESD) in Bio-Diesel Production

Engineering for sustainable development (ESD) is an integrated systems approach, which aims at developing a balance between the requirements of the current stakeholders without compromising the ability of the future generations to meet their needs. This is a multi-criteria decision-making process that involves the identification of the most optimal sustainable process, which satisfies economic, ecological, social criteria as well as safety and health requirements. Certain difficulties are encountered when ESD is applied such as ill-defined criteria, scarcity of information, lack of process-specific data, metrics and the need to satisfy multiple decision makers. To overcome these difficulties ESD can be broken down into three major steps, starting with the life cycle assessment (LCA) of the process, followed by generation of non-dominating alternatives, and finally selecting the most sustainable process by employing an analytic hierarchical selection process. This methodology starts with the prioritization of the sustainability metrics (health and safety, economic, ecological and social components). Then the alternatives are subjected to a pair-wise comparison with respect to each Sustainable Development (SD) indicator and prioritized depending on their performance. The SD indicator priority score and each individual alternative's performance score together are used to determine the most sustainable alternative. In this paper, the analysis approach and metrics for ESD are applied to bio-diesel production.     

基于集对分析的化工工艺本质安全性评价方法

为了提高化工工艺本质安全性评价的有效性和全面性,根据集对分析理论建立了四元联系数评价模型。模型选用传统的本质安全指标及其分级标准,对各指标进行赋权,以甲基丙烯酸甲酯合成工艺路线为例进行实用性验证,最终确定了多条工艺路线的本质安全程度优劣顺序,并明确各自的本质安全程度。结果表明,集对分析方法能够客观全面地评价化工工艺路线的本质安全性,可以用于化工工艺路线的优选过程,为工艺安全管理和技术改进提供指导。     

Risk-based route evaluation against country-specific criteria of risk tolerability for hazmat transportation through Indian State Highways

Risk-based route evaluation is necessary for decision making by authorities for regulating hazardous materials (hazmats) transport vehicles. The paper highlights risk estimation and its representation for three highway study routes in western India using frequency analysis through logic diagrams and scenario based detailed consequence analysis of accidental releases considering 26 hazmats from UN Classes-2, 3, 6 and 8 categories. The 3 routes have been evaluated based on several layers of analysis namely hazmat-wise, route-segment-wise, route-wise and overall assessment including presentation of normalized risk figures. The results show that compared to the risk on city route segment, individual risks on other two routes are higher and extend beyond ALARP (As Low As Reasonably Practicable) region when assessed against HSE, UK risk criteria, whereas, societal risks on all three routes are within the ALARP except some part in the higher fatality area. But, considering the general mortality rates in India and sustained economic growth, the authors proposed widening of the ALARP region for individual risk tolerability of transportation activity of essential commodities that benefits society to a large extent in this developing economy. However, specific risk reduction measures have also been suggested to improve upon the risk picture in the study area.     

Route evaluation for hazmat transportation based on total risk - A case of Indian State Highways

Risk-based hazmat transportation route evaluation involves risk calculations taking into consideration the probability of collision related accident occurrence and detailed consequence analysis of various event scenarios. Probabilistic hazmat transportation risk assessment mainly depends on three important factors i.e. accident rate, Average Daily Traffic and population density besides route length which has a definite bearing on it. An effort has been made to estimate the route segment specific (location-specific) accident rate instead of aggregate National or State average values in order to bring specificity into the issue of decision making to avoid routes with higher accident rates. Instead of using default accident rate for different highway types developed with the US data, which are not well-comparable when used in Indian situations; the author used site-specific truck accident data. Subsequently, Loss of Containment (LOC) probabilities and spillage probabilities for different route segments have been computed and compared. Finally, route segment-wise total risk is estimated which is a convenient measure of the average number of persons likely to be exposed from all the possible consequence event scenarios resulting from releases of different hazmats being transported along the studied routes. The present study highlights the route evaluation carried out based on total risk computation, without going through detailed event based consequence analysis on two State Highway routes and one major urban road passing through important industrial corridors of Surat District in western India, to enable routing decisions by local authorities and also for planning emergency mitigation purposes.     

A transportation-location problem model for pedestrian evacuation in chemical industrial parks disasters

A successful emergency management for chemical industrial parks (CIPs) accidents includes the route and shelter selection. Both of them are based on the collection of chemicals, atmosphere, geographic and population databases of CIPs. This decision process can be considered as a kind of transportation-location problem (TLP). In this paper, a conceptual model of emergency decision system for TLP of CIPs has been reported and a new multi-objective TLP model of pedestrian evacuation has also been proposed. The model includes sub-criteria, and the affected areas are categorized into a priority hierarchy based on human vulnerability model (HVM). The model can be used to design shelter places and guide the evacuation of the affected people. Besides, it can maximize the total time satisfaction level of evacuees combined with the routes passable probabilities. Finally, a case study shows that this model is flexible and applicable to various scenarios and risk measures.     

Development of inherent safety and health index for formulated product design

The numerous formulated products which are introduced to the market consist of chemical ingredients that may cause various safety and health hazards to the consumers. Therefore, it is extremely important to practice a systematic methodology to formulate products with acceptable safety and health performances. This work presents an index-based methodology to assess the safety and health hazards of the ingredients during the early formulation stage of product design. Hence, new inherent safety and health sub-indexes are introduced to improve the current safety and health hazards that are needed in formulated product design. The inherent safety and health sub-indexes are assigned with scores based on the degree of potential hazards. A higher score indicates a higher safety risk or severe health effect, and vice versa. The proposed methodology will greatly assist the users to identify the adverse safety and health effects caused by the ingredients. Hence, it is pivotal to eliminate or reduce the safety and health impacts from product usage. A case study on common ingredients used in the formulation of paint is presented on this study to describe the proposed method.     

不同空间尺度下危化品运输路径优化

为了解决化工园区危化品运输路径优化问题,研究了化工“园区间”与“园区内”2种空间尺度下危化品运输的影响因素差异性,提出以最小化运输阻抗、最小化运输风险和最小化风险敏感度为优化目标的不同空间尺度下危化品运输路径优化模型。通过目标量化确定每条路径上的目标值,将标准化后的目标值引入到Dijkstra算法和集成目标函数最优折衷路径的扩展标号法中,对危化品运输多目标优化模型进行求解。研究结果表明:不同空间尺度下的危化品运输最优路径不同,应根据危化品运输的实际情况对运输路径进行选择。最后,以平顶山某化工园区的抽象路网为例对优化模型进行验证。     

Computer-aided assessment of occupationally healthier processes during research and development stage

Each year more people die from occupational related diseases than are killed in industrial accidents. Therefore it is critical to start considering health aspect early when developing a new chemical process. In this paper, a computer-aided tool for assessing inherent occupational health is proposed for chemical process research and development stage. The method was developed based on the reaction chemistry data, which is the only data available at this stage. Three types of approaches were formulated to calculate the route index value using additive type, average type and worst case type calculations. The tool can be used to rank the alternative chemical synthesis routes by their health properties as well as characterize the hazard level of single process. Finally the tool was applied to six process routes for methyl methacrylate production for demonstration. The case study revealed hazards of the processes from different perspectives, e.g. the results from the additive-type calculation were mainly affected by the total number of steps in the route, which indicates the impact of process complexity on the level of hazard. The introduction of such tool provides a swift yet reliable means that will encourage health criteria to be considered earlier in process development besides economic, safety and environment.     

Chemical process route selection based upon the potential toxic impact on the aquatic,terrestrial and atmospheric environments

This paper proposes a method to estimate the inherent environmental friendliness of a chemical process plant by considering the potential toxicity impact on the aquatic, terrestrial and atmospheric environments. A worst-case scenario of a total loss of containment in the plant is assumed. The method proposed by [Gunasekera, M.Y., Edwards, D.W. (2003). Estimating the environmental impact of catastrophic chemical releases to the atomosphere: an index method for ranking alternative chemical process routes. Trans. IChemE., Part B, Process Safety and Environmental Protection, 81(B6), 463–474] for determining the inherent atmospheric environmental friendliness of a chemical plant is combined with the method proposed by [Cave, S.R., Edwards, D.W. (1997). Chemical process route selection based on assessment of inherent environmental hazard. Computers Chem. Engng., 21, S965–S970], which estimates the inherent friendliness to the aquatic and terrestrial environments.Application of this method to six routes to produce methyl methacrylate shows that the acetone cyanohydrin based route is potentially the least inherently environmentally friendly. The highest potential hazard is observed in the aquatic environment due to the chemicals associated with the acetone cyanohydrin route.     

Simple graphical method for inherent occupational health assessment

The concept of inherently safer design was introduced to design a fundamentally safer process so that hazards can be avoided or minimized rather than controlled or managed. The ideology has later been extended to the environmental, but not health criteria due to its complicated underlying principles. Even though health risk methods are already established, majority are for existing plants assessment. Early consideration of health aspect starting from process design stage however, has received much less attention. This paper introduces a simple graphical method to evaluate the inherent occupational health hazards of chemical processes during the R&D stage. A survey was conducted to identify the important health parameters for the graphical method development, involving nine world inherent safety and health experts. Based on their input, process mode, material volatility, operating pressure and chemical health hazard (toxicity and adverse effect) are the significant factors affecting inherent health hazards of chemical processes. The choice of parameters was bounded by the information availability at this stage. The method was applied on six routes to methyl methacrylate and ten routes to acetic acid. The parameters were plotted for each subprocess of the alternative routes. The ‘healthiest’ route was selected based on thorough hazards assessment across all the subprocesses. The first case study reveals the tertiary butyl alcohol as the ‘healthiest’ one as it poses relatively lower, or at least comparable hazards to the other routes due to exposure and health impacts. Meanwhile the acetic acid case study indicates ethanol oxide and ethyl oxide based routes as the inherently healthier as they operate at lower operating pressure besides posing comparable hazards level for the other three parameters, compared to the other routes. The case studies show that the inherent occupational health of a chemical process can already be evaluated easily in the R&D stage with the simple graphical method proposed.     

一种新型危险化工工艺安全评估方法的设计

在安全生产过程中,建设项目风险评价在我国经过几十年的发展,无论在模型亦是方法上均有所进步,但对化工项目进行危险化工工艺风险等级评价的研究并不多见。本文按照危险化工工艺表征涉及的影响因素,在参考了日本劳动省"六阶段"的定量评价表以及危险度评价法并对15种危险化工工艺定性分析的基础上,提出了一种基于危险度评价法的更为全面的危险化工工艺辨识方法。该评价方法可用于确定危险化工工艺的风险等级。为化工企业工艺危险的实时评估和安全管理提供技术支撑和科学途径。     

Statistical fault detection using PCA-based GLR hypothesis testing

Safe process operation requires effective fault detection (FD) methods that can identify faults in various process parameters. In the absence of a process model, principal component analysis (PCA) has been successfully used as a data-based FD technique for highly correlated process variables. Some of the PCA detection indices include the T² or Q statistics, which have their advantages and disadvantages. When a process model is available, however, the generalized likelihood ratio (GLR) test, which is a statistical hypothesis testing method, has shown good fault detection abilities. In this work, a PCA-based GLR fault detection algorithm is developed to exploit the advantages of the GLR test in the absence of a process model. In fact, PCA is used to provide a modeling framework for the develop fault detection algorithm. The PCA-based GLR fault detection algorithm provides optimal properties by maximizing the detection probability of faults for a given false alarm rate. The performance of the PCA-based GLR fault detection algorithm is illustrated and compared to conventional fault detection methods through two simulated examples, one using synthetic data and the other using simulated continuously stirred tank reactor (CSTR) data. The results of these examples clearly show the effectiveness of the developed algorithm over conventional methods.     

How do different process options and evaluation settings affect economic and environmental assessments? A case study on methyl methacrylate (MMA) production processes

We present an investigation on how economic and environmental assessment results change when different process options or evaluation settings are considered. As the main case study the production technology of methyl methacrylate (MMA) is investigated. Six commercial processes using different reaction routes are modelled and evaluated with respect to their economic and environmental performance. On these six base case models different process options and evaluation settings are considered and the resulting impacts on the assessment results are quantified. Major findings of the study are that the more decision-variables become fixed, the smaller becomes the impact of the decisions still to be taken—but not only with respect to the economic performance but also with regard to the environmental assessment result. Along the process development steps the potential impacts on the economic and environmental performance decrease to the same degree. The results obtained for the evaluation settings do not show such a systematic pattern as those for the process options. This finding indicates that decision makers face many options in the economic and especially the environmental assessment of chemical processes which might lead to quite different magnitudes in variability due to either the choice of method or the choice of method parameters. This paper demonstrates that the resulting variability might be crucial with respect to the decision making outcome.     

Multi-criteria decision-making considering risk and uncertainty in physical asset management

In this work we present a method for risk-informed decision-making in the physical asset management context whereby risk evaluation and cost-benefit analysis are considered in a common framework. The methodology uses quantitative risk measures to prioritize projects based on a combination of risk tolerance criteria, cost-benefit analysis and uncertainty reduction metrics. There is a need in the risk and asset management literature for a unified framework through which quantitative risk can be evaluated against tolerability criteria and trade-off decisions can be made between risk treatment options. The methodology uses quantitative risk measures for loss of life, loss of production and loss of property. A risk matrix is used to classify risk as intolerable, As Low As Reasonably Practicable (ALARP) or broadly tolerable. Risks in the intolerable and ALARP region require risk treatment, and risk treatment options are generated. Risk reduction benefit of the treatment options is quantified, and cost-benefit analysis is performed using discounted cashflow analysis. The Analytic Hierarchy Process is used to derive weights for prioritization criteria based on decision-maker preferences. The weights, along with prioritization criteria for risk reduction, tolerance criteria and project cost, are used to prioritize projects using the Technique for Order Preference by Similarity to Ideal Solution. The usefulness of the methodology for improved decision-making is illustrated using a numerical example.     

Determination of the optimal escape routes of underground mine networks in emergency cases

Escaping is natural in the case of accidents in underground mines. Determining the optimal escape route is one of the most important factors for relief of miners in the emergency cases. This paper aims at developing a mathematical method to determine the shortest escape time from a given point to alternative points of an underground mine network. It also aims to find the shortest routes between each pair of the given points. The first point refers to the place of the accident where some miners may exist, and the alternative points show the safe places that the miners can escape to. After determining the shortest escape time and its corresponding route between each pair of mine work junctions, it is possible to set an electronic board that shows the access route to the nearest safe location by an arrow sign in each mine work. In this paper, Floyd–Warshall and π algorithms are used to determine the shortest escape time between the place of accident and safe places as well as their corresponding routes. Those algorithms are rigorous since they are supported by mathematical proof. Finally, the algorithms are implemented on the network of a certain underground coal mine and the results are presented.     

Smart chemical industry parks in China: Current status,challenges, and pathways for future sustainable development

The chemical industry has been pivotal to the rapid economic expansion and high standards of living in China. As an important carrier of the chemical industry, China has designated as many as 723 chemical industrial parks (CIPs). Unfortunately, safety concerns have become an obstacle to the sustainability of China's CIPs. Ever since the two devastating hazardous chemical accidents, namely “Tianjin Port 8·12 Explosion” and “Jiangsu 3·21 Explosion,” which occurred in 2015 and 2019 respectively, China has prioritized the safety of CIPs. The smart chemical industrial parks (SCIPs) are considered the optimal strategies toward the goal of sustainable development in China's CIPs. However, there has been a lack of research and subsequent discussion on the role of SCIPs in the forthcoming years. The period between 2020 and 2025 is considered a crucial period for the future development of CIPs and SCIPs in China mainly because the country has released a series of important government documents and national standards (such as “Fourteenth Five-Year (2020–2025) Plan for Hazardous Chemical Safety” and “Guidelines of SCIPs construction”) to promote hazardous chemical safety. With the aim of analyzing the future sustainable development for the construction of SCIPs in China, this paper proposes a systematic methodology in order to conduct an integrated and in-depth review on the standardization construction status (framework with Chinese characteristics, key events, spatial features, and national pilots), future tasks, problems, and sustainable development pathways of China's SCIPs. The method is implemented in accordance with the current scenarios of hazardous chemical safety in China and the latest government documents, regulations, and standards. Furthermore, this study provides basic data and a basis for future studies associated with the safety and sustainability of the SCIPs construction and chemical industry, both within China and in other countries.