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.     

Mitigation performance of the process protection system on the accident consequences of H2S-containing natural gas release and explosion

Toxic loads and explosion overpressure loads pose grave threats to the offshore oil and gas industry. Many safety measures are adopted to prevent and mitigate the adverse impacts caused by toxic loads and explosion overpressure loads. As a general safety barrier, the process protection system has been widely used but rarely evaluated. In order to assess the barrier ability, the mitigation performance of the process protection system is concerned in this study. Firstly, several chain accidents of H₂S-containing natural gas leakage and explosion are simulated by varying the response time of the process protection system with CFD code FLACS. Qualitative assessment is conducted based on the variation of the dangerous load profiles. Furthermore, the quantitative assessment of the mitigation performance is accomplished by considering its ability in reducing the probability of fatality. Emergency evacuation and no emergency evacuation are considered respectively in the quantitative assessment. The results prove that the process protection system takes effect on mitigating the toxic impact and explosion overpressure impact. The results also demonstrate that although the emergency evacuation may result in a severer explosion load to the operator, the process protection system can mitigate the adverse impacts regardless of whether the emergency evacuation is conducted or not.     

Recent application of Computational Fluid Dynamics (CFD) in process safety and loss prevention: A review

In recent years, significant progress has been made to ensure that process industries are among the safest workplaces in the world. However, with the increasing complexity of existing technologies and new problems brought about by emerging technologies, a strong need still exists to study the fundamentals of process safety and predict possible scenarios. This is attained by conducting the corresponding consequence modeling and risk assessments. As a result of the continuous advancement of Computational Fluid Dynamics (CFD) tools and exponentially increased computation capabilities along with better understandings of the underlying physics, CFD simulations have been applied widely in the areas of process safety and loss prevention to gain new insights, improve existing models, and assess new hazardous scenarios. In this review, 126 papers from 2010 to 2020 have been included in order to systematically categorize and summarize recent applications of CFD for fires, explosions, dispersions of flammable and toxic materials from accidental releases, incident investigations and reconstructions, and other areas of process safety. The advantages of CFD modeling are discussed and the future of CFD applications in this research area is outlined.     

Taxonomic and functional variations in the microbial community during the upgrade process of a full-scale landfill leachate treatment plant – from conventional to partial nitrification-denitrification

• Upgrade process was investigated in a full-scale landfill leachate treatment plant. • The optimization of DO can technically achieve the shift from CND to PND process. • Nitrosomonas was mainly responsible for ammonium oxidation in PND system. • An obviously enrichment of Thauera was found in the PND process. • Enhanced metabolic potentials on organics was found during the process update. Because of the low access to biodegradable organic substances used for denitrification, the partial nitrification-denitrification process has been considered as a low-cost, sustainable alternative for landfill leachate treatment. In this study, the process upgrade from conventional to partial nitrification-denitrification was comprehensively investigated in a full-scale landfill leachate treatment plant (LLTP). The partial nitrification-denitrification system was successfully achieved through the optimizing dissolved oxygen and the external carbon source, with effluent nitrogen concentrations lower than 150 mg/L. Moreover, the upgrading process facilitated the enrichment of Nitrosomonas (abundance increased from 0.4% to 3.3%), which was also evidenced by increased abundance of amoA/B/C genes carried by Nitrosomonas. Although Nitrospira (accounting for 0.1%–0.6%) was found to stably exist in the reactor tank, considerable nitrite accumulation occurred in the reactor (reaching 98.8 mg/L), indicating high-efficiency of the partial nitrification process. Moreover, the abundance of Thauera, the dominant denitrifying bacteria responsible for nitrite reduction, gradually increased from 0.60% to 5.52% during the upgrade process. This process caused great changes in the microbial community, inducing continuous succession of heterotrophic bacteria accompanied by enhanced metabolic potentials toward organic substances. The results obtained in this study advanced our understanding of the operation of a partial nitrification-denitrification system and provided a technical case for the upgrade of currently existing full-scale LLTPs.     

The role of analogues in radioecology

If no data are available for a specific radionuclide its analogue could be used in radioecological models. They might be used not only in the frame of screening modelling. Relevant processes and features have to be known, such as time scales of these processes, physical, chemical and biological properties of the environment and relevant media. An analogue could only be proven to be valid by comparing its behaviour in the conditions of interest, while confidence in the validity of an analogue will increase as the quality of the justification increases, there will always be some residual uncertainty. Several main types of analogy can be used when measured or recommended values are not available: the same parameter obtained for another isotope of the same element; the same parameter obtained for another element; a different parameter obtained for the same element. There are several cases, when analogues might be applied as indicators of the determining processes in the radioecological studies.     

Process design optimization and risk analysis

Hazard identification and risk assessment are key aspects in process plant design. They are often applied in the final stages of the process at whatever the cost, unless financial constraints are imposed. However, a much better solution would be to introduce risk analysis earlier by including it in earlier stages of the design process, such as when the cost of a plant and the cost of any accidents that may occur are estimated. In this paper, an optimization methodology is proposed, in which both cost and risk (with a deterministic approach) are taken into account, to improve on the current situation. If a decision variable is chosen, an objective function will be established that makes it possible to analyze variations in overall costs, including the cost of the investment and the cost of accidents. This leads to an optimum situation in which costs are kept to a minimum. Of course, this optimization is subject to constraints, the greatest of which is the fact that risk must not exceed tolerated threshold levels. The procedure is explained and two examples, one involving a toxic release and the other a BLEVE/fireball, are used to illustrate it.     

煤与瓦斯突出影响因素评价分析的模糊层次分析方法

在综合分析煤与瓦斯突出的影响因素的基础上,采用模糊层次分析法（FAHP）建立了煤与瓦斯突出模糊层次分析模型并进行了实例分析,确定了煤与瓦斯突出各影响因素的权重系数。评价结果表明：地应力、地质构造、瓦斯压力等是影响煤与瓦斯突出的主要因素。为制定相应的煤与瓦斯突出防治措施,提供了科学的理论依据和切合实际情况的评价方法。     

生物倍增工艺同步脱氮除磷强化途径分析

通过对生物倍增工艺处理市政污水的沿程污染物降解规律的考察表明,工艺对有机物的去除效果显著,COD和BOD5出水分别为47.80 mg/L和19.80 mg/L;氨氮去除率可达100%。发现厌氧区提前发生反硝化并一定程度上影响系统除磷效果;通过对各主要影响因素进行分析,认为低碳源的进水条件是影响系统同步脱氮除磷效果的关键因素;提出在进水口直接添加碳源以及分点进水的碳源分配＋辅助化学除磷的方式可强化氮磷去除效果。     

基于AHP的可听噪声影响因素权值分析

影响超高压输电线路可听噪声的因素众多,对影响可听噪声的因素进行合理分析确定其对可听噪声影响的权重是进行可听噪声预测和合理有效降低可听噪声的前提。对影响可听噪声的因素进行分析并运用层次分析法（AnalyticHierarchyProcess,AHP）对影响可听噪声的主要因素进行加权分析,以定量的形式确定影响因素的相对重要度。结果表明,应用层次分析法确定的可听噪声影响因素权重符合实际,准确性较高,为可听噪声选择主要影响因素用于预测及有效降低可听噪声提供参考依据。     

A process integration approach to industrial water conservation: a case study for a Chinese steel plant

A systematic approach to optimizing water network has traditionally been utilized to exam and plan water conservation in industrial processes. In the present case study, water-pinch technology was used to analyze and optimize the water network of a steel plant near China's Zhangjiakou city. A system design was developed and a limiting constraint (Cl(-) concentration) was identified based on investigations of water quality then the minimum freshwater and wastewater targets were determined without considering water losses. The analysis was then extended by calculating the additional input of freshwater required to balance the actual water losses. A nearest-neighbor algorithm (NNA) was used to distribute the freshwater and recycled water among each of the plant's operations. The results showed that with some reconstruction of the water network, the flow rates of freshwater and wastewater could be decreased by 57.5% and 81.9%, respectively.