Fault-dynamic modelling of a phthalic anhydride reactor

A new methodology, fault-dynamic modelling, has been developed for analysis of potentially hazardous situations in the process industries. Traditional fault-tree analysis is used to determine the combinations of component failure that can lead to a particular process upset condition. Realistic dynamic modelling is then used to calculate the time available for corrective action once the upset has started. The method is applied to a phthalic anhydride reactor. The results of the analysis identify three process upsets that can lead to catastrophic failure in 2–5 min if left uncorrected. Other process upsets lead to safe conditions.