7
Risk Assessment and Management of Chemical
Processes
7.1
The Aim of Process Risk Assessment
Chemical manufacturing involves producing often complex target molecules that
have to be built up over multiple steps. This can mean that the necessary reaction
and processing steps are carried out across different reactors and in multiproduct (or
even multipurpose) production plants, potentially at large volumes and operating
both day and night. Ensuring the safety of these processes is essential to prevent
accidents and protect the health of the plant’s employees as well as of the
surrounding community and environment.
In the context of process risk assessment, a chemical process is considered to
involve the production of one or more chemical products. This includes (1) the
chemical reaction where raw materials (reactants) are converted to the desired
product as well as to by-products and waste; (2) physical separation and purification
operations such as crystallization, filtration, and distillation used to obtain the
desired product specification; and (3) handling, transfer, and storage of chemicals.
Risks can exist due to the use of hazardous substances and conditions in
chemical processes, as well as their susceptibility to a wide range of potential
deviations. Critical deviations from planned operating procedures can stem from
the technical equipment and controls involved, from human error during operation,
or from environmental factors. They can result in severe accidents that have direct
impacts on human health, the environment, and the equipment being used. These
events include mainly fires, explosions, and releases of toxic substances into the
atmosphere.
Process risk assessment aims to avoid, control, and mitigate critical process risks,
with a special focus placed on the guiding principle of inherent process safety.
Risk assessment and management should take place (1) at all stages during the
development of new processes or installations and (2) for existing processes each
time a modification to the process is made and as part of process safety management
© The Author(s), under exclusive license to Springer Nature Switzerland AG 2021
K. Hungerbühler et al., Chemical Products and Processes,
https://doi.org/10.1007/978-3-030-62422-4_7
159
Risk Assessment and Management of Chemical
Processes
7.1
The Aim of Process Risk Assessment
Chemical manufacturing involves producing often complex target molecules that
have to be built up over multiple steps. This can mean that the necessary reaction
and processing steps are carried out across different reactors and in multiproduct (or
even multipurpose) production plants, potentially at large volumes and operating
both day and night. Ensuring the safety of these processes is essential to prevent
accidents and protect the health of the plant’s employees as well as of the
surrounding community and environment.
In the context of process risk assessment, a chemical process is considered to
involve the production of one or more chemical products. This includes (1) the
chemical reaction where raw materials (reactants) are converted to the desired
product as well as to by-products and waste; (2) physical separation and purification
operations such as crystallization, filtration, and distillation used to obtain the
desired product specification; and (3) handling, transfer, and storage of chemicals.
Risks can exist due to the use of hazardous substances and conditions in
chemical processes, as well as their susceptibility to a wide range of potential
deviations. Critical deviations from planned operating procedures can stem from
the technical equipment and controls involved, from human error during operation,
or from environmental factors. They can result in severe accidents that have direct
impacts on human health, the environment, and the equipment being used. These
events include mainly fires, explosions, and releases of toxic substances into the
atmosphere.
Process risk assessment aims to avoid, control, and mitigate critical process risks,
with a special focus placed on the guiding principle of inherent process safety.
Risk assessment and management should take place (1) at all stages during the
development of new processes or installations and (2) for existing processes each
time a modification to the process is made and as part of process safety management
© The Author(s), under exclusive license to Springer Nature Switzerland AG 2021
K. Hungerbühler et al., Chemical Products and Processes,
https://doi.org/10.1007/978-3-030-62422-4_7
159