244
10 Illustrative Case Study
(a) Regarding fire and explosion hazards:
• Are safety measures necessary? If yes, which type of measures?
• When should the safety measures be applied?
(b) Regarding side reactions (consider the reactivity interaction matrix in
Table 10.3):
• Which hazardous side reactions can occur?
• Which safety measures need to be considered?
(c) Regarding temperature control:
• What is the temperature control strategy?
• Why is the synthesis reaction conducted at 190 ◦ C?
• Why is the synthesis reaction not operated at the boiling point of the reaction
mixture?
(d) Regarding thermal process safety:
• What is the adiabatic temperature rise and the MTSR?
• With these two values in mind, which considerations are important with
respect to thermal process safety?
• Classify the potential impacts of each reaction, and also identify the criticality class for each. For the synthesis reaction and the precipitation reaction,
assume that T 24 > MTSR and MTT.
10.2.3 Risk Identification (Step 3)
Considering the data collected in step 1 and the safe process conditions defined in
step 2, the process risks can be identified with one of the methods introduced in
Chap. 7.
Task: Fill in the missing information in Table 10.4 for the identification of risks
during the synthesis and precipitation reactions using a HAZOP method.
10.2.4 Risk Analysis (Step 4)
10.2.4.1 Consequence Analysis
To analyze the consequence of an HCN release scenario, consider the potential
effects on a neighboring manufacturing site located 500 m downwind from the
reactor.
10 Illustrative Case Study
(a) Regarding fire and explosion hazards:
• Are safety measures necessary? If yes, which type of measures?
• When should the safety measures be applied?
(b) Regarding side reactions (consider the reactivity interaction matrix in
Table 10.3):
• Which hazardous side reactions can occur?
• Which safety measures need to be considered?
(c) Regarding temperature control:
• What is the temperature control strategy?
• Why is the synthesis reaction conducted at 190 ◦ C?
• Why is the synthesis reaction not operated at the boiling point of the reaction
mixture?
(d) Regarding thermal process safety:
• What is the adiabatic temperature rise and the MTSR?
• With these two values in mind, which considerations are important with
respect to thermal process safety?
• Classify the potential impacts of each reaction, and also identify the criticality class for each. For the synthesis reaction and the precipitation reaction,
assume that T 24 > MTSR and MTT.
10.2.3 Risk Identification (Step 3)
Considering the data collected in step 1 and the safe process conditions defined in
step 2, the process risks can be identified with one of the methods introduced in
Chap. 7.
Task: Fill in the missing information in Table 10.4 for the identification of risks
during the synthesis and precipitation reactions using a HAZOP method.
10.2.4 Risk Analysis (Step 4)
10.2.4.1 Consequence Analysis
To analyze the consequence of an HCN release scenario, consider the potential
effects on a neighboring manufacturing site located 500 m downwind from the
reactor.