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Journal of loss prevention in the process industries
Butterworth-Heinemann Turpin Transactions Ltd.
Journal of loss prevention in the process industries

Butterworth-Heinemann Turpin Transactions Ltd.

0950-4230

Journal of loss prevention in the process industries/Journal Journal of loss prevention in the process industriesSCIISTPEI
正式出版
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    A new real-gas model to characterize and predict gas leakage for high-pressure gas pipeline

    Yuan F.Zeng Y.Khoo B.C.
    14页
    查看更多>>摘要：High-pressure gas pipe leakage is a topic of great concern in the risk assessment and safety management of pipeline systems. Traditional ideal-gas models with the assumption of fully ruptured leak loss are valid for a large leak hole in low-pressure gas pipelines (3–14 bar). This paper developed a new model for small leaks in high-pressure gas pipelines, which improves the traditional models in two aspects: the introduction of a mass fraction to characterize the proportion of leaked gas flow to in-pipe gas flow, and the integration of the real-gas thermodynamics into the fundamental governing equations to include the gas compressibility factor in the high-pressure conditions (>14 bar). To examine the validity and practicality of the new real-gas model, comprehensive comparison tests were carried out with the results of the benchmark numerical simulations and the hazard modelling software ALOHA, respectively. In the light of prediction accuracy, the new real-gas model shows its advantage over the traditional ideal-gas model, the improved ideal-gas model, and the semi-empirical correlation proposed by previous research. The virtues of high accuracy and short computational time confirmed the effectiveness of the new real-gas model in the responsive evaluation of high-pressure gas pipe leakage with small leak holes.
      原文链接:
    • NSTL
    • Elsevier

    Effects of the feeding procedure on the thermal behaviors of autocatalytic esterifications in semibatch processes

    Chen Q.Ni Y.Liang J.Ni L....
    11页
    查看更多>>摘要：Esterification reactions between anhydrides and alcohols catalyzed by sulfuric acid have broad applications in the food, cosmetic, and pharmaceutical industries. However, the exothermic behavior cannot be well explained, especially in semibatch reactors with different feeding procedures. In this study, a series of esterification processes in semibatch systems were conducted with a wide range of feeding rates with two different substrates. The structures of initial catalytic substrates were characterized using in situ Fourier Transform Infrared (FTIR) spectroscopy. A total of 11 reaction pathways, including those for the initial activation of substrates and the subsequent reactions of the feeding process, were calculated by the density functional theory (DFT) method. Three possible catalytic cycles of the esterification with specific acid catalysis, protonated intermediate, and protonated intermediate and H2O, were established for the semibatch esterification reaction based on calculated results and experimental evidence. Thermal safety parameters such as reaction enthalpy (ΔHr), adiabatic temperature rise (ΔTr,ad), and maximum temperature of the synthetic reaction (MTSR) were determined based on Wilson equation used to calibrate mixing heat. The results reveal that mixing heat was 2.5 kJ/mol with same mole ratio of n-butanol (nB) and propionic anhydride (PA). The reactions started by PA are dominant, no matter whether the substrate is nB or PA. The initial reaction rate is restricted by the low concentration of catalyst and active reactant when nB is used as substrate, which lead to significant reactant accumulation with high MTSR of approximately 160 °C. Furthermore, feeding nB into PA allows a controllable increase in the ΔTr,ad realized by changing the feeding rate and limiting the accumulation of reactant.
      原文链接:
    • NSTL
    • Elsevier

    Risk probability evaluation for the effect of obstacle on CO2 leakage and dispersion indoors based on uncertainty theory

    Wang Z.Li Y.Tong X.Gong J....
    10页
    查看更多>>摘要：Carbon dioxide is a common gas in the chemical industry, and it is asphyxiating. A test system was established to determine the characteristics of indoor gas diffusion. The system comprised an enclosed space, gas discharge system, data acquisition system, and obstacle. CO2 gas concentration due to an indoor leak was measured, and characteristics of CO2 diffusion indoors in the presence of an obstacle were elucidated. The effects of obstacle height, obstacle width, and obstacle–leakage distance on gas diffusion were determined. An obstacle was discovered to hinder CO2 diffusion in the enclosed space. With increasing obstacle height, the gas was more likely to accumulate in front of the obstacle before spreading on the ground around the side of the obstacle. CO2 accumulation behind the obstacle was mainly due to ground accumulation rather than direct accumulation from the leakage source. However, the difference in CO2 concentration in the interior space was negligible for different obstacle heights. Obstacle width only weakly affected the concentration of CO2. Obstruction reduces the volume of space available to a gas. To minimize misjudgment, risk probability evaluation of the dense-gas leakage was proposed based on uncertainty theory. The combined standard uncertainty was calculated in specific cases, and the probability of misjudgment in risk evaluation was determined. The results provided scientific basis for early detection and rescue strategies during indoor CO2 leaks in the presence of an obstacle.
      原文链接:
    • NSTL
    • Elsevier

    The CFD modeling of bund overtopping phenomena and prediction of dynamic pressure on the bund

    Huo J.Wang Z.Luan X.Jing M....
    12页
    查看更多>>摘要：The storage tank of hazardous materials is usually equipped with bund system for hazard mitigation in case of a release incident. The catastrophic release incident requires an effective bund system to control overtopping and withstand the liquid dynamic pressure. This work developed three-dimensional (3D) Computational Fluid Dynamic (CFD) models based on RNG k-ε and Large Eddy Simulation (LES) model, respectively. These two CFD models were compared in terms of overtopping fraction and flow behavior, and both were validated against the experimental results. The validated 3D RNG k-ε model was used to investigate the flow behavior and dynamic pressure of the circular and square bund. Based on the results, the 3D RNG k-ε model is slightly better than the 3D LES model in terms of predicting the overtopping fraction and the height of central spike in this study; the 3D RNG k-ε model predicts the height of central spike better than the 2D model, and has the advantage to simulate complex bund design; the findings on flow behavior and dynamic pressure of the circular and square bund will help provide a scientific basis to design the bund system for minimizing the overtopping fraction and withstanding the liquid dynamic pressure.
      原文链接:
    • NSTL
    • Elsevier

    Optimal selection of safety recommendations: A hybrid fuzzy multi-criteria decision-making approach to HAZOP

    Cheraghi M.Eslami Baladeh A.Khakzad N.
    17页
    查看更多>>摘要：One of the most important outputs of Hazard and Operability (HAZOP) study is a list of recommendations (safety measures) for improving the safety of the system under study. Although, it is generally assumed that all the recommendations should be implemented, due to the limited resources (budget, time, etc.) simultaneous implementation of all the recommendations is not feasible in reality. The large number of recommendations, a wide range of factors which should be evaluated by experts, and the uncertainty in the expert opinions make the conventional methods ineffective. Despite the widespread use of HAZOP, the decision as to which recommendations to implement is still a challenge for process safety managers. The present study aims to develop (i) a comprehensive hierarchy of factors for the evaluation of the recommendations, (ii) a novel methodology by integrating the Best Worst Method (BWM) and the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) for ranking the recommendations and (iii) fuzzy logic and group decision-making are used to consider the imprecision of expert opinions so as to improve the accuracy of the results. The proposed model is capable of considering most factors of recommendations for any number of HAZOP recommendations. The methodology can be applied to a broad range of hazardous facilities and industries. In the present study, however, its application has been demonstrated for a sulfuric acid storage system.
      原文链接:
    • NSTL
    • Elsevier

    Insight into the dust explosion hazard of pharmaceutical powders in the presence of flow aids

    Bu Y.Yuan C.Hou X.Addo A....
    8页
    查看更多>>摘要：Coating of nanoscale flow aids is widely used in pharmaceutical applications to increase the flowability of cohesive powders. For combustible pharmaceutical active ingredients and excipients, it is unclear whether increased flowability affects the dust explosion hazard. In this work, acetaminophen (APAP) and microcrystalline cellulose (MCC) were studied with and without a coating of silica nanoparticles. A full set of explosion parameters for the pure materials and their flow-improved mixtures was determined in accordance with ASTM standards. The results show that parameters including minimum ignition temperature, minimum explosible concentration, and maximum explosion pressure were independent of powder flow properties, while the presence of flow aids led to significantly lower minimum ignition energy values for both APAP and MCC, and a slightly higher maximum rate of pressure rise for APAP. The connection between dust flowability and the dust explosion hazard is discussed with respect to these experimental results.
      原文链接:
    • NSTL
    • Elsevier

    A step toward lifting the fog off mist explosions: Comparative study of three fuels

    El - Zahlanieh S.Sivabalan S.Dos Santos I.S.Brunello D....
    13页
    查看更多>>摘要：Gases, vapors, and dusts are all potential explosion threats; however, mists should also be taken into account. Indeed, dozens of accidents involving hydrocarbon mists were identified in incident surveys. Mist explosions continue to occur, highlighting the need to evaluate and assess the validity of present approaches for assessing mist ATEX risks and to establish reliable standardized safety parameters for fuel mists. In a modified apparatus based on the 20 L explosion sphere, three fluids of industrial interest were investigated. A new siphon injection system comprising a Venturi junction was installed, offering a wide range of dispersion performances. This system was controlled by a specifically developed program, ensuring the apparatus's versatility and adaptability to various tested liquids. It enables precise control of the gas carrier flow, liquid flow, and injection and ignition durations, allowing modification of the dilution rate of a particular droplet size distribution (DSD). The mist cloud dispersed in the 20 L sphere was characterized by determining its DSD using an in-situ laser diffraction sensor and by performing Particle Image Velocimetry (PIV). Mists of kerosene, diesel and ethanol were then subjected to tests to assess their lower explosive limit (LELmist), minimum ignition energy (MIE), maximum explosion pressure (Pmax), and rate of pressure rise (dP/dtmax). For instance, it was found that the LELmist of ethanol, kerosene Jet A1, and diesel fuel for a DSD averaged at 8–10 μm reach 77, 94, and 93 g/m3 respectively. This LELmist was also shown to increase with increasing DSD in the case of Jet A1 mists. A sensitivity study was also performed to emphasize the impact of parameters such as the fuel type, the DSD, and the mist temperature. Findings showed that the explosion severity is strongly influenced by the chemical nature and the volatility of the dispersed fuel. Moreover, controlling the sphere temperature was proven to be a crucial step when using such apparatus for the evaluation of the explosibility of mists. An evaporation model based on the d2 law was also developed to visualize the vapor-liquid ratio before ignition. These findings have already led to the development of a new procedure for determining safety standards for hydrocarbon mists, as well as tools to assess mist explosion risks. They have proven that it is possible to evaluate the ignition sensitivity and explosion severity of fuel mists using a single well-known apparatus.
      原文链接:
    • NSTL
    • Elsevier

    Chinese international process safety research: Collaborations, research trends, and intellectual basis

    Li J.Feng C.Goerlandt F.Reniers G....
    16页
    查看更多>>摘要：This article presents a bibliometric analysis and mapping of the Chinese process safety research, focusing on the contributions made in core process safety journals and on the influences of international collaborations and knowledge sources on the developments of this research domain. Collaboration networks, term co-occurrence networks, and co-citation network were analyzed to identify trends, patterns, and the knowledge distribution of the Chinese research on process safety. Work to data has been clustered mainly on safety of chemical processes, fire and explosion, and risk management and accidents. Chinese research contributions are concentrated in only few journals, while the corresponding intellectual base draws on the wider literature focused on understanding and modeling phenomena, and on the broader risk research literature, although to a lesser extent. While various foreign authors are highly cited by Chinese authors, only very few direct collaborations with international scholars are identified. The results are used as a basis for a discussion on future research directions and developments for the community. Increased focus on uncertainty treatment and handling of black swan events, risk evaluation and economic aspects of safety decisions, interorganizational risk management, road and maritime transport of hazardous substances, risk perception and communication, and integrated safety and security assessment, are highlighted as fruitful directions for future scholarship. It is hoped that the insights obtained from this work can facilitate new and consolidated collaborations, as well as further invigorate the Chinese process safety domain, ultimately contributing to improved safety performance of process industries in China and elsewhere.
      原文链接:
    • NSTL
    • Elsevier

    Propylene column pressure relief valves chattering resulting in explosion and fire of the Steam Cracker unit

    Herink T.Doskocil J.Ruzicka M.Henry P.A....
    16页
    查看更多>>摘要：The Refinery and petrochemical production facilities process and produce the gaseous and liquid flammable hydrocarbons under the pressure conditions. In case of any failure, improper design or human mistake there can be autonomous and independent pressure relieve systems activated to release the pressure to the flare systems to protect the equipment against the overpressure, damages and other consequences. The paper describes the failure occurred at the Steam Cracker unit in Litvinov, Czech Republic in 2015. As a result of a loss of cooling followed by loss of reflux event, the pressure relief system of the Propylene Column was activated whereas the pressure relief valves opened up and chattered, resulting in loosening of flange bolts and loss of containment. The release of the propylene vapor ignited, resulting in subsequent explosion and fire at the Propylene Column area. The interruption of steam and instrument air supply caused by the fire damages led to the other extensive fire of four pyrolysis heaters. The extraordinary event description, root cause analysis, investigation as well as the corrective actions are introduced and analyzed.
      原文链接:
    • NSTL
    • Elsevier

    Incorporating the occupational health in the optimization for the methanol process

    Hernandez-Perez L.G.Villicana-Garcia E.Cansino-Loeza B.Ponce-Ortega J.M....
    16页
    查看更多>>摘要：The analysis of social aspects, such as occupational health, is as important as economic and environmental criteria in the design of sustainable chemical processes. Occupational health analyzes the relationship between work and health while enabling the identification of hazards that can cause injuries due to chronic exposure of the workers. This paper presents a multi-objective optimization approach for the methanol production process from natural/shale gas, different alternatives are proposed for the process configurations based on different equipment and technologies. The objective functions consist of maximizing the net profit, minimizing the total annual CO2 emissions, and minimizing the occupational health hazard. The Process Route Healthiness Index is used to evaluate occupational health. The process model is developed using the Aspen HYSYS? process simulator. To carry out the optimization, a metaheuristic algorithm is used; the improved multi-objective differential evolution (I-MODE) algorithm was used with programming in Microsoft Excel visual basic for applications. Linking routines are established to enable the transfer of values of the process variables. A set of decision variables are established in a search interval whose manipulation has a considerable impact on the performance of the objective functions. The results offer feasible alternatives for the values of the search variables and show a considerable improvement in the specified objective functions. Different scenarios are proposed to prioritize each of the objectives for which the decision-maker can make a selection of the best values and the configuration that best suits specific interests.
      原文链接:
    • NSTL
    • Elsevier