Guidelines for Inherently Safer Chemical Processes - A Life Cycle Approach

Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally.
 

The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process.
 
It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.

List of contents

Preface vii
 
Acknowledgements ix
 
Figures xxiii
 
Tables xxvi
 
1. Introduction 1
 
1.1 Objectives, Intended Audience, and Scope of this Book 1
 
1.1.1 Objectives 1
 
1.1.2 Intended Audience 2
 
1.1.3 Scope 2
 
1.2 Integration of this Guidance with Other CCPS Guidance 2
 
1.3 Organization of this Book 3
 
1.4 History of Inherent Safety 4
 
1.5 References 9
 
2. The Concept of Inherent Safety 12
 
2.1 Inherent Safety and Process Risk Management 12
 
2.2 Inherent Safety Defined 15
 
2.3 Shared characteristics 16
 
2.4 Inherently Safer Strategies 18
 
2.5 Inherent safety throughout the process Life cycle 22
 
2.6 Inherently Safer Approaches 24
 
2.6.1 Orders of Inherent Safety 27
 
2.7 Layers of Protection 30
 
2.8 Integrating Inherent Safety in Process Risk Management Systems 32
 
2.9 Summary 40
 
2.10 References 40
 
3. Minimize - An Inherently Safer Strategy 44
 
3.1 Minimize 44
 
3.2 Reactors 47
 
3.3 Continuous Stirred Tank Reactors 48
 
3.4 Tubular Reactors 49
 
3.5 Loop Reactors 49
 
3.6 Reactive Distillation 51
 
3.7 Storage of Hazardous Materials 54
 
3.8 Process Piping 57
 
3.9 Process Equipment 58
 
3.10 Limitation of Effects 60
 
3.11 References 61
 
4. Substitute - An Inherently Safer Strategy 64
 
4.1 Reaction Chemistry 64
 
4.2 Green Chemistry 72
 
4.3 Solvents 73
 
4.4 Refrigerants 75
 
4.5 Firefighting Agents 76
 
4.6 Heat Transfer Media 76
 
4.7 Informed Substitution 77
 
4.8 References 83
 
5. Moderate - An Inherently Safer Strategy 87
 
5.1 Dilution 87
 
5.2 Refrigeration 88
 
5.3 Less Energetic Process Conditions 91
 
5.4 Secondary Containment - Dikes and Containment Buildings 94
 
5.5 Segregation 98
 
5.6 References 100
 
6. Simplify - An Inherently Safer Strategy 103
 
6.1 Leaving Things Out 104
 
6.2 Eliminating Unnecessary Spares 105
 
6.3 Inherently Robust Process Equipment 107
 
6.4 Preventing Runaway Reactions 110
 
6.5 Simplifying Heat Transfer 113
 
6.6 Simplifying Liquid Transfer 114
 
6.7 Reactor Geometry 116
 
6.8 Optimizing Catalyst Selectivity 116
 
6.9 Separation of Process Steps 116
 
6.10 Limitation of Available Energy 119
 
6.11 Simplification of the Human-Machine Interface 120
 
6.11.1 Overview 120
 
6.11.2 Equipment Layout, Accessibility, and Operability 121
 
6.11.3 Maintainability 121
 
6.11.4 Error Prevention 123
 
6.11.5 Design of Equipment and Controls - Making Status Clear 123
 
6.12 Summary 124
 
6.13 References 124
 
7. Applying Inherent Safety Strategies to Protection Layers 126
 
7.1 Operating Procedures 128
 
7.2 Maintenance Procedures 129
 
7.3 Relocation 129
 
7.4 Containment 130
 
7.5 More Robust Process Equipment and Design 131
 
7.6 Simplified Process Equipment and Design 132
 
7.7 Distributed Control Systems 133
 
7.8 Summary 134
 
7.9 References 134
 
8. Life Cycle Stages 136
 
8.1 General Principles Across All Life cycle Stages 136
 
8.2 Concept 137
 
8.3 Research 139
 
8.3.1 Inherently Safer Synthesis 141
 
8.3.2 Types of Hazards Associated with Research 142
 
8.3.3 Hazards Identification Methods 148
 
8.4 D

About the author

The Center for Chemical Process Safety (CCPS) was founded in 1985 to develop technology and management practices that mitigate or eliminate process safety incidents in the chemical and petrochemical industries. Since that time, CCPS has published more than 100 books and held dozens of international conferences, each representing the most advanced thinking in process safety. CCPS is supported by the contributions and voluntary participation of more than 200 companies globally. CCPS is also the world's largest provider of undergraduate engineering curriculum materials through its SAChE program, with more than 160 universities participating from around the world.

Summary

Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally.

The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process.

It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.

Product details

• Authors: CCPS, (Center for Chemical Process Safety) Ccps, Ccps (Center for Chemical Process Saf, Ccps (Center For Chemical Process Safety), Center for Chemical Process Safety (Ccps, Center for Chemical Process Safety (CCPS)
• Publisher: Wiley, John and Sons Ltd
• Languages: English
• Product format: Hardback
• Released: 30.11.2019
• EAN: 9781119529163
• ISBN: 978-1-119-52916-3
• No. of pages: 528
• Subjects: Natural sciences, medicine, IT, technology > Technology > Chemical engineering; Chemie, Arbeitssicherheit, chemistry, Chemical Engineering, Industrial Chemistry, chemische Verfahrenstechnik, Technische u. Industrielle Chemie, Chemical and Environmental Health and Safety, Arbeitssicherheit u. Umweltschutz i. d. Chemie, Prozesssicherheit, Process Safety