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# 2007 IChemE
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Loss of reactor
cooling or agitation during
an exothermic reaction
Reactor over
-pressurization
Overcharging with
compressed gas or liquid
Excessive vapour generation
Dust explosion
Occupational
health
Protection
approaches
Due to
Emergency venting
Containment
Crash cooling
Reaction inhibition
Adopting suitable
operating procedures.
Using relief pressure valve
Containment, PPE,
automation
IC plant issues/
risk assessment
Lower because of
lower inventory
Not clear
# 2007 IChemE
METHOD
The IMPULSE project is developing a number of industrial
case studies in applications in a range of industry sectors
and by the end of the project all of these will be assessed for
their SHE and Sustainability performance. The work
reported here concentrates on the application to pharmaceutical production, and in particular hydrogenation. In
order to understand the scope and nature of real industrial
issues and concerns and to investigate the current hazard
issues and what would change with an equivalent IC plant
the following approach has been adopted.
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.
.
CASE STUDY A
In order to have a better understanding of the hazards a survey
was carried out at one of the companies participating in
IMPULSE which operates a range of batch chemicals processes, including hydrogenation. The questions were
divided into 7 sections such as training, cost, monitoring,
hazards, storage and handling of H2. The questions were put
to the technologists responsible for the technical support of
an operating multi-purpose hydrogenation unit in the UK.
The companys response to the questionnaire
indicated that in order to achieve a safe plant various
different hazard identification approaches are used, such as
COSHH, studies based on the 6-stage ICI hazard assessment
system, COSHH assessment, manual handling assessment.
More detailed studies are done by third parties such as contractors/consultants.
It was concluded that in the hydrogenation plant many
safety precautions are taken and safety assessment delivers a
high level of performance. Their major worry is about the
nature of hydrogen. As it is highly flammable they believed
that reducing the inventory would certainly reduce the
hazards and capital cost. However, they also believe that
the novel technology has its own problems. For example,
the need for reactors with wide processing capability is
one of the main concerns. In addition the presence of impurities might be a big driver in novel technology so getting rid
of impurity is another substantial concern. Whether moving
from conventional plant to novel plant is cost effective or
not is another concern; as usual money is important. It is
important for the people who invest for it to know the cost
effectiveness of moving from conventional plant to the
IMPULSE plant. SHE issues might be a big driver for
H2. The risk most probably will change in IMPULSE
plant for example the pressure in the conventional plant
# 2007 IChemE
CASE STUDY B
A hydrogenation process operated by another IMPULSE
partner was considered. This hydrogenation step is one
stage in a longer synthetic chain. Initially, a comparison
was made of all safety issues for the exisiting process and
an outline design for an IC hydrogenation process. Here,
an attempt was made to develop a side-by-side comparison
of all of the safety issues in the two types of plant. An
excerpt of the results is given in Table 2.
It can be seen from Table 2 even at this stage that our
knowledge of the detailed design of the IC plant is not
Table 2. Excerpt of comparison of equipment hazards in Case Study B hydrogenation process and assumed IC process
Issues/features
Current
process
Manhole
Yes
No
Leakage of H2
from flanges
Yes
Leakage of N2
(used for inerting)
Yes
Exothermic
reaction
Existence of
solvent storage
Pressure
Yes
Yes
45 psi
Number of flanges
Existence of
agitator
Existence of
ventilation system
Quality of construction
Hazard concerns
related to these issues
in Case Study B
IC
Operator exposure
in inspection
Fire and explosion due to
high amount of leakage
Hazard concerns
related to these
issues in IC plant
None
Operator suffocation
Lower inventory,
reduction of leak rate,
but possibly more leaks
Eliminated?
Explosion
Flammable
High p
25
Yes
Probably not
Yes
Hydrogenation would be
in a well-vented place
It may change e.g. due
to corrosion a better
alloy and protection
layer is needed.
Failure of
ventilation system
# 2007 IChemE