Principle 12:
Inherently Safer Chemistry for
Accident Prevention
Group 4
Table Of Contents
01
Introduction
03
Process Intensification
(Minimization)
name
05
name
name
02
Substitution
04
Attenuation
name
Limitation of effect
name
06
Simplification
name
01
Introduction
Inherently Safer Chemistry for Accident Prevention:
Compounds and processes for forming compounds
used in chemical processes must be selected to minimize the
possibility of chemical accidents, including releases, explosions,
and fires.
Why Inherently Safer Design Important?
Flixborough, England (1974)
a large release of cyclohexane
from a caprolactam plant
Pasadena, Texas (1989)
a leak of gas from a
polyethylene plant
Bhopal, India (1984)
the worst disaster in the history
of the chemical industry
•
Inherent - “existing in something as a permanent and
inseparable element...”
safety “built in”, not “added on”
•
Eliminate or minimize hazards rather than control hazards.
•
“Safer,” not “Safe”
Hazard:


An inherent physical or chemical characteristic
that has the potential for causing harm to people,
the environment, or property.
Hazards are intrinsic to a material, or its
conditions of use.
Examples:
•
Phosgene - toxic by
inhalation.
•
Acetone – flammable.
High pressure steam –
potential energy due to
pressure, high temperature.
•
Traditional safety approach
“Add on” safety features
○
Prevent - alarms, safety
interlocks, procedures,
training.
○
Mitigate – sprinkler
systems, water curtains,
emergency response
systems and procedures.
Inherently safer design
Eliminate or significantly reduce
process hazards.
Limit effects
by design, location or transportation of
equipment so that the worst possible
condition produces less danger.
Error tolerance
Minimization
Reducing the amount of hazardous
material present at any one time.
Principles
Substitution
Equipment and processes can be designed
to be capable of withstanding possible faults
or deviations from design.
Simplification
Replacing one material with
another of less hazard.
Eliminating problems by design rather
than adding additional equipment or
features to deal with them.
Moderation
Reducing the strength
of an effect.
02
Process Intensification
(Minimization)
Process Intensification (or minimization)
Key goal: Reduction of unit operations and chemical plants.
11
Benefits of PI
Major Cost Saving
Safer Processes
Smaller Equipment/ Plant
High Product Purity
Short time to the Market
High Selectivity
Operational Excellence
Quality by Design
Less waste/ by products
Process Intensification in Reactors
•
•
Reactors refer more scope for
reduction.
All types of reactors are large not a
large output output is desired, but
because conversion is low, reaction is
slow, or both.
What controls chemical reaction?


Heat removal.
Mass transfer (mixing or between
phases/across surfaces).


Chemical equilibrium.
The process itself.
Example:
Nitroglycerin Production
•
Reaction is highly exothermic
•
Usually 2 liquid phases – an
aqueous/acid phase and an
organic/solvent phase.
The rate of the reaction is controlled by:
•
Mixing – bringing reactants into contact with each other
•
Mass transfer – from acid/aqueous phase (nitric acid) to
organic phase (organic substrate)
•
Heat removal
Catalyst (usually
sulfuric acid) feed
or pre-charge
Nitric acid gradual
addition
Organic Substrate and
solvents pre-charge
Batch Reactor
~6000 gallons
CSTR Nitration Process
Raw
Material
Feeds
 Decrease the probability that any
risk can happen.
Organic substrate
Catalyst
Nitric Acid
 The conversion will be higher.
Reactor ~ 100 gallons
Product
03
Substitution
Substitution
•
Substitute a less hazardous reaction chemistry
•
Replace a hazardous material with a less hazardous alternative.
Substitute materials
Water based coatings and paints in place of solvent based alternatives:
•
Reduce fire hazard
•
Less toxic
•
Less odor
•
More environmentally friendly
•
Reduce hazards for end user and also for the manufacturer
Substitution- Refrigeration
pre 1930
1930s
Toxic, flammable
refrigerants
Inherently safer
alternative (CFCs)
1980s
Discovery of
environmental
problems
Reaction Chemistry-
Acrylic Esters
•
•
•
Acetylene - flammable, reactive
Carbon monoxide - toxic, flammable
Nickel carbonyl - toxic, environmental hazard
(heavy metals), carcinogenic
•
•
Anhydrous HCl - toxic, corrosive
Product - a monomer with reactivity
(polymerization) hazards
Reppe Process:
𝐍𝐢 𝐂𝐎 𝟒
𝐇𝐂𝐥
𝐂𝐇 ≡ 𝐂𝐇 + 𝐂𝐎 + 𝐑𝐎𝐇
𝐂𝐇𝟐 − 𝐂𝐇𝐂𝐎𝟐 𝐑
Alternate Chemistry
Propylene Oxidation Process
Inherently safe?
No, but Inherently safer
THANK YOU
FOR LISTENING
456
Venus is the second
from the Sun
20
Mars is actually a
very cold place
300
Jupiter is the
biggest planet
Two Simple Actions
Mercury
Mercury is the closest to the
Sun and the smallest one in
the Solar System—it’s only a
bit larger than the Moon
Venus
Venus has a beautiful name
and is the second planet
from the Sun. It’s hot and has
a poisonous atmosphere
Three Ways To Use Less Plastic
Mercury
It’s the closest to the
Sun and the smallest
in the System
Venus
Venus has a beautiful
name and is the
second from the Sun
Mars
Despite being red,
Mars is cold. It’s full of
iron oxide dust
How To Consciously Consume
Venus
Jupiter
Venus is the second
planet from the Sun
It’s the biggest planet
in the Solar System
Mars
Saturn
Despite being red,
Mars is a cold place
Saturn is a gas giant
and has several rings
150,000
Big numbers catch your audience’s attention
Awesome
Words
A Picture Is
Worth A
Thousand
Words
A Picture Always
Reinforces The Concept
Images reveal large amounts of
data, so remember: use an
image instead of a long text. Your
audience will appreciate it
Eco-Friendly Countries
Mars
Mars is actually a
very cold place
Neptune
It’s the farthest planet
from the Sun
Saturn
It’s composed of
hydrogen and helium
Eco-Friendly Brands
10%
35%
25%
30%
Venus is the second
planet from the Sun
Saturn is composed
of hydrogen
Mars is actually a
very cold place
Jupiter is the
biggest planet
To modify this graph, click on it, follow the link, change the data
and paste the new graph here, replacing this one.
You can see how to modify the graph here
RRR
Recyclable
Reusable
Reduce
Glass
Mercury is the closest
planet to the Sun
Jupiter is the biggest
planet of them all
Venus is the second
planet from the Sun
Plastic
Saturn is made of
hydrogen and helium
Mars is actually a very
cold place
Venus has a nice
name, and it’s hot
Metal
Venus is an extremely
hot planet
Mars is actually full of
iron oxide dust
The Earth is the only
planet with life
Paper
Mercury is the
smallest planet
It was named after the
Roman god
Saturn is the only
planet with rings
Principles
• Reducing the amount of hazardous
material present at any one time
• Eg: by using smaller batches.
Replacing one material with • Eg. cleaning with water and detergent
rather than a flammable solvent
another of less hazard
Minimization:
Moderation:
Simplification:
Limitation
Simplification
• Reducing the strength of an effect
• Eg. having a cold liquid instead of a gas at
high pressure
•Eliminating problems by design rather than adding additional
equipment or features to deal with them
•Changing designs or reaction conditions rather than by
adding protective equipment that may fail or be neglected
•Using simple plants rather than complex one.
35
Plastic Time Life
01
02
03
04
1 Year
5 Years
20 Years
500 Years
Venus is a
planet with high
temperatures
Despite being
red, Mars is a
cold place
Mercury is the
closest planet to
the Sun
Jupiter is the
biggest planet
of them all
Desktop Software
You can replace the image
on the screen with your own
work. Just right-click on it
and select “Replace image”
Thanks
Does anyone have any questions?
addyouremail@freepik.com
+91 620 421 838
yourcompany.com
CREDITS: This presentation template was
created by Slidesgo, including icons by Flaticon
and infographics & images by Freepik.
Please keep this slide for attribution