化工过程本质安全评估方法研究进展与展望

doi:10.16085/j.issn.1000-6613.2021-2004

摘要/Abstract

摘要：

可持续性发展已经成为社会、生态和经济发展的关键。可持续制造的发展道路需要平衡环境、社会和经济各方面。本质安全设计是减少风险、实现化学工业可持续发展的最有效的方法之一，本质安全设计可以永久性地消除或减少化工过程中涉及的危害。本文综述了本质安全的历史发展、本质安全四大原则的概念、本质安全四大原则应用的使用潜力、本质安全设计评估工具，并系统介绍了本质安全设计评估方法的研究进展和存在的问题，包括基于参数的得分索引本质安全方法、基于参数的数值索引本质安全方法、基于图示的本质安全方法、基于风险分析的本质安全方法和基于多目标评价的本质安全方法，分析比较了各种方法的优缺点，并对本质安全评估方法的未来发展和完善提出了一些见解。

关键词: 可持续发展, 化工过程, 本质安全, 全生命周期, 本质安全评估方法

Abstract:

Sustainability is the key to social, ecological and economic development. The development path of sustainable manufacturing requires a balance between environmental, social and economic aspects. Inherent safe design is one of the most effective ways to reduce risk to achieve sustainable development of chemical industry. Inherent safe design can permanently eliminate or reduce the hazards involved in chemical processes. In this paper, an overview is presented covering the origins of inherent safety concept, its historical development, the concept of the four principles of inherent safety, the stages of application and potential use of the four principles of inherent safety throughout the life cycle of the process industry, and methods for inherent safe design assessment. The research progress and problems of inherent safe design assessment methods are introduced, which includes parameter-based score inherent safety assessment methods, parameter-based numerical inherent safety assessment methods, graph-based inherent safety assessment methods, risk analysis-based safety assessment methods and multi-objective-based inherent safety assessment method. The advantages and disadvantages of various methods are analyzed and compared and the future development and improvement of those methods were also commented.

Key words: sustainable development, chemical processes, inherent safety, life cycle, inherent safety assessment methods

中图分类号:

TQ086

朱佳兴, 郝琳, 刘国钊, 卫宏远. 化工过程本质安全评估方法研究进展与展望[J]. 化工进展, 2022, 41(8): 4009-4024.

ZHU Jiaxing, HAO Lin, LIU Guozhao, WEI Hongyuan. Research progress and prospect on inherent safety assessment methods for chemical processes[J]. Chemical Industry and Engineering Progress, 2022, 41(8): 4009-4024.

图/表 4

参考文献 86

1	HINRICHSEN D. Report of the World Commission on Environment and Development: our common future[R]. URV-Dow Chair for Sustainable Development,1987.
2	National Research Council. Sustainability and the U.S. EPA[M]. Washington D C: The National Academies Press, 2011.
3	CANO-RUIZ J A, MCRAE G J. Environmentally conscious chemical process design[J]. Annual Review of Energy and the Environment, 1998, 23(1): 499-536.
4	NIKOLOPOULOU A, IERAPETRITOU M G. Optimal design of sustainable chemical processes and supply chains: a review[J]. Computers & Chemical Engineering, 2012, 44: 94-103.
5	GLAVIČ P, PINTARIČ Z N, BOGATAJ M. Process design and sustainable development: a European perspective[J]. Processes, 2021, 9(1): 148.
6	KLETZ T A. What you don’t have, can’t leak[J]. Chemistry & Industry, 1978, 42: 287-292.
7	KLETZ T A, AMYOTTE P. Process plants: a handbook for inherently safer design[M]. Boca Raton: CRC Press, 2010.
8	KLETZ T A. Plant design for safety: a user-friendly approach[M]. New York: Hemisphere Publishing Corporation, 1991.
9	ECKERMAN I. Bhopal gas catastrophe 1984: causes and consequences[M]//NRIAGU J. Encyclopedia of environmental health. 2nd ed. Amsterdam: Elsevier, 2019: 272-287.
10	KLETZ TREVOR A. Cheaper, safer plants or wealth and safety at work: notes on inherently safer and simpler plants[M]. Warwickshire: Institution of Chemical Engineers, 1985.
11	KLETZ T A. Inherently safer plants[J]. Plant/Operations Progress, 1985, 4(3): 164-167.
12	Center for Chemical Process Safety. Inherently safer chemical processes: a life cycle approach[M]. 2nd ed. New York: John Wiley & Sons Inc., 2010.
13	Center for Chemical Process Safety. Final report: definition for inherently safer technology in production, transportation, storage, and use[R]. New York: Chemical Security Analysis Center, 2010.
14	ANURADHA H B B, GUNASEKERA M Y, GUNAPALA O. Comparison of chemical routes based on inherent safety, health and environmental impacts of accidental and daily operational releases[J]. Process Safety and Environmental Protection, 2020, 133: 358-368.
15	Center for Chemical Process Safety. Guidelines for inherently safer chemical processes[M]. 3th ed. New York: John Wiley & Sons Inc., 2019.
16	HURME M, RAHMAN M. Implementing inherent safety throughout process lifecycle[J]. Journal of Loss Prevention in the Process Industries, 2005, 18(4/5/6): 238-244.
17	KIDAM K, SAHAK H A, HASSIM M H, et al. Inherently safer design review and their timing during chemical process development and design[J]. Journal of Loss Prevention in the Process Industries, 2016, 42: 47-58.
18	PARK S, XU S, ROGERS W, et al. Incorporating inherent safety during the conceptual process design stage: a literature review[J]. Journal of Loss Prevention in the Process Industries, 2020, 63: 104040.
19	SRINIVASAN R, SRINIVASAN B, IQBAL M U, et al. Recent developments towards enhancing process safety: inherent safety and cognitive engineering[J]. Computers & Chemical Engineering, 2019, 128: 364-383.
20	ATHAR M, SHARIFF A M, BUANG A. A review of inherent assessment for sustainable process design[J]. Journal of Cleaner Production, 2019, 233: 242-263.
21	GAO X M, ABDUL RAMAN A A, HIZADDIN H F, et al. Review on the inherently safer design for chemical processes: past, present and future [J]. Journal of Cleaner Production, 2021, 305: 127154.
22	AHMAD S I, HO W S, HASSIM M H, et al. Development of quantitative SHE index for waste to energy technology selection[J]. Energy, 2020, 191: 116534.
23	AICHE. Dow’ fire & explosion index hazard classification guide[M]. Hoboken: John Wiley & Sons Inc, 1994.
24	KHAN F I, ABBASI S A. Multivariate hazard identification and ranking system[J]. Process Safety Progress, 1998, 17(3): 157-170.
25	ORTIZ-ESPINOZA A P, JIMÉNEZ-GUTIÉRREZ A, EL-HALWAGI M M, et al. Comparison of safety indexes for chemical processes under uncertainty[J]. Process Safety and Environmental Protection, 2021, 148: 225-236.
26	LAWRENCE D. Quantifying inherent safety of chemical process routes[D]. Loughborough: Loughborough University, 1996.
27	EDWARDS D W, LAWRENCE D. Assessing the inherent safety of chemical process routes: is there a relation between plant costs and inherent safety?[J]. Process Safety and Environmental Protection, 1993, 71: 252-258.
28	HEIKKIL A M. Inherent safety in process plant design: an index-based approach[D]. Espoo: Helsinki University of Technology, 1999.
29	PALANIAPPAN C, SRINIVASAN R, TAN R. Expert system for the design of inherently safer processes. 1. Route selection stage[J]. Industrial & Engineering Chemistry Research, 2002, 41(26): 6698-6710.
30	PALANIAPPAN C, SRINIVASAN R, TAN R B. Expert system for the design of inherently safer processes. 2. Flowsheet development stage[J]. Industrial & Engineering Chemistry Research, 2002, 41(26): 6711-6722.
31	LI X, ZANWAR A, JAYSWAL A, et al. Incorporating exergy analysis and inherent safety analysis for sustainability assessment of biofuels[J]. Industrial & Engineering Chemistry Research, 2011, 50(5): 2981-2993.
32	GANGADHARAN P, SINGH R, CHENG F Q, et al. Novel methodology for inherent safety assessment in the process design stage[J]. Industrial & Engineering Chemistry Research, 2013, 52(17): 5921-5933.
33	LEONG C T, SHARIFF A M. Inherent safety index module (ISIM) to assess inherent safety level during preliminary design stage[J]. Process Safety and Environmental Protection, 2008, 86(2): 113-119.
34	HASSIM M H, HURME M. Inherent occupational health assessment during process research and development stage[J]. Journal of Loss Prevention in the Process Industries, 2010, 23(1): 127-138.
35	HASSIM M H, HURME M. Inherent occupational health assessment during preliminary design stage[J]. Journal of Loss Prevention in the Process Industries, 2010, 23(3): 476-482.
36	HASSIM M H, HURME M. Inherent occupational health assessment during basic engineering stage[J]. Journal of Loss Prevention in the Process Industries, 2010, 23(2): 260-268.
37	SO W Y, HASSIM M H, AHMAD S I, et al. Inherent occupational health assessment index for research and development stage of process design[J]. Process Safety and Environmental Protection, 2021, 147: 103-114.
38	GUNASEKERA M Y, EDWARDS D W. Chemical process route selection based upon the potential toxic impact on the aquatic, terrestrial and atmospheric environments[J]. Journal of Loss Prevention in the Process Industries, 2006, 19(1): 60-69.
39	LIEW W H, HASSIM M H, NG D K S. Sustainability assessment for biodiesel production via fuzzy optimisation during research and development (R&D) stage[J]. Clean Technologies and Environmental Policy, 2014, 16(7): 1431-1444.
40	LIEW W H, HASSIM M H, NG D K S, et al. Systematic framework for sustainability assessment of biodiesel production: preliminary engineering stage[J]. Industrial & Engineering Chemistry Research, 2015, 54(50): 12615-12629.
41	LIEW W H, HASSIM M H, NG D K S. Systematic framework for sustainability assessment on chemical production pathway: basic engineering stage[J]. Process Safety and Environmental Protection, 2016, 104: 161-177.
42	EE A W L, KUZNETSOVA E, LEE T E J, et al. Extended inherent safety index: analysis of chemical, physical and biological inherent safety[J]. Journal of Cleaner Production, 2020, 248: 119258.
43	SULTANA S, HAUGEN S. Development of an inherent system safety index (ISSI) for ranking of chemical processes at the concept development stage[J]. Journal of Hazardous Materials, 2022, 421: 126590.
44	GUPTA J P, EDWARDS D W. A simple graphical method for measuring inherent safety[J]. Journal of Hazardous Materials, 2003, 104(1/2/3): 15-30.
45	SRINIVASAN R, NHAN N T. A statistical approach for evaluating inherent benign-ness of chemical process routes in early design stages[J]. Process Safety and Environmental Protection, 2008, 86(3): 163-174.
46	GAO Xiaoming, ABDUL RAMAN A A, HIZADDIN H F, et al. Systematic inherent safety and its implementation in chlorine liquefaction process[J]. Journal of Loss Prevention in the Process Industries, 2020, 65: 104133.
47	GENTILE M, ROGERS W J, MANNAN M S. Development of a fuzzy logic-based inherent safety index[J]. Process Safety and Environmental Protection, 2003, 81(6): 444-456.
48	TADIC D, SAVOVIC I, MISITA M, et al. Development of a fuzzy logic-based inherent safety index for food industries[J]. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2014, 228(1): 3-13.
49	SONG D, YOON E S, JANG N. A framework and method for the assessment of inherent safety to enhance sustainability in conceptual chemical process design[J]. Journal of Loss Prevention in the Process Industries, 2018, 54: 10-17.
50	VÁZQUEZ D, RUIZ-FEMENIA R, CABALLERO J A. OFISI, a novel optimizable inherent safety index based on fuzzy logic[J]. Computers & Chemical Engineering, 2019, 129: 106526.
51	LEONG C T, SHARIFF A M. Process route index (PRI) to assess level of explosiveness for inherent safety quantification[J]. Journal of Loss Prevention in the Process Industries, 2009, 22(2): 216-221.
52	SHARIFF A M, LEONG C T, ZAINI D. Using process stream index (PSI) to assess inherent safety level during preliminary design stage[J]. Safety Science, 2012, 50(4): 1098-1103.
53	ZAINI D, AZMI M S, LEONG C T. Three-tier inherent safety quantification (3-TISQ) for toxic release at preliminary design stage[J]. Applied Mechanics and Materials, 2014, 625: 426-430.
54	PASHA M, ZAINI D, MOHD SHARIFF A. Inherently safer design for heat exchanger network[J]. Journal of Loss Prevention in the Process Industries, 2017, 48: 55-70.
55	ATHAR M, SHARIFF A M, BUANG A, et al. Inherent safety for sustainable process design of process piping at the preliminary design stage[J]. Journal of Cleaner Production, 2019, 209: 1307-1318.
56	ATHAR M, SHARIFF A M, BUANG A, et al. Process equipment common attributes for inherently safer process design at preliminary design stage[J]. Process Safety and Environmental Protection, 2019, 128: 14-29.
57	ATHAR M, SHARIFF A M, BUANG A, et al. Equipment-based route index of inherent safety[J]. Process Safety Progress, 2019, 39: e12108.
58	CASAL J. Fire accidents[M]//Evaluation of the effects and consequences of major accidents in industrial plants. Amsterdam: Elsevier, 2018: 75-150.
59	AHMAD S I, HASHIM H, HASSIM M H. Numerical descriptive inherent safety technique (NuDIST) for inherent safety assessment in petrochemical industry[J]. Process Safety and Environmental Protection, 2014, 92(5): 379-389.
60	GUPTA J P, EDWARDS D W. A simple graphical method for measuring inherent safety[J]. Journal of Hazardous Materials, 2003, 104(1): 15-30.
61	HASSIM M H, HURME M, EDWARDS D W, et al. Simple graphical method for inherent occupational health assessment[J]. Process Safety and Environmental Protection, 2013, 91(6): 438-451.
62	SHAH S, FISCHER U, HUNGERBÜHLER K. A hierarchical approach for the evaluation of chemical process aspects from the perspective of inherent safety[J]. Process Safety and Environmental Protection, 2003, 81(6): 430-443.
63	AHMAD S I, HASHIM H, HASSIM M H. A graphical method for assessing inherent safety during research and development phase of process design[J]. Journal of Loss Prevention in the Process Industries, 2016, 42: 59-69.
64	AHMAD S I, HASHIM H, HASSIM M H, et al. A graphical inherent safety assessment technique for preliminary design stage[J]. Process Safety and Environmental Protection, 2019, 130: 275-287.
65	KHAN F I, ABBASI S A. Inherently safer design based on rapid risk analysis[J]. Journal of Loss Prevention in the Process Industries, 1998, 11(6): 361-372.
66	SHARIFF A M, RUSLI R, LEONG C T, et al. Inherent safety tool for explosion consequences study[J]. Journal of Loss Prevention in the Process Industries, 2006, 19(5): 409-418.
67	SHARIFF A M, ZAINI D. Toxic release consequence analysis tool(TORCAT) for inherently safer design plant[J]. Journal of Hazardous Materials, 2010, 182(1/2/3): 394-402.
68	SHARIFF A M, ZAINI D. Inherent risk assessment methodology in preliminary design stage: a case study for toxic release[J]. Journal of Loss Prevention in the Process Industries, 2013, 26(4): 605-613.
69	SHARIFF A M, LEONG C T. Inherent risk assessment: a new concept to evaluate risk in preliminary design stage[J]. Process Safety and Environmental Protection, 2009, 87(6): 371-376.
70	SHARIFF A M, WAHAB N A. Inherent fire consequence estimation tool(IFCET) for preliminary design of process plant[J]. Fire Safety Journal, 2013, 59: 47-54.
71	SHARIFF A M, WAHAB N A, RUSLI R. Assessing the hazards from a BLEVE and minimizing its impacts using the inherent safety concept[J]. Journal of Loss Prevention in the Process Industries, 2016, 41: 303-314.
72	RATHNAYAKA S, KHAN F, AMYOTTE P. Risk-based process plant design considering inherent safety[J]. Safety Science, 2014, 70: 438-464.
73	KHAN F I, AMYOTTE P R. I2SI: a comprehensive quantitative tool for inherent safety and cost evaluation[J]. Journal of Loss Prevention in the Process Industries, 2005, 18(4/5/6): 310-326.
74	KHAN F I, AMYOTTE P R. Integrated inherent safety index(I2SI): a tool for inherent safety evaluation[J]. Process Safety Progress, 2004, 23(2): 136-148.
75	TUGNOLI A, LANDUCCI G, COZZANI V. Key performance indicators for inherent safety: application to the hydrogen supply chain[J]. Process Safety Progress, 2009, 28(2): 156-170.
76	ORTIZ-ESPINOZA A P, JIMÉNEZ-GUTIÉRREZ A, EL-HALWAGI M M. Including inherent safety in the design of chemical processes[J]. Industrial & Engineering Chemistry Research, 2017, 56(49): 14507-14517.
77	AHMAD S I, HASHIM H, HASSIM M H, et al. Inherent safety and economic graphical rating(InSafE) method for inherent safety and economic assessment[J]. Process Safety and Environmental Protection, 2021, 149: 602-609.
78	MEDINA-HERRERA N, GROSSMANN I E, MANNAN M S, et al. An approach for solvent selection in extractive distillation systems including safety considerations[J]. Industrial & Engineering Chemistry Research, 2014, 53(30): 12023-12031.
79	EINI S, SHAHHOSSEINI H R, JAVIDI M, et al. Inherently safe and economically optimal design using multi-objective optimization: the case of a refrigeration cycle[J]. Process Safety and Environmental Protection, 2016, 104: 254-267.
80	EINI S, SHAHHOSSEINI H, DELGARM N, et al. Multi-objective optimization of a cascade refrigeration system: exergetic, economic, environmental, and inherent safety analysis[J]. Applied Thermal Engineering, 2016, 107: 804-817.
81	FONSECA J D, COMMENGE J M, CAMARGO M, et al. Sustainability analysis for the design of distributed energy systems: a multi-objective optimization approach[J]. Applied Energy, 2021, 290: 116746.
82	MEDINA H, ARNALDOS J, CASAL J. Process design optimization and risk analysis[J]. Journal of Loss Prevention in the Process Industries, 2009, 22(5): 566-573.
83	MEDINA-HERRERA N, JIMÉNEZ-GUTIÉRREZ A, MANNAN M S. Development of inherently safer distillation systems[J]. Journal of Loss Prevention in the Process Industries, 2014, 29: 225-239.
84	GUILLEN-CUEVAS K, ORTIZ-ESPINOZA A P, OZINAN E, et al. Incorporation of safety and sustainability in conceptual design via a return on investment metric[J]. ACS Sustainable Chemistry & Engineering, 2018, 6(1): 1411-1416.
85	Shin Yee TEH, CHUA Kian Boon, HONG Boon Hooi, et al. A hybrid multi-objective optimization framework for preliminary process design based on health, safety and environmental impact[J]. Processes, 2019, 7(4): 200.
86	NAWAZ W, LINKE P, KOҪ M. Safety and sustainability nexus: a review and appraisal[J]. Journal of Cleaner Production, 2019, 216: 74-87.

阶段	可获取的信息
研究阶段	化学反应和MSDS信息
概念设计阶段	工艺流程图（PFD）、设备清单、容器设计、反应器模型、仿真建模
基础设计	P&ID图、过程控制方案、详细质量和能量平衡、水利学、厂区布局
详细设计	机械设计、仪器规格、供应商详细资料、平面图
工程总承包	管道等距、建造规格
操作	调测日志、操作日志、维护日志

阶段	可获取的信息
研究阶段	化学反应和MSDS信息
概念设计阶段	工艺流程图（PFD）、设备清单、容器设计、反应器模型、仿真建模
基础设计	P&ID图、过程控制方案、详细质量和能量平衡、水利学、厂区布局
详细设计	机械设计、仪器规格、供应商详细资料、平面图
工程总承包	管道等距、建造规格
操作	调测日志、操作日志、维护日志

S/%	分数
0≤S<10	1
10≤S<20	2
20≤S<30	3
30≤S<40	4
40≤S<50	5
50≤S<60	6
60≤S<70	7
70≤S<80	8
80≤S<90	9
90≤S<100	10

S/%	分数
0≤S<10	1
10≤S<20	2
20≤S<30	3
30≤S<40	4
40≤S<50	5
50≤S<60	6
60≤S<70	7
70≤S<80	8
80≤S<90	9
90≤S<100	10

[1]	索寒生, 贾梦达, 宋光, 刘东庆. 数字孪生技术助力石化智能工厂[J]. 化工进展, 2023, 42(7): 3365-3373.
[2]	孙逊, 赵越, 玄晓旭, 赵珊, YOON Joon Yong, 陈颂英. 基于水力空化的化工过程强化研究进展[J]. 化工进展, 2022, 41(5): 2243-2255.
[3]	李欣铜, 陈志冰, 魏志强, 李苏桐, 陈旭, 宋凯. 具有输入数据注意力机制的卷积神经网络用于氟化工产品质量预测[J]. 化工进展, 2022, 41(2): 593-600.
[4]	姚羽曼, 罗文嘉, 戴一阳. 数据驱动方法在化工过程故障诊断中的研究进展[J]. 化工进展, 2021, 40(4): 1755-1764.
[5]	邹志云, 朱文超, 刘英莉, 孟磊, 郭宁, 于蒙. 小型特种精细化工过程自动化和信息化研究发展趋势探讨[J]. 化工进展, 2020, 39(S2): 269-275.
[6]	李俊杰,程婉静,梁媚,严晓辉,杨靖东,张岳玲,冯连勇,田亚峻,谢克昌. 基于熵权-层次分析法的中国现代煤化工行业可持续发展综合评价[J]. 化工进展, 2020, 39(4): 1329-1338.
[7]	何皓,邢子恒,李顶杰,张佳,张家仁,王凌. 可持续航空生物燃料的推广应用及行业影响与应对措施[J]. 化工进展, 2019, 38(08): 3497-3507.
[8]	袁健宝,王政,徐一凡,杨燕霞,贾小平,王芳. 基于复杂网络边负载分配理论的化工过程级联故障风险传播路径[J]. 化工进展, 2019, 38(08): 3525-3533.
[9]	李洪, 孟莹, 李鑫钢, 高鑫. 蒸馏过程强化技术研究进展[J]. 化工进展, 2018, 37(04): 1212-1228.
[10]	刘有智. 谈过程强化技术促进化学工业转型升级和可持续发展[J]. 化工进展, 2018, 37(04): 1203-1211.
[11]	姜英, 王政, 秦艳, 袁健宝, 贾小平, 王芳. 基于复杂网络的化工过程层次符号有向图模型建立及关键节点识别[J]. 化工进展, 2018, 37(02): 444-451.
[12]	孙冰, 朱红伟, 姜杰, 石宁. 微混合与微反应技术在提升化工安全中的应用[J]. 化工进展, 2017, 36(08): 2756-2763.
[13]	宋泓阳, 孙晓岩, 项曙光. 人工神经网络在化工过程中的应用进展[J]. 化工进展, 2016, 35(12): 3755-3762.
[14]	韦朝海, 廖建波, 胡芸 . 煤的基本化工过程与污染特征分析[J]. 化工进展, 2016, 35(06): 1875-1883.
[15]	杨贺勤, 刘志成, 谢在库. 绿色化工技术研究新进展[J]. 化工进展, 2016, 35(06): 1575-1586.