Guidance on Safety/Health for Process Intensification Including MS Design. Part IV: Case Studies

The new technology of process intensification by multiscale equipment can significantly contribute to the achievement of a safer design by switching from batch/semi-batch to continuous operation combined with a reduction of the inventory of hazardous substances in critical stages. On the other hand, the shift to higher space-time-yields and temperatures comprises new risks (see Parts I and II). A tool was developed for preliminary risk assessment to cover characteristic features of micro-designed equipment, called HAZOP-LIKE study (see Part III). The generic case studies were applied to two demonstration projects within the IMPULSE project: sulfur dioxide oxidation and the alkylation reaction for the production of ionic liquids. The generic templates proved to be applicable and support comprehensive risk analysis studies on processes with hidden deviations not obviously following traditional HAZOP studies.