Development of a Software Tool for Hazard Identification Based on Process Simulation

Computer-aided process engineering provides industrially widely applied software solutions that can be successfully exploited for safety analysis. In this work, simulation-based hazard identification tool with demonstrative applications is proposed. HAZOP study was selected as the base methodology and commercial simulator Aspen HYSYS was employed as the simulation environment. Two case studies, ammonia synthesis plant and propylene glycol production, differing in employed unit operations were selected to determine robustness and reliability of the proposed tool. Hazards and operability problems were identified utilizing advanced mathematical algorithms such as parametric sensitivity analysis coupled with runaway effect detection and steady state multiplicity identification. Reactive systems of both case studies are well known for their nonlinear behavior and the presence of steady state multiplicity. This phenomenon was successfully simulated using Aspen HYSYS built-in solver.