Deviation propagation analysis along a cumene process by using dynamic simulations

•Dynamic simulations of deviation propagations are studied along a chemical process.•The complex case study is the benzene alkylation into cumene in liquid-phase.•The process comprises a reactor and 3 distillation columns with a recycle stream.•Overpressure and flooding risks are evaluated with Aspen Plus Dynamics software.•A study's strength is in process control strategy and safety device sizing. The dynamic response of benzene alkylation process to a set of deviations is analyzed with Aspen Plus Dynamics. A quantitative risk assessment is developed through simulations of deviation scenarios. The process comprises a reactor and three distillation columns with a recycle stream. The simulation scenarios are determined according to lessons learnt from accidents. This study underlines the conditions that induce an overpressure or a flooding in a distillation column. Three scenarios are proposed: feed flowrate variations, coolant flowrate reduction and cooling of the reboiler steam. Thereafter, the results allow calculating a set of risk indexes related to flooding and overpressure phenomena. This study underlines the deviation propagation effects that can be expected in all the process equipment. Moreover, it represents a significant contribution to the definition of the process control strategy and the necessary safety barriers.