Probabilistic assessment of the safety profile of the Fischer–Tropsch process with a supercritical solvent

Inherent safety assessment during the design stage of chemical processes is typically conducted based on average values for design parameters. Under those conditions, the single‐point deterministic process performance assessment may be affected by the phenomenon known as the ‘flaw of averages’ in the presence of irreducible sources of uncertainty (performance evaluated at average conditions does not represent average performance). In this work, an inherent process safety assessment developed under a probabilistic formulation is presented. An evaluation of the proposed approach is performed in the case of a gas‐to‐liquid process system using a supercritical solvent for Fischer–Tropsch reactor systems. The pertinent uncertainty analysis is carried out using Monte Carlo simulation techniques to account for the propagation of uncertainty through the inherent process safety model and the derivation of probability distribution profiles for the associated metrics, thus statistically characterizing ranges of potential performance outcomes. The response variables were the autothermal reactor and the syngas flows. The results show that the input variables associated to the autothermal flow potentially generate the most hazardous conditions for the process. The results also show how the metrics are affected when uncertainty is explicitly taken into account at the design stage of the process, offering a more nuanced assessment and characterization of the inherent process safety profile. Relation of input variables with response variables and selection of uncertain input variables for Monte Carlo techniques through sensitivity analysis.