Application of smart overpressure protection devices to batch and semi-batch processes: The smart relief mode

Abstract

Smart overpressure protection devices (SmOPs) combine complex mathematical models implemented to safety-related programmable logic controllers (sPLC) with adaptable mechanical safety devices. The devices dynamically adjust set points and relief areas based on real-time hazard potential assessments and are being used to protect chemical reactors against exothermal runaway reactions. Providing two modes of operation, the "zero-emission mode" prevents reactions from exceeding reactor limits, while the "smartrelief mode" initiates controlled fluid discharge to avoid exceeding the permissible plant limits. In this article, the “smart relief mode” of smart overpressure protection devices as an innovative safety solution for chemical reactors is introduced. It is applied to two different types of reaction and shows three different typical industrial use cases.