Application of Smart Overpressure Protection Devices to batch and semi-batch processes: The zero-emission mode

Abstract

Chemical reactors in batch- and semi-batch processes are mainly protected by mechanical safety devices or safety integrity systems against critical runaway reactions. Both devices have in common, to limit with their fixed set conditions and discharge areas the productivity and flexibility of chemical plants. Besides, the trend in the industry is to reduce/avoid toxic and explosives to be discharges trough safety devices due to the increased requirements for climate- and environmental protection. A new idea in that regard is to connect the advantages of mechanical safety devices and safety integrated systems in so called smart overpressure protection devices (SmOP). Here, a predictive CSE conversion model (PreCoM) is online tracking the hazard potential of a chemical reaction and defines individual shutoff limits for the reaction. Its zero-emission mode ensures flexible, reaction independent application without fluid discharge. The smart relief mode is maximizing the plant utilization with individual shutoff limits and is minimizing the pollution with controlled discharge areas. In this article, the SmOP concept and the utilization of the PreCoM model for two different reactions and three industrial use cases for zero-emission application is being presented.