Process Intensification: Safety Pros and Cons

One of the best ways of preventing accidents is to avoid hazards by inherently safer design. The adoption of such principles is now required by EU legislation. As many processes, particularly those in the chemicals, nuclear and oil industries, involve the production, handling and use of hazardous substances, process intensification (PI) is one way in which the inventory of such substances, and the consequences of a process failure, may be significantly reduced. PI, therefore, has the potential to be a significant factor in the implementation of inherent safety. However, conflict can arise between PI and some inherent safety practices. For example, certain PI technologies require higher energy inputs or to be operated at higher temperatures. The processes may be more complex or call for a more complex control system. For this reason, both the process (including the chemistry, where appropriate) and plant need to be considered together to reach a comprehensive understanding of the safety issues. This paper gives some examples of how process intensification has, or might have, improved safety. Some of the issues that need to be considered are also discussed. In order to promote the benefits of process intensification, and draw attention to safety considerations, HSE is co-sponsoring a process intensification network (PIN) in liaison with industry and the Department of Trade and Industry.