Inherently Safer Chemical Processes

Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally. The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process. It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.

Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. It discusses strategies for substituting more benign chemicals at the development stage, minimizing risk in the transportation of chemicals, using safer processing methods at the manufacturing stage, and decommissioning a manufacturing plant. Since the publication of the original concept book in 1996, there have been many developments on the concept of inherent safety. This new edition provides the latest knowledge so that engineers can derive maximum benefit from inherent safety.

Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally. The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process. It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.

Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. It discusses strategies for substituting more benign chemicals at the development stage, minimizing risk in the transportation of chemicals, using safer processing methods at the manufacturing stage, and decommissioning a manufacturing plant. Since the publication of the original concept book in 1996, there have been many developments on the concept of inherent safety. This new edition provides the latest knowledge so that engineers can derive maximum benefit from inherent safety.

How far will an ounce of prevention really go? While the answer to that question may never be truly known, Process Plants: A Handbook for Inherently Safer Design, Second Edition takes us several steps closer. The book demonstrates not just the importance of prevention, but the importance of designing with prevention in mind. It emphasizes the role

Content Description #Includes bibliographical references and index.

Combines academic theory with practical industry experience Updated to include the latest regulations and references Covers hazard identification, risk assessment, and inherent safety Case studies and problem sets enhance learning Long-awaited revision of the industry best seller. This fully revised second edition of Chemical Process Safety: Fundamentals with Applications combines rigorous academic methods with real-life industrial experience to create a unique resource for students and professionals alike. The primary focus on technical fundamentals of chemical process safety provides a solid groundwork for understanding, with full coverage of both prevention and mitigation measures. Subjects include: Toxicology and industrial hygiene Vapor and liquid releases and dispersion modeling Flammability characterization Relief and explosion venting In addition to an overview of government regulations, the book introduces the resources of the AICHE Center for Chemical Process Safety library. Guidelines are offered for hazard identification and risk assessment. The book concludes with case histories drawn directly from the authors' experience in the field. A perfect reference for industry professionals, Chemical Process Safety: Fundamentals with Applications, Second Edition is also ideal for teaching at the graduate and senior undergraduate levels. Each chapter includes 30 problems, and a solutions manual is now available for instructors.

The use of hazardous chemicals such as methyl isocyanate can be a significant concern to the residents of communities adjacent to chemical facilities, but is often an integral part of the chemical manufacturing process. In order to ensure that chemical manufacturing takes place in a manner that is safe for workers, members of the local community, and the environment, the philosophy of inherently safer processing can be used to identify opportunities to eliminate or reduce the hazards associated with chemical processing. However, the concepts of inherently safer process analysis have not yet been adopted in all chemical manufacturing plants. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience presents a possible framework to help plant managers choose between alternative processing options-considering factors such as environmental impact and product yield as well as safety- to develop a chemical manufacturing system. In 2008, an explosion at the Bayer CropScience chemical production plant in Institute, West Virginia, resulted in the deaths of two employees, a fire within the production unit, and extensive damage to nearby structures. The accident drew renewed attention to the fact that the Bayer facility manufactured and stores methyl isocyanate, or MIC - a volatile, highly toxic chemical used in the production of carbamate pesticides and the agent responsible for thousands of death in Bhopal, India, in 1984. In the Institute accident, debris from the blast hit the shield surrounding a MIC storage tank, and although the container was not damaged, an investigation by the U.S. Chemical Safety and Hazard Investigation Board found that the debris could have struck a relief valve vent pipe and cause the release of MIC to the atmosphere. The Board's investigation also highlighted a number of weaknesses in the Bayer facility's emergency response systems. In light of these concerns, the Board requested the National Research Council convene a committee of independent experts to write a report that examines the use and storage of MIC at the Bayer facility. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience also evaluates the analyses on alternative production methods for MIC and carbamate pesticides preformed by Bayer and the previous owners of the facility.