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Investigation of Inherently Safer Design Through Process Intensification: Novel Safety Assessment Methodology and Case Study in C3–Alkyne Hydrogenation Distillation Process

Inherently Safer Design (ISD) describes a strategy that reduces and even eliminates inherent hazards in processes. However, ISD principles improving inherent safety always involves tradeoffs between these two competing factors: safety and costs. In inherent safety aspects, process intensification (PI), one of the methodologies in ISD, aims to eliminate units and simplify the process. Therefore, synchronous promotion of cost-efficiency and safety is achieved. Nevertheless, applying PI strategies in the design stage may result in adverse safety effects, and eliminating units may cause risk transfer and risk accumulation, which could lead to serious consequences when accidents occur. In this study, we introduced a novel methodology involved in a better-suited indicator, Advanced Comprehensive Inherent Safety Index (ACISI), along with Quantitative Risk Analysis (QRA) to evaluate the safety performance of PI designs in the early stage. To further illustrate, a case study of C3-alkyne selective hydrogenation di...