Rigorous dynamic simulation methodology for scenario-based safety analysis of pressure-swing distillation considering independent protections

Process engineers often assess process safety performance early in the design stage to reduce or eliminate potential hazards cost-effectively. Process simulation tools widely used in design can provide fast and precise hazard evaluation using limited design information. However, there is a knowledge gap on how to build rigorous dynamic process models and how model configurations can affect safety analysis results. This study applied commercial dynamic simulation software, Aspen Dynamics, to address these issues through rigorous dynamic simulations and safety analysis of a two-column pressure-swing distillation with top recycling. The study implements and simulates various layers of protection, including basic process controls, alarms, safety instrumented systems, and pressure relief systems, and evaluates their impact on accident prevention. The hazardous scenarios considered are overpressure and flooding in the distillation columns, and the dynamic responses to a set of deviations such as coolant and steam utility failures and undesired throughput and composition disturbances are investigated. A scenario-based safety analysis is performed to assess the dynamic safety performance and the effectiveness of protection layers. The results indicate that the presented scenario-based dynamic safety analysis methodology is essential for accurately determining dynamic column behaviors, thereby better assisting in determining process safety time and designing effective safety systems.