Step by step to zero emission of chemical reactors
SmartHIP (Smart Technology for High Integrity Overpressure Protection) is a CSE research project for the protection of chemical reactors with mere safety instrumented systems (SIS) by online-based safety models. In comparison to mechanical safety devices like safety valves or bursting discs, no emission will occur (zero emission) and downstream equipment are no longer required (i.e. flares or cyclones). By means of a SmartHIP the safety window of a plant is enlarged to increase safety and productivity. Three steps are planned to get closer to this goal.
In the first step, both proven and new safety models were developed. To enable an application under real conditions, the models were transferred from the developed environment to a Failsafe Programmable Logic Controller (FPLC). In order to simulate reactor data of an exothermic reaction with a runaway behaviour, an interface was created using OPC between the FPLC and the simulation software, so that the simulated values could be transferred in both directions. This allowed the correctness of the implementation to be checked. In addition, real effects such as peaks or time delays of the program in the FPLC could now be investigated and the influence on the adiabatic temperature and pressure increase could be determined.
In addition to the implementation, a first data fusion model was also applied to the safety models, which as a result significantly reduced the uncertainties of the individual models. Thereby, a closer driving to the reactor boundaries was possible. Despite the successful model, further data fusion approaches will be investigated and compared in the second step.
In the final step, the safety concept must be validated using a pilot reactor, so that the accuracy and reliability can be checked under real operating conditions. For this purpose, the design and construction will be planned in the near future.