Inherently safer design substitution

Hazard and Risk Analysis Consideration should be given to identifying process hazards as early as possible in the process equipment design, so that measures can be taken to reduce or eliminate the hazards. Inherently safer design strategies, such as minimize, substitute, moderate, and simplify, should be implemented. 

Substitution of an hazardous chemical is often an even more complex problem, in particular regarding the trade-off between inherently safer design and sustainable chemistry. Several examples are discussed in subsequent chapters. We thus limit our discussion here to a few aspects. Up until around the 1960s the Reppe process was employed for of synthesis of acrylic esters ... 

Although many engineers provide only the minimum adequate vessel design to minimize costs, it is inherently safer to minimize the use of safety interlocks and administrative controls by designing robust equipment. Passive hardware devices can be substituted for active control systems. For example, if the design pressure of the vessel system is higher than the maximum expected pressure, an interlock to trip the system on high pressure or temperatures may be unnecessary. 

A primary objective of any safety program is to maintain or reduce the level of risk in the process. The design basis, especially inherently safer features that are built into the installation, must be documented. Management of change programs must preserve and keep the base record current and protect against elimination of inherently safer features. For identical substitution, the level of risk in the process is... 

Many of the incidents in this book were the result of leaks of hazardous materials, and the recommendations describe ways of preventing leaks by providing better equipment or procedures. As we have seen, equipment can fail or can be neglected, and procedures can lapse. The most effective methods, therefore, of preventing leaks of hazardous materials are to use so little that it hardly matters if it all leaks out (intensification or minimization) or to use a safer material instead (substitution). If we cannot do this and have to store or handle large amounts of hazardous material, we should store or handle it in the least hazardous form (attenuation or moderation). Plants in which this is done are said to be inherently safer because they are not dependent on added-on equipment or procedures that might fail the hazard is avoided rather than controlled, and the safety is inherent in the design. 

Minimize, or eliminate, the risks from these hazards by reducing scale, substituting safer (greener) chemicals used as solvents and reagents, and designing processes that are inherently safer and eliminate, or produce biodegradable, wastes. 

The need to evaluate alternatives often arises once the decision to eliminate chemicals of concern is made. Sometimes a chemical of concern can be eliminated through product design such as through the use of a material that is inherently flame retardant or a fabric barrier without the need for added flame-retardant chemicals. But when the only currently feasible option appears to be a chemical substitution, then the alternatives must be evaluated and assessed to ensure that they are in fact greener than the chemical they are intended to replace. We provide as examples of implementing alternatives assessment, the Green Screen for Safer Chemicals and the DfE Flame Retardants in Printed Circuit Boards Partnership. 

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