HAZOP review of a pyrolysis plant
Process safety
As a HAZOP expert, Prohead Engineering is also called upon to second experts to HAZOPs and HAZOP reviews and to rewrite corporate HAZOP procedures.
About the case
Context:
A new pyrolysis plant for processing wood waste into activated carbon and green energy was designed and built by an EPC partner. To assess the safety and reliability of the design, Prohead Engineering was asked to carry out an independent HAZOP review.
Approach:
Our process engineers organised and facilitated the HAZOP sessions together with the client and the EPC contractor. The main process steps were examined: raw material feed, carbonisation, gas cleaning and afterburning. Thanks to the systematic approach according to IEC 61882, several points for improvement were identified, including:
- Refinement of instrumentation and measuring points to monitor process conditions more closely.
- Optimisations in gas cleaning (scrubbers and polishers) to increase reliability and availability.
- Recommendations for the emergency discharge and combustion installation, with a focus on redundancy and safe positioning.
To support communication with senior management, the main scenarios were presented in the form of a bow-tie.
Result:
The HAZOP produced a series of concrete optimisations that were immediately integrated into the engineering. This led to:
- a more robust process design,
- improved safety for staff and the surroundings,
- and higher operational reliability of the pyrolysis plant.
Added value:
Because we were involved at an early stage, the findings did not merely serve as recommendations but could be incorporated straight away into further engineering and detailed design. As a result, the HAZOP review became a guiding step in the safe and efficient delivery of the installation.