Thermal risk in batch reactors: Case of peracetic acid synthesis

• Evaluate and optimize synthesis of PAA with HP and AA based on accident assessment criterion and probabilistic approach.
• A sensitivity analysis is performed under different reactions conditions and simulated.
• Monte Carlo simulations are used to calculate the conditional probability of accidents for synthesis of PAA.
• The optimal synthesis and molar ratio of PAA with inherent safety can also be identified.

The present paper deals with accidents risk in batch reactors. It identifies the conditions for the occurrence of a thermal runaway and develops a probabilistic approach to assess the relevant risk. It investigates also the conditions for optimal synthesis of peracetic acid (PAA) with hydrogen peroxide (HP) and acetic acid (AA). The kinetic model of reversible reaction and side reaction of PAA synthesis is used to predict reactor temperature and molar ratio of PAA by ASPEN PLUS software. A sensitivity analysis is performed under different conditions such as constant temperature or adiabatic process with different concentrations of sulfuric acid. Assuming a prior cooling system failure, the conditions for reaction runaway triggering a thermal accident are identified in the case of PAA synthesis. Monte Carlo simulations are used in order to calculate the conditional probability of accident and optimize the synthesis of PAA.