Safety analysis of intensified processes

Safety of intensified processes was analyzed by a checklist-based approach. The checklist was formulated using the concept of layers of protection for a chemical process. With real cases, it was shown that several positive and negative effects on safety can be detected in process intensification. The general claim that safety is always improved by process intensification was questioned.

► Safety of intensified processes was analyzed by a checklist-based approach.
► A checklist was developed for process safety analysis on the basis of the protection layer concept.
► With real cases it was shown that several positive and negative effects on safety can be detected in process intensification.
► Negative and positive effects in the inherent safety layer are the most important and should be taken seriously.
► It is dangerous to assume that safety is always improved through intensification.