Safety evaluation of rectisol process based on quantitative hazard and operability analysis

Zhang Haiyan; Li Peirui; Zhang Zhonglin; Hao Xiaogang; Zhou Yuan; Wu Xiaolu; Yang Jingxuan; Abudulad Abuliti; Guan Guoqing

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Safety evaluation of rectisol process based on quantitative hazard and operability analysis

Updated：2026-05-14

- Safety evaluation of rectisol process based on quantitative hazard and operability analysis
- Chinese Journal of Chemical Engineering Vol. 90, Issue 2, Pages: 33-44(2026)
- Affiliations：
  
  College of Chemistry and Chemical Engineering, Taiyuan University of Technology, Taiyuan 030024, China
  Shanghai Electric Guokong Global Engineering Corporation, Taiyuan 030001, China
  Shanxi Science and Technology Service Co., Ltd., Taiyuan 030001, China
  Shanxi David Engineering Technology Co., Ltd, Taiyuan 030024, China
  Graduate School of Science and Technology, Hirosaki University, 3-Bunkyocho, Hirosaki 036-8561, Japan
  Energy Conversion Engineering Laboratory, Institute of Regional Innovation (IRI), Hirosaki University, 3-Bunkyocho, Hirosaki 036-8561, Japan
- Author bio：
  
  Corresponding authors. E-mail addresses: zlzhang@tyut.edu.cn (Z. Zhang)
  Corresponding authors. E-mail addresses: xghao@tyut.edu.cn(X. Hao)
  Corresponding authors. E-mail addresses: guan@hirosaki-u.ac.jp(G. Guan).
- Funds：
- DOI：
  CLC：
- Received：12 February 2025，
  
  Revised：2025-09-16，
  
  Accepted：17 September 2025，
  
  Online First：28 November 2025，
  
  Published：2026-02
- Accepted：
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Zhang Haiyan, Li Peirui, Zhang Zhonglin, et al. Safety evaluation of rectisol process based on quantitative hazard and operability analysis[J]. Chinese Journal of Chemical Engineering, 2026, 90(2): 33-44.
DOI：

Zhang Haiyan, Li Peirui, Zhang Zhonglin, et al. Safety evaluation of rectisol process based on quantitative hazard and operability analysis[J]. Chinese Journal of Chemical Engineering, 2026, 90(2): 33-44. DOI：

摘要

Abstract

In order to break through the limitations of the traditional hazard and operability (HAZOP) analysis

this study established a gray evaluation model based on gray theory for the riskiness ranking of deviations and semi-quantitative analysis of risk levels. A quantitative HAZOP analysis combining HAZOP with Aspen Plus

Aspen Dynamics

Fault Tree Analysis (FTA)

Risk Matrix and Layer of Protection Analysis (LOPA) was performed for high risk deviations. The dynamic model of the methanol washing unit in the rectisol process was established by Aspen Dynamics and the effects of different deviations on the risk indicators and operability indicators were investigated. Then

the risk of deviations was ranked according to the simulation results and the high-risk deviations were identified. Subsequently

the sensitivity analysis module of Aspen Plus software was used to calculate the fluctuation range of highrisk deviations

whose results were imported into Aspen Dynamics to simulate and analyze the risk level of accidents

and then FTA was used to quantify the probability of accidents. Synchronizing the two to the risk matrix determined the deviations to have initial risk ratings of 10 and 15

both of which are high-risk deviations. The HAZOP quantitative analysis report is finalized after reducing the residual risk level of the deviation to 9 (low risk) through LOPA analysis. The results of the case study showed that the method can verify the accuracy of the gray evaluation model to a certain extent

and the quantitative HAZOP analysis report is of guiding significance for actual production.

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references

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