A holistic approach for process design, control and safety analysis through a model-based improved HAZOP that utilizes dynamic simulations, is presented and illustrated for the formic acid (FA) process. First, this study develops a plantwide control (PWC) system for the FA process having a reactive dividing-wall column (R-DWC) and multiple material recycles besides the snowball effect, presence of which poses difficulty in PWC. A systematic and hierarchical integrated framework of simulation and heuristics is used for PWC design. Performance of the developed control structure is assessed using several criteria having PWC perspectives. Results indicate that the developed PWC system rejects typical disturbances while maintaining FA purity. Finally, process safety is studied using a new model-based improved HAZOP, where quantitative as well as qualitative analysis can be performed unlike only qualitative analysis in conventional HAZOP. Novelty of this work is the study of PWC and safety of an intensified FA process.

提出并举例说明了通过甲酸模拟（FA）工艺通过基于模型的改进的HAZOP进行过程设计，控制和安全性分析的整体方法，该方法利用了动态模拟。首先，这项研究开发了一种用于FA工艺的全厂控制（PWC）系统，该系统具有反应性分隔壁塔（R-DWC）和除雪球效应外的多种材料回收利用，这对PWC造成了困难。PWC设计使用模拟和启发式的系统和分层的集成框架。已开发的控制结构的性能使用具有PWC角度的几个标准进行评估。结果表明，开发的PWC系统在保持FA纯度的同时，可以抑制典型干扰。最后，使用基于新模型的改进型HAZOP对过程安全性进行了研究，与传统的HAZOP中仅进行定性分析不同，可以进行定量和定性分析。这项工作的新颖性是对PWC和强化FA过程安全性的研究。