Many researchers report optimizations of chemical processes based on steady-state analysis. However, neglecting the time factor may lead sometimes to more waste generation and/or hazardous safety consequences. In this regard, we recently detailed a comprehensive modeling of a fluidized bed reactor (FBR) for Unipol^® polypropylene process using the sequential modular simulation approach while incorporating the hydrodynamic correlations. Furthermore, a steady-state analysis and optimization technique was used to increase the plant profitability. The current manuscript presents dynamic modeling to identify process constraints that obstruct the process improvement recommended by the previous study. The current dynamic model was validated using industrial operational scenarios. The dynamic model was then utilized to explore the response of the FBR control system protection layer to unplanned operational scenarios, its ability to avoid waste generation, and achieve process safety. As such, an automated HAZOP study based on layer of protection analysis concept was applied for this purpose. As a result, to apply the recommended scheme by the steady-state study while ensuring safety and cleaner production in the process, it is necessary to revamp the existing FBR cooling system. The extra cost for revamping the cycle gas cooler is trivial compared to the potential increase in the process safety besides the plant productivity.

许多研究人员报告了基于稳态分析的化学过程优化。然而，忽视时间因素有时可能会导致更多的废物产生和/或危险的安全后果。在这方面，我们最近详细介绍了 Unipol ^®流化床反应器 (FBR) 的综合建模聚丙烯工艺使用顺序模块化模拟方法，同时结合流体动力学相关性。此外，稳态分析和优化技术被用来提高工厂的盈利能力。当前的手稿提出了动态建模，以识别阻碍先前研究推荐的过程改进的过程约束。当前的动态模型使用工业操作场景进行了验证。然后利用动态模型来探索 FBR 控制系统保护层对计划外操作场景的响应、其避免废物产生和实现过程安全的能力。因此，为此目的应用了基于保护层分析概念的自动化 HAZOP 研究。因此，为了应用稳态研究推荐的方案，同时确保过程中的安全和清洁生产，需要对现有的 FBR 冷却系统进行改造。除了工厂生产力之外，与过程安全性的潜在增加相比，改造循环气体冷却器的额外成本微不足道。