Application of simulation tools to HAZOP analysis of exothermic reaction processes

Introduction: The article addressed the integration between process simulation and HAZOP studies as a tool for risk analysis in the chemical industry. It was identified that, despite the effectiveness of traditional HAZOP, its qualitative nature and dependence on expert judgment limited its scope in complex systems. In response, it was proposed to review the use of simulation - in steady state and dynamic - as a support to improve the identification and evaluation of deviations in industrial processes, especially in CSTR type reactors. Development: The principles of chemical process simulation and its application using tools such as Aspen HYSYS were described. The advantages of mathematical modeling for predicting the behavior of a system in the face of disturbances were analyzed. In particular, a case of propylene glycol production in a CSTR reactor was studied, highlighting the influence of parameters such as temperature, reactant flow and unstable operating zones. Key concepts of the HAZOP study, the LOPA methodology and the design of protection layers were reviewed and linked to data obtained from detailed simulations. Visual tools such as bifurcation diagrams and operational windows were exemplified. Conclusions: The review evidenced that the use of simulation strengthens risk analyses by complementing the HAZOP approach with quantitative data. This combination improved the accuracy of the analysis, reduced the study execution time and increased the reliability of the results. It was concluded that the integration of advanced simulators represents a key trend in the evolution towards more digitized and efficient risk management.