Systemic risk control in anthraquinone-based hydrogen peroxide synthesis: A technical review

Abstract

The anthraquinone process, the dominant method for global hydrogen peroxide production, poses complex safety challenges due to the handling of highly reactive substances, despite operating under relatively moderate temperature and pressure conditions. This review provides a comprehensive analysis of the primary safety hazards associated with each stage of the process, including hydrogenation, oxidation, extraction, and purification. Critical risk factors, such as the formation of explosive hydrogen-oxygen mixtures and the autocatalytic decomposition of hydrogen peroxide are thoroughly examined. The review systematically examines advanced safety strategies for hazard mitigation, with particular focus on precision pressure control, pH stabilization, solvent optimization, and automated process control systems. Furthermore, the importance of continuous equipment monitoring, solvent volatility profiling, and system integrity assessments is highlighted as key to ensuring safe and stable operations. Looking ahead, future research should focus on the development of next-generation catalysts with enhanced selectivity, as well as the integration of real-time safety monitoring and predictive maintenance technologies. These innovations are crucial for managing the increasing complexity of large-scale hydrogen peroxide production, ensuring both operational efficiency and inherent safety as industrial demands evolve.