Journal of Loss Prevention in The Process Industries最新文献

{"title":"Artificial intelligence in process safety: A review of opportunities, challenges, and future directions for the chemical process industries","authors":"D. Christopher Selvam ,&nbsp;T. Raja ,&nbsp;Divyesh Rameshbhai Vaghela ,&nbsp;Mansingh Meena ,&nbsp;Sasmeeta Tripathy ,&nbsp;Bhavan Kumar ,&nbsp;Honganur Raju Manjunath ,&nbsp;Kulmani Mehar ,&nbsp;Yuvarajan Devarajan","doi":"10.1016/j.jlp.2026.105917","DOIUrl":"10.1016/j.jlp.2026.105917","url":null,"abstract":"<div><div>The Chemical Process Industries (CPIs) are undergoing a data-driven transformation, as artificial intelligence (AI), the Industrial Internet of Things (IIoT), and advanced analytics are redefining critical safety operations. This review consolidates recent applications of AI for hazard identification, dynamic risk assessment, early incident detection, and proactive barrier management in refineries and petrochemical facilities, emphasizing reported enhancements of 30–60 % in anomaly detection and near-miss classification compared to traditional methodologies. Ongoing challenges include sparse and biased incident datasets, limited interpretability, difficulties in validating algorithms under actual plant conditions, and regulatory ambiguities that limit widespread deployment. To mitigate these deficiencies, the paper proposes a multilayered framework that aligns AI functions with process safety management (PSM) elements, including asset integrity, alarm management, and emergency response. Future research priorities include the development of explainable, certifiable artificial intelligence, digital-twin-driven predictive risk assessment, and the integration of functional safety and risk governance standards, such as International Electrotechnical Commission (IEC) 61511 and ISO 31000. The review delineates pathways to establish safer, cleaner, and more resilient chemical and energy systems globally.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105917"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145977010","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Definition of a simplified risk assessment methodology for NaTech scenarios triggered by tornado","authors":"Fabrizio Santamato ,&nbsp;Clara Iannantuoni ,&nbsp;Valentina Busini","doi":"10.1016/j.jlp.2026.105915","DOIUrl":"10.1016/j.jlp.2026.105915","url":null,"abstract":"<div><div>Natural catastrophic events affecting technological systems may lead to the release of hazardous materials, giving rise to so-called “NaTech” events. The increasing number of NaTech events observed over recent years, possibly related to climate change, has reinforced interest in and the need to investigate the risk of exposure to natural hazards affecting the process industry. In the literature, most attention has been devoted to accidents triggered by floods and earthquakes, whereas no specific analysis protocols aimed at assessing the risk posed by tornadoes and severe wind gusts on production facilities are currently available. Consequently, the objective of this paper is to fill a gap in NaTech risk assessment by proposing a qualitative methodology for assessing the risk related to tornadoes and severe wind gusts. The proposed approach provides a basis for an objective, although simplified, comparison of both the risk posed by different plants potentially exposed to extreme wind events and the identification of the most critical equipment within a single plant. The analysis, partly based on existing qualitative methods, requires limited resources and data and relies on index-based evaluations.</div><div>A screening phase is first carried out by assessing the statistical incidence of the natural event using a European database, followed by the application of a qualitative method for evaluating equipment vulnerability and the consequences of their failure. Although the methodology was initially developed using data from the Italian territory, it can be applied to other countries, as demonstrated by the location sensitivity analysis performed at the end of the case study. The application of the methodology to a real case study showed that vertically developed and exposed assets, such as flare stacks, process columns, and gasoline storage tanks, represent the most critical equipment, consistently associated with medium to high risk levels. The sensitivity analysis, performed by relocating the same plant into different geographical areas, confirmed the robustness of the approach, as highly vulnerable assets remained critical across all locations, while less vulnerable equipment (e.g., pumps and phase separators) exhibited risk levels strongly dependent on local wind hazard conditions. These results demonstrate the capability of the methodology to effectively discriminate among territorial risk levels and to support the identification of installations requiring more detailed quantitative analyses.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105915"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145938638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dynamic risk analysis for emergency repair of sudden natural gas pipeline leakages","authors":"Lei Zhao ,&nbsp;Tengda Ge ,&nbsp;Qing Zhu ,&nbsp;Long Zhao ,&nbsp;Zhixiang Xing ,&nbsp;Yifei Yan ,&nbsp;Weimin Han ,&nbsp;Gang Qi","doi":"10.1016/j.jlp.2026.105931","DOIUrl":"10.1016/j.jlp.2026.105931","url":null,"abstract":"<div><div>Natural gas pipeline leakages pose significant risks of fire and explosion accidents, often resulting in severe consequences. Developing and applying risk analysis techniques for emergency repairs can effectively mitigate such incidents and minimize losses. However, existing risk analysis models are predominantly static and qualitative, failing to account for the multiple states and dependencies of input events, which increases model uncertainty. Moreover, the probabilities of risk factors are often limited, missing, or unknown, leading to data uncertainty. To address these challenges, this study proposes a dynamic risk analysis model for emergency repair of sudden gas pipeline leakages. A Bayesian network (BN) is used to address model uncertainty, while Hierarchical Bayesian analysis (HBA) and cloud model-based fuzzy set theory (CMFST) are employed to handle data uncertainty. The emergency repair process is divided into four stages, and a fault tree is constructed to identify risk factors, determine their logical relationships, and develop accident scenarios. The fault tree is then mapped into a BN to overcome the limitations of traditional models. To address data scarcity, expert elicitation is integrated into CMFST to derive crisp probabilities that reflect both ambiguity and randomness, while precursor data are employed in HBA to calculate and update crisp probabilities. By combining HBA and CMFST, the most probable risk factors leading to repair failure are identified through the robust inference capabilities of BN. As new observations become available, the probability of repair failure is dynamically updated over time by integrating BN and HBA, enabling continuous risk analysis. The results demonstrate the applicability and effectiveness of the developed model, offering a feasible solution for emergency repair risk analysis of sudden gas pipeline leakages under uncertainty.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105931"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076873","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization method for fire rescue equipment allocation based on fuzzy needs assessment and AnyLogic simulation","authors":"Yi Yang ,&nbsp;Jikuo Zhang ,&nbsp;Guanxia Zheng ,&nbsp;Yun-Ting Tsai","doi":"10.1016/j.jlp.2025.105898","DOIUrl":"10.1016/j.jlp.2025.105898","url":null,"abstract":"<div><div>The suitability and rationality of fire and rescue equipment allocation are central to effectively responding to regional fires and emergency operations. However, current fire station equipment deployment in China is largely based on standardized national guidelines, with limited consideration of regional variations and local risk profiles. This study integrates fuzzy set-valued statistics for demand assessment and AnyLogic agent-based modelling for dynamic simulation. This method is based on the Standard for Construction of Urban Fire Station in China. It combines local fire safety risk assessments, disaster and accident risk analyses, and evaluations of existing firefighting equipment to determine the actual needs for firefighting and rescue resources. These factors are then used to derive formulas that calculate both the required quantities and the prioritization of equipment allocation in each region. The result is a customized allocation framework that is adaptable to the unique operational conditions and risks of different regions.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105898"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145879945","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Process safety risk assessment against natural disasters: A cross-system scenario analysis perspective","authors":"Kaixin Shen ,&nbsp;Meng Lan ,&nbsp;Siqi Du ,&nbsp;Yiping Bai ,&nbsp;Jialin Wu ,&nbsp;Wenguo Weng","doi":"10.1016/j.jlp.2025.105905","DOIUrl":"10.1016/j.jlp.2025.105905","url":null,"abstract":"<div><div>The increasing frequency of natural disasters, particularly typhoons, exacerbates safety challenges for the process industry. While prior studies have concentrated on direct physical damage risks, the external risks arising from power system dependence were largely overlooked. One major challenge lies in the computational burden of large-scale scenario sets generated under disaster uncertainties, which makes detailed outage analysis infeasible. As a mainstream solution, existing scenario reduction techniques typically operate from a downstream, consequence-centric perspective (e.g., selecting representatives by damaged-facility counts). Such approaches often overlook the underlying temporal and spatial patterns of typhoon events and limit the suitability of the reduced set for complex risk assessments. To address these challenges, this study proposes a novel disaster-centric scenario reduction framework based on a Transformer-based Variational Autoencoder (VAE). The framework leverages a Transformer encoder to capture long-range temporal correlations in typhoon time series and employs the VAE to extract latent patterns, thereby enabling efficient compression of multi-dimensional typhoon scenario collections. A semi-supervised mechanism is integrated to leverage historical extreme cases to strengthen detection of extreme events. A subsequent two-stage strategy, combining anomaly detection and clustering, explicitly retains detected extremes while compressing non-extreme scenarios. Validation demonstrates that the selected representative scenarios effectively preserve the original outage risk distribution while reducing the scenario set by over 70 %. The validated representative set was then integrated with a purpose-built spatiotemporal risk metric, the Outage-Duration-Exceedance Probability (ODEP), to support in-depth analyses of power reliability and backup allocation for industrial parks. A comparison between disaster-induced and random-failure modes reveals significant systemic differences, highlighting the deficiencies of applying random-failure models to disaster-related outage risk assessment in industrial safety. Through this cross-system perspective, the proposed methodology provides an advanced and reliable solution for disaster-related safety risk management in the process industry.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105905"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880061","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Stage-wise CFD framework for analyzing pipeline Releases: The Satartia CO2 pipeline rupture case study","authors":"Chi-Yang Li,&nbsp;Zihao Wang,&nbsp;Tylee L. Kareck,&nbsp;Qingsheng Wang","doi":"10.1016/j.jlp.2026.105929","DOIUrl":"10.1016/j.jlp.2026.105929","url":null,"abstract":"<div><div>Carbon Capture, Utilization, and Storage (CCUS) relies on extensive CO₂ pipeline networks, making credible consequence assessment of pipeline failures essential to public safety and project feasibility. Computational Fluid Dynamics (CFD) offers high-fidelity dispersion predictions in complex environments, but end-to-end analyses are often prohibitive due to demanding geometry preparation, discretization requirements, model selection, and computational cost. This work develops a stage-wise CFD framework that partitions the model into: (i) in-pipe depressurization to obtain transient mass flow histories, (ii) near-field jet expansion to approach ambient conditions and define a physically consistent handoff plane, and (iii) far-field atmospheric dispersion over realistic terrain. The framework has been applied to analyze the Satartia CO₂ pipeline rupture, while integrating terrain data, contemporaneous meteorology, and pipeline operating parameters. The simulation peaks at 33,316 ppm 9 min after the rupture, slightly above the incident's highest measured value of 28,000 ppm. Additionally, the simulation's 15-min time-averaged maximum (25,319 ppm) indicates the incident did not reach the CO₂ Short Term Exposure Limit (STEL). Beyond CO₂ pipelines, this framework generalizes to other releases from pipelines where hazards are governed by concentration profiles, providing a reproducible and computationally tractable pathway for consequence modeling in pipeline safety.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105929"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034228","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Layout optimization and risk analysis of chemical devices under the synergistic effects of multiple fires","authors":"Di Xiao,&nbsp;Hui-hui Lu,&nbsp;Shu-Yu Chen,&nbsp;Xiang Liu,&nbsp;Jia-Jia Jiang,&nbsp;Jun-Cheng Jiang","doi":"10.1016/j.jlp.2025.105866","DOIUrl":"10.1016/j.jlp.2025.105866","url":null,"abstract":"<div><div>In chemical devices, irrational layouts accelerate the propagation of synergistic and domino effects across devices, thereby increasing the severity of accidents. In this paper, the failure probability of each chemical device is estimated by dynamic target device time to failure (<em>ttf</em>) and escalation threshold when synergistic effects of multiple fires are considered. The failure probabilities are further converted into accident damage costs. Then, the optimization model considering the synergistic effects is constructed by combining the other costs. The layout model is solved by combining the simulated annealing (SA) algorithm and the particle swarm optimization (PSO) (PSO-SA) algorithm. Finally, as a case study, ethane, ethanol, and acetic acid tank farm layouts are derived considering synergistic effects and without synergistic effects. When synergistic effects are not considered, the tank layout is more centralized. At the same time, other related costs are reduced while pipeline costs are increased. One of the most hazardous tanks was then selected as the initial tank for accident risk analysis. This work may provide some support for designers in terms of chemical device layout.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105866"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145621871","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on the coupled flame propagation dynamics of hydrogen/air deflagration in interconnected vessels","authors":"Xiaorui Liu ,&nbsp;Lixin Cong ,&nbsp;Bing Han ,&nbsp;Junwei Zhou ,&nbsp;Dong Yu","doi":"10.1016/j.jlp.2026.105933","DOIUrl":"10.1016/j.jlp.2026.105933","url":null,"abstract":"<div><div>Hydrogen deflagration in interconnected vessels is more destructive than that in isolated vessels. In this study, a three-dimensional transient model of hydrogen/air explosions in an interconnected device was developed using large eddy simulation (LES). The coupling interactions among flame propagation, pre-compression, and backflow phenomenon were systematically investigated, revealing that the pressure piling originates from the flame–flow feedback between the ignition vessel and the secondary vessel. Moreover, the influences of geometric scale and ignition location were investigated. As the volume ratio increases, the peak overpressure in the secondary vessel rises monotonically, reaching 1414 kPa at a ratio of 14:1. The pipe diameter exhibits a negative correlation with the maximum overpressure, whereas increasing pipe length weakens the pre-compression but slightly enhances the peak overpressure. In addition, ignition in the larger vessel leads to a significantly more hazardous explosion than ignition in the smaller vessel.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105933"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076872","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Tsunami fragility for anchored floating-roof atmospheric tanks","authors":"Antonio Vitale ,&nbsp;Georgios Baltzopoulos ,&nbsp;Iunio Iervolino","doi":"10.1016/j.jlp.2026.105928","DOIUrl":"10.1016/j.jlp.2026.105928","url":null,"abstract":"<div><div>One of the issues for quantitative risk assessment in the process industry, is incorporating so-called NaTech risk, that is considering the potential consequences of natural hazards, whose impact on facilities can cause accidents such as explosions, fires, or toxic substance release. In this context, this paper explores the behaviour of anchored atmospheric storage tanks under tsunami, with the goal of quantifying their vulnerability via parametric fragility functions. Three archetype tanks with different aspect ratios were considered, while tsunami vulnerability was evaluated for different filling levels. The effects of tsunami-induced pressure on the tanks were calculated numerically following an equivalent-static approach, based on nonlinear analyses of finite element models. Each tank was subjected to various combinations of tsunami inundation levels and increasing flow velocities, obtaining structural response of each tank's steel shell and anchorage system. Parametric tsunami fragility curves were obtained, also with the aid of a site-specific conditional tsunami hazard model, surrogating vector-valued hazard analysis. It was found that the predominant failure mode depends on the aspect ratio and filling level, with emptier tanks being more vulnerable overall. The fragilities were then used to quantify the risk associated with loss of content due to structural failure, and the results were also compared those from existing models.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105928"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076971","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electrochemical performance and thermal stability of Co3O4 modified high nickel ternary cathode materials","authors":"Yan Tang ,&nbsp;Jia-Ping Zhao ,&nbsp;Lin-Jie Xie ,&nbsp;Qi-Tong Ke ,&nbsp;Chen Liang ,&nbsp;Jun-Cheng Jiang ,&nbsp;An-Chi Huang","doi":"10.1016/j.jlp.2025.105901","DOIUrl":"10.1016/j.jlp.2025.105901","url":null,"abstract":"<div><div>LiNi_xCo_yMn_1-x-yO₂ (NCM, x &gt; 0.6) is a high-nickel ternary cathode material extensively utilized in the renewable energy sector due to its cost-effectiveness and high energy density. Nonetheless, its utilization is constrained by structural instability, interfacial side reactions, and thermal safety concerns. This investigation involved the application of varying concentrations of Co₃O₄ onto the surface of NCM for modification purposes. The influence of coating quantity on the thermal safety and electrochemical performance of the material was examined in conjunction with morphological characterization, electrochemical testing, and thermal safety assessment. The findings indicate that Co₃O₄ coating acts as a physical barrier to isolate NCM from the electrolyte, diminish lithium-nickel intermixing, and improve the structural stability of the material. Electrochemical tests revealed that the 1 % Co₃O₄-coated NCM delivered superior cycling stability. After 200 cycles at 0.2C, the capacity retention rate reached 82.85 %, which was 16 % higher than the pristine NCM (66.85 %), and the discharge specific capacity at 3C is 133.3 mAh/g. Thermal analysis results indicate that Co₃O₄ coating increases the initial temperature of thermal runaway in NCM material. In summary, a modest Co₃O₄ coating can synergistically optimize the electrochemical performance and safety of high nickel ternary NCM materials by refining surface structure, promoting interface charge transmission, and improving thermal stability.</div></div>","PeriodicalId":16291,"journal":{"name":"Journal of Loss Prevention in The Process Industries","volume":"100 ","pages":"Article 105901"},"PeriodicalIF":4.2,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145836621","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}