{"title":"Research on the thermal runaway characteristics and risks of square soft lithium‐ion batteries nail penetration","authors":"Jun Wang, Le Wang, Renming Pan, Xia Zhou","doi":"10.1002/prs.12613","DOIUrl":"https://doi.org/10.1002/prs.12613","url":null,"abstract":"To conduct a comprehensive investigation into the nail penetration thermal runaway (TR) characteristics of 16 Ah/5 Ah lithium‐ion batteries (LIBs) and their modules. The study aims to analyze the burst characteristics and examine the variations in TR behavior under specific conditions, with the goal of improving early warning and protection against LIB TR incidents. The research findings demonstrate that mechanical nail penetration can rapidly trigger TR, resulting in the highest temperature 522.3°C within 51.9 s, and the fastest is 20 s. In the case of LIB modules, a secondary temperature rise occurs, exhibiting an increased rate of up to 77%. Notably, when the battery bulges, there is a release of high‐temperature two‐phase heat flow accompanied by a significant discharge of combustible gases. This escalation increases the risk of further explosions. Moreover, the study observes repeated spray fires and the generation of a considerable amount of smoke. Additionally, the study highlights the role of sudden rise in temperature and the release of H2 as early indicators of TR. These findings provide valuable theoretical insights into the characteristics and risks of square soft LIBs, enhance safety measures, and contribute to the development of early warning systems for LIBs.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"209 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140942473","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Safety considerations for hydrometallurgical metal recovery from lithium‐ion batteries","authors":"Sakshi Jain, Seyed Mojtaba Hoseyni, Joan Cordiner","doi":"10.1002/prs.12618","DOIUrl":"https://doi.org/10.1002/prs.12618","url":null,"abstract":"This paper presents a comprehensive overview of the critical process safety considerations inherent in hydrometallurgical metal recovery within the lithium‐ion battery (LiB) recycling process. As hydrometallurgy application in LiB recycling is still in the early stages of development, it is crucial to identify the hazards and provide safety recommendations. Hazards related to hydrometallurgy are identified and categorized in process, toxic, fire, explosion, corrosion, environment, storage, and transport hazards. Risk reduction measures are suggested using the hierarchy of control methodology to eliminate and reduce risks to as low as reasonably practicable (ALARP), based on UK regulatory framework.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"41 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140940788","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Retrospective on the risk matrix, part II: Mathematics","authors":"James A. Moseman","doi":"10.1002/prs.12614","DOIUrl":"https://doi.org/10.1002/prs.12614","url":null,"abstract":"We present a review of mathematical and engineering science foundation of the risk matrix (RM). The objective was to locate and evaluate information surrounding its use. RM is governed by number theory, set theory, metrology, and functional analysis, which explains the strengths and weakness of its use. Although incorrectly reported, ordinal multiplication rigidly sets the cell numeric allocation. No scientific support was found for changing the ordinal ranks, although one reduction is introduced. Existing evidence suggests that the RM is unreliable. An example is given. Suggestions for beneficial use of the RM are provided.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"144 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140940477","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Optimal hybrid layout of point and open‐path gas detectors in process facilities of natural gas stations","authors":"Fei Xiao, Hao Qian, Lisheng Liu, Lingling Shao","doi":"10.1002/prs.12607","DOIUrl":"https://doi.org/10.1002/prs.12607","url":null,"abstract":"Because open‐path gas detectors offer superior technical performance, leakage monitoring systems tend to use a hybrid layout of point and open‐path gas detectors. However, most research on the optimized layout of leakage monitoring has focused only on point gas detectors. In this paper, an optimization model for a hybrid layout of point and open‐path gas detectors was proposed considering the cost–benefit ratio and detection time. As the measured value of an open‐path gas detector is an integral concentration, a monitor line in the simulation was calculated via the approximate rectangle method. The results showed that the use of a multiobjective gas detector layout considering the cost–benefit ratio and an improved non‐dominated sorting genetic algorithm (NSGA‐II) could optimize the layout of hybrid detectors. The hybrid layout was analyzed in a case study of process facilities at a natural gas station. As the number of detectors increased (safety investment), the proportion of open‐path gas detectors increased, improving both leakage monitoring performance and the cost–benefit ratio. Additionally, the layout of the point gas detectors was analyzed. A comparison of objective function values for detection time showed the superiority of the hybrid layout in our research.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"37 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140940596","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Special Issue: The 4th International Symposium on Urban and Industrial Safety","authors":"Xin Zhang, Yong Pan","doi":"10.1002/prs.12616","DOIUrl":"https://doi.org/10.1002/prs.12616","url":null,"abstract":"","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"22 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140940604","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"AI‐PSM: Where are we now?","authors":"Rainer Hoff","doi":"10.1002/prs.12610","DOIUrl":"https://doi.org/10.1002/prs.12610","url":null,"abstract":"Since its public debut in late 2022, ChatGPT has sparked growing interest in AI (Artificial Intelligence) within the Process Safety Management (PSM) community, serving as a tool for data capture and industry‐wide knowledge utilization. While machine learning (ML) had previously been explored in process safety, the emergence of large language models with chat‐style interfaces has made AI more accessible to non‐experts. Over the past year, I have managed the “AI‐PSM” LinkedIn group, facilitating discussions among PSM practitioners on the AI applications in PSM. These discussions have been analyzed using Prof. Thomas Malone's “4 Roles of AI” framework. This paper explores prevailing sentiments among AI‐PSM group members using Malone's model, addressing challenges such as mathematical problem‐solving, errors, and benchmarking.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"148 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140940680","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Introductions from the new editors of Process Safety Progress","authors":"Albert Ness","doi":"10.1002/prs.12612","DOIUrl":"https://doi.org/10.1002/prs.12612","url":null,"abstract":"","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"10 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140834555","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Procedure excellence: Changing paradigms to enable human reliability","authors":"Elliot Wolf‐Stokes, Rob Fisher","doi":"10.1002/prs.12603","DOIUrl":"https://doi.org/10.1002/prs.12603","url":null,"abstract":"A multi‐year review of process safety event learning data revealed that procedure usability and human factors were leading the trends of performance deviations by front‐line personnel. These insights prompted an enterprise‐wide Agile project to build capability focused on effective written guidance using science‐based tools and advanced error reduction techniques. Application of the Agile methodology was critical to gaining stakeholder commitment and establishing a comprehensive procedure integrity lifecycle to drive continuous improvement. Chemours partnered with an external consultant to create a holistic framework applicable to vital process safety roles with an orientation toward operational excellence. We share preliminary learnings and best practices leveraged from the nuclear industry, including systemic drivers to procedural deviations, the “top five error drivers” in written guidance, human performance modes (mental models), and key principles to enable human reliability.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"48 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140635844","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Experimental study on the explosion‐resistant performance of blast walls and doors of gas facilities","authors":"Young Jo Ryu, Yong Gil Lee, Dal Jae Park","doi":"10.1002/prs.12606","DOIUrl":"https://doi.org/10.1002/prs.12606","url":null,"abstract":"This study aims to provide experimental data necessary for the validation of the test conditions given in the current standard for high‐pressure gas facility KGS FU111. A series of experiments were conducted in a shock tube on 15 specimens (walls and doors) constructed according to the design recommendations in KGS FP112. The design elements of 12 walls are the materials, the thickness, and the holder positions, while the 3 doors were made of steel plates with different types and structures. The shock tube tester used in dividual specimens were exposed to blast overpressure of 0.11 or 0.17 MPa. From the acquired data and visual inspection, we conclude that the current designs of blast mitigation for high‐pressure gas‐storage facilities in KGS FP112 are acceptable for an accidental overpressure of up to 0.17 MPa, provided that both sides of the wall are supported by auxiliary structures such as adjacent barriers. Furthermore, the walls and doors as in KGS FP112 show comparable protection performances. Nevertheless, recommendations for doors are as follows: it may require additional latches and remain closed, and when designing the facility, the doorway may be located in a place with less possibility of direct exposure to the overpressure.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"1 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140628368","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"An integrated system theoretic process analysis with multilevel flow modeling for the identification of cyber‐physical hazards in a process industry","authors":"Feilong Zhang, Liangchao Chen, Bo Zhang, Jianwen Zhang, Qianlin Wang, Pengchao Wang, Jianfeng Yang, Zhan Dou","doi":"10.1002/prs.12604","DOIUrl":"https://doi.org/10.1002/prs.12604","url":null,"abstract":"The deep integration of information technology and process industry production systems makes system failure increasingly multi‐source and multi‐scale. In contrast to conventional hazard methods, system theoretic process analysis (STPA) can analyze the hazards in system control processes from the perspective of interactions among the system components. Theoretically, this method offers advantages that are better suited for modern production systems. However, as of now, the integration between STPA and process industrial production systems is still lacking. To address this issue, this study improved the original STPA method. First, we propose the “5 flows” concept for the process industrial cyber‐physical systems. The systems are described using multilevel flow modeling (MFM). This leads to the development of the MSTPA method, which is specifically designed to analyze the cyber‐physical hazards in process industrial production systems. Subsequently, the cyber‐physical hazards of a fluidized‐bed catalytic cracking unit are analyzed in detail using the MSTPA method as an example. The results show that MSTPA can identify cyber‐physical hazards in multiple dimensions. It is proved that, compared with the original STPA and traditional hazard methods, the MSTPA method can better identify cyber‐physical hazards in process industrial production systems.","PeriodicalId":20680,"journal":{"name":"Process Safety Progress","volume":"39 1","pages":""},"PeriodicalIF":1.0,"publicationDate":"2024-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140564701","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}