Journal of Chemistry and Chemical Research

In light of the high-risk nature inherent in the potassium nitrate decomposition production process and the constraints associated with existing HAZOP analysis and Safety Instrumented System (SIS) applications, this study undertakes comprehensive risk identification and safety protection optimization efforts. By employing HAZOP analysis, critical risk deviations are pinpointed, including elevated temperatures within the decomposition reactor, excessive pressure in the primary evaporator, and deficiencies in the original safety protection layers. In accordance with the IEC 61508 and IEC 61511 standards, a Safety Integrity Level (SIL) 3 assessment is conducted for key nodes. Subsequently, SIS optimization strategies are formulated, encompassing sensor redundancy selection and logic controller redundancy configuration. On-site verification demonstrates that post-optimization, the SIS response time has been reduced by 65.2%, the accuracy of fault diagnosis has been enhanced by 13.5 percentage points, and the occurrence of major risks has been entirely eliminated. This study offers technical support for the safety management of potassium nitrate production processes and analogous industrial applications.

Potassium nitrate production facility; HAZOP analysis; Safety Instrumented System; Safety integrity level; Configuration optimization