Study of Protection Strategies Against Explosions and Runaway Reactions in Compliance with Directive 2012/18/EU and Industrial Standards

Abstract

The Final Degree Project titled “Study of Protection Strategies Against Explosions and Runaway Reactions in Compliance with Directive 2012/18/EU and Industrial Standards" addresses the critical importance of safety in the industrial sector, specifically within chemical plants. This study focuses on the prevention, protection, and mitigation of major accidents caused by runaway reactions and pressure increases in storage tanks containing hazardous substances, aligning with Directive Seveso III and other relevant industrial standards. The document examines significant historical cases to highlight the importance of addressing all aspects of industrial production. Explosion protection strategies are evaluated using frameworks and guidelines for pressure relief device design. It further proposes the use of specific protection systems, such as rupture disks, dimensioned according to these international standards, to protect or minimize the impact of such events. Among the key findings, the analysis highlights three notable accidents. The first is a catastrophic fire in petrochemical storage tanks, which led to a large-scale domino effect due to inadequate safety spacing and the absence of external fire protection systems. Non-compliance with industrial standards exacerbated the consequences, resulting in significant environmental damage, infrastructure destruction, and financial losses. The second case involves a runaway reaction caused by human error and poor pressure relief system design, where improper safety measures failed to contain the rapid pressure increase, leading to catastrophic equipment failure. This highlights the necessity of designing effective safety devices using DIERS methodologies and industrial standards. The third case examines a runaway reaction triggered by insufficient risk analysis and a production batch increase, which overwhelmed the existing pressure relief and cooling systems. The lack of system resizing to handle the increased load resulted in severe overpressure and thermal escalation, causing substantial damage.This work demonstrates that many industrial accidents are preventable through proper design, regular maintenance, comprehensive training, and strict adherence to safety regulations. Additionally, it emphasizes the necessity of proactive risk management, rigorous personnel training, and adopting advanced safety technologies to ensure the protection of workers, the environment, and the operational sustainability of industrial facilities.