It’s dangerous! What preparations should be made before the commissioning of a new chemical plant project?

Make efforts to carry out proper staff training, including simulations for emergency plan training, as part of preventive measures

The entire process flow must be memorized, with contingency plans and emergency solutions in place for each stage, as well as training and assessments for the operators. In short, safety first

I would like to ask about the production experience of similar factories in China! ! Prepare plans to handle various accidents! !

We also built a pilot-scale industrial plant before, and it was again related to flammable, explosive, and toxic substances as mentioned by LZ. So, I have a deep understanding of it. In my opinion, first of all, one should not rush into testing the vehicle blindly. All personnel involved in the test drive must receive centralized training. It’s not just the processes and equipment. The most important thing is the properties of the device and all the materials involved in each step of the reaction. Second, be fully mentally prepared – industrial testing differs from pilot tests of a Chinese style; many unexpected problems may arise, so experienced personnel must be assigned to each stage. Identify and detect problems in a timely manner. Third, as the person in charge of this task, one must have a certain level of expertise, as well as remain calm and composed. Haha, just my personal opinion; for reference only

Judging from the post that posed the question, it should be the fine chemicals (fine intermediates) industry or the chemical pharmaceutical industry. I think those in charge of safety should hire an engineer with 30 years of experience in the production of fine chemical intermediates, such as dye intermediates. It also depends on the size of your company. The light chemical industry is looking for an equipment engineer with 30 years of experience. The process engineers require two specialists, one in fine chemicals and one in light chemicals. Then, conduct proper safety training for employees; in companies of this type, training is provided only at the level of team leaders or shift supervisors.

Colleagues: I am deeply grateful to see such enthusiastic participation from all of you! Regarding the discussion above, I would like to add a few more points here. The process for transitioning from pilot-scale production to industrial-scale production in this case involves scaling up the process by 15 times directly based on the pilot results. It deals with an agrochemical intermediate, and all the raw materials involved are chemical hazards. Therefore, we have been preparing for this for quite some time now; these preparations include staff training, calibration of equipment and instruments, individual unit tests of the equipment, joint tests of various components of the system, and the development of emergency response plans. However, due to the novelty of this process, the uncertainties associated with scaling up production, and especially the highly exothermic nature of certain reactions, I, as the person in charge of this project, have been feeling quite anxious. I really hope that colleagues with testing experience can offer more suggestions. Once again, I would like to say thank you to you all! :handshake

The original poster has been very careful; testing requires thorough attention to detail. It is important to have plans in place, but human factors also play a significant role, so attention should be paid to the placement of experienced employees.

Safety first! Especially due to the strong exothermic nature of some reactions, be careful to prevent explosions!

Safety first; try to leave as few people as possible at the test site! After all, the chemical industry is full of uncertainties; anything can happen

Always keep in mind the principle of careful operation and putting safety first. Provide proper employee training to enhance safety awareness.