Identification of critical operational hazards in a biogas upgrading pilot plant through a multi-criteria decision-making and FTOPSIS-HAZOP approach

Abstract

The hazard and operability analysis (HAZOP) is one of the most popular approaches for risk management, although weaknesses such as the limited number of risk factors considered, the inaccuracy of experts’ opinions or the limited process knowledge might compromise the quality of the results. In this context, conventional HAZOP analysis can be improved via a Fuzzy Multi-Attribute HAZOP technique. Under a fuzzy logic, Analytic Hierarchy Process and the Technique for Order of Preference by Similarity to Ideal Solution can be combined with Fuzzy Multi-Attribute HAZOP to determine the weight of risk factors and to rank critical hazards. The inherent risks biogas upgrading, such as explosiveness, overpressure, or premature deterioration of equipment, should be identified for planning of critical control points and for enabling a proper maintenance plan. Previous models were applied to a photosynthetic biogas upgrading and a biogas-to-polyhydroxyalkanoates production pilot plant in order to identify and get more information about associated risks of the operation of these valorization biotechnologies, sometimes not fully provided by HAZOP analysis. Biotrickling filter and the polyhydroxyalkanoates production tank were identified as the most critical subsystems, with contributions of 33.3% and 17.8% to the overall risk, respectively (within quartile 1, Q1). Additionally, biogas and recycling/feeding streams clustered a large number of operational risks (up to 83.4% of total risk within Q1). The sensibility analysis demonstrated the reliability and robustness of the final ranking. The results of this analysis will support preventive maintenance by identifying critical monitored points when scaling-up biological biogas upgrading processes.