Chemical & Petrochemical
The major-hazard industry par excellence: exothermic reactions, toxic and flammable products, Seveso-classified sites. From steam cracker to fine chemicals, process control rests on risk analysis, safety instrumented systems and a process-safety culture inherited from the largest industrial disasters.
The main families
Bulk intermediates
Steam cracking, olefins and aromatics, polymers. Continuous, very high capacity, strong energy integration.
Acids, bases, gases
Ammonia, chlorine, sulfuric acid, industrial gases. Continuous processes, major toxic and corrosive hazards.
High-value products
Active ingredients, additives, pigments. Often batch production (ISA-88), recipes, traceability, flexibility.
Key challenges
- Runaway reactions — thermal runaway of an exothermic reaction is the number-one hazard. Cooling, inhibition, relief venting, reactor design.
- Major hazard — Seveso — sites above dangerous-substance thresholds are Seveso-classified (Directive 2012/18/EU): safety report, emergency plans, inspection.
- Risk analysis — HAZOP then LOPA determine the protection layers and the SIL of the safety instrumented functions.
- ATEX — gases, vapours AND combustible dusts. Zones everywhere, Ex marking on every device.
- Toxicity & REACH — substance registration and control (REACH regulation), worker exposure, emissions.
Key technologies
Standards & references
In addition, the sector relies on the Seveso III directive (2012/18/EU) for major-hazard control, on REACH (EC 1907/2006) for substances, and on NAMUR recommendations for process instrumentation.
- IEC 61511 — Functional safety for process (SIS)
- IEC 61508 — Base functional safety standard
- ISA-88 — Batch control
- ISA-95 — Enterprise / control integration
- IEC 62443 — Industrial cybersecurity
- ATEX Directive 2014/34/EU — Ex equipment
- IEC 60079-0 — Explosive atmospheres, general
- NAMUR NE 43 — 4-20 mA fault signalling
Major players
Chemical producers
BASF, Dow, SABIC, INEOS, LyondellBasell, Covestro, Solvay, Arkema, Air Liquide, Linde.
Engineering & EPC
Technip Energies, thyssenkrupp Uhde, Linde Engineering, Worley, Fluor.
Automation & DCS
Emerson DeltaV, Honeywell Experion, Yokogawa CENTUM, ABB 800xA, Siemens PCS 7.
Safety systems
HIMA, Schneider Triconex, Honeywell Safety Manager, Yokogawa ProSafe-RS.
Landmark accidents
Modern process safety was born from these disasters. Each shaped a regulation or practice still in force today.
| Event | Year | Location | Lesson |
|---|---|---|---|
| Flixborough | 1974 | United Kingdom | 28 deaths. Cyclohexane vapour cloud explosion. Birth of major-hazard regulation and modern process safety. |
| Seveso | 1976 | Italy | Dioxin release. Gave its name to the European "Seveso" directive on major-hazard sites. |
| Bhopal | 1984 | India | Methyl isocyanate (MIC) leak; thousands dead. The worst industrial disaster in history. Inherent design, minimal storage, barriers. |
| AZF Toulouse | 2001 | France | 31 deaths. Ammonium nitrate explosion. Tightened site classification and land-use control around plants in France. |