氯碱工艺危险化学品双重预防机制构建与实践

Construction and Practice of Dual Prevention Mechanism for Hazardous Chemicals in Chlor-Alkali Process

摘要: 为解决氯碱工艺危险化学品安全风险管控难题，弥补现有双重预防机制在罐区重大危险源针对性适配不足、智能化监控与现场风险防控需求脱节的问题，本研究基于AQ 3036-2010标准规范与双重预防机制核心要求，采用作业危害分析法与安全检查表法，对氯碱工艺生产、储存及运输全流程的危险有害因素进行系统辨识。研究构建了包含可能性、严重性及可监测性三个维度的风险分级指标体系，运用风险矩阵法确定各风险点的等级，并据此制定差异化的风险管控措施。同时，依据罐区安全监控装备设置要求，设计了硬件感知层、数据传输层、软件支撑层与应用服务层四层架构的智能化监控平台，实现对工艺参数、环境浓度及安全状态的动态监测、三级智能预警及应急联锁控制。在某大型氯碱企业为期一年的实践应用中，风险辨识覆盖率从85%提升至100%，重大风险管控覆盖率达100%；隐患整改完成率从82%提升至98%以上；电解槽超温超压预警准确率达99%，罐区泄漏监测响应及时率达100%；设备完好率从90%提升至98%，人员操作合规率从88%提升至97%，年新增经济效益约800万元，且未发生一般及以上安全生产事故。该双重预防机制有效实现了氯碱工艺危险化学品的风险分级管控与隐患排查治理闭环管理，显著提升了企业安全绩效，可为氯碱行业及相关高危化工领域的安全管理提供可复制的技术方案与实践经验。

Abstract: To address the safety risk control challenges of hazardous chemicals in the chlor-alkali process and to fill the gap in the existing dual prevention mechanism regarding the insufficient targeted adaptation to major hazards in tank areas and the disconnection between intelligent monitoring and on-site risk control needs, this study, based on the AQ 3036-2010 standard and the core requirements of the dual prevention mechanism, utilized the Job Hazard Analysis and Safety Checklist methods to systematically identify hazardous and harmful factors throughout the entire process of production, storage, and transportation in the chlor-alkali process. A risk classification index system encompassing three dimensions of possibility, severity, and detectability was established. The risk matrix method was employed to determine the risk levels of each risk point, and differentiated risk control measures were formulated accordingly. In accordance with the requirements for the installation of safety monitoring equipment in tank areas, a four-layer intelligent monitoring platform was designed, including hardware perception layer, data transmission layer, software support layer, and application service layer, to achieve dynamic monitoring of process parameters, environmental concentrations, and safety conditions, as well as three-level intelligent early warning and emergency interlock control. During a one-year practical application in a large chlor-alkali enterprise, the risk identification coverage rate increased from 85% to 100%, and the coverage rate of major risk control reached 100%; the completion rate of hidden danger rectification rose from 82% to over 98%; the accuracy rate of over-temperature and over-pressure early warning for electrolytic cells reached 99%, and the timely response rate of tank area leakage monitoring was 100%; the equipment integrity rate increased from 90% to 98%, and the compliance rate of personnel operations rose from 88% to 97%, with an annual increase in economic benefits of approximately 8 million yuan, and no general or higher-level production safety accidents occurred. This dual prevention mechanism effectively achieves closed-loop management of risk classification control and hidden danger investigation and governance for hazardous chemicals in the chlor-alkali process, significantly enhancing enterprise safety performance, and can provide replicable technical solutions and practical experience for safety management in the chlor-alkali industry and related high-risk chemical fields.