Reactor runaway temperature excursion
Posted: 19 Jul 2026, 10:04
In a scenario of reactor runaway temperature excursion, what control & safety layers should respond?
That is one of the highest-consequence scenarios in the process industries because temperature rise accelerates reaction rate, which generates more heat, creating a positive feedback loop. According to the LOPA philosophy in Center for Chemical Process Safety guidance and the IEC 61511 functional safety lifecycle, protection should be provided by multiple independent layers—not a single control loop. The basic line of defense is the temperature control loop coming under basic process control system.
Typical actions should include:
Increase cooling water or thermal oil circulation.
Reduce steam or heating medium.
Reduce catalyst addition rate.
Reduce reactant feed.
Adjust recycle ratio.
Slow agitator only if process-specific analysis supports it.