In the process industry, the production of isocyanates involves numerous technological and chemical risks that can seriously endanger the health and safety of employees. In this master’s thesis, we examined the isocyanate production process, using the HAZOP and FMEA methods to analyze potential risk scenarios, identify critical points, and assess the probability, detectability, and consequences of potential incidents. The theoretical part presents the properties and use of isocyanates, applicable legal regulations, key safety standards, and the hierarchy of technical and organizational measures for risk management. The analysis covered typical hazards such as toxic emissions, uncontrolled exothermic reactions, and mechanical failures, and emphasized the importance of using closed process systems, local ventilation, redundant sensors, and optimization of alarm systems. The FMEA analysis enabled the prioritization of events by significance, revealing that the classical FMEA approach includes methodological limitations due to subjectivity and lack of real process data. Nevertheless, the conducted analysis provided guidelines for improving existing measures, which are also applicable to similar chemical process plants. The findings indicate that for long-term safety improvements, it is reasonable to upgrade existing methods with advanced approaches such as fuzzy logic, cloud models, and integration with the topological model of alarm systems. Based on the results, guidelines were also proposed to extend the existing analysis to storage and transportation phases, as these often pose additional risks. Thus, this thesis contributes to greater awareness of the importance of a preventive approach and provides a useful basis for further development of systematic risk management in the isocyanate production industry.
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