Developing a Risk Index for Pilot and Research-scale Process Operations

Pilot and research-scale process facilities pose safety challenges distinct from industrial plants, due to dynamic configurations, novelty and data uncertainty, and a strong reliance on non-routine operations and human intervention; consequently, traditional process safety methods, while essential, are not always ideal for rapid screening and comparison in academic R&D settings. This work proposes a structured safety index for pilot and research-scale operations, integrating four complementary dimensions: process and substance hazards, design and mechanical integrity, operations and human factors, and technical barriers and emergency readiness. The index adopts a discrete scoring system and is intended for comparative prioritization rather than predictive risk quantification. The methodology is demonstrated on a pilot-scale Fischer–Tropsch unit, showing that configuration-dependent and operational factors dominate the risk profile, while intrinsic hazards are partially offset by limited inventories and data maturity. The approach supports transparent safety management and helps target follow-up analyses. Future work will focus on broader validation across different pilot facilities and experimental campaigns, as well as on integrating the index with quantitative risk assessment to evaluate release consequences and potential escalation scenarios.