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Mainly in the first part of COVID-19 pandemics, sodium hypochlorite was used as disinfectant, surprisingly also to spray over people. Several hazards may be associated to the production of this compound, such as chlorine gas toxicity and explosive hazards, due to the presence of hydrogen and chlorine, and corrosive hazards. Thus, loss prevention strategies must be ad-hoc developed to mitigate the risks. In the present work, the risk assessment of the first block of the process was performed, focusing the attention on chlorine risks. To this end, HAZOP analysis was first performed to identify the most critical top event, noticing the major issues in the quality of the final product and in the release of chlorine from pipes. Then, the fault tree analysis was built to calculate its failure rate. CFD simulations were used instead of empirical model to assess with a rigorous approach the chlorine dispersion, taking into account all the boundary conditions. In particular, by setting a hazardous chlorine concentration of 180 ppm corresponding to 50% fatalities for chlorine exposition for an exposure of 60 min, results without aspiration demonstrate the possibility for the cloud to impact workers at ground level also very far from the source point, while the chlorine cloud is moved upwards with a maximum length of 6.5 m when an aspiration is used, although the air ventilation speed is kept low.

Several studies have shown that combining TiO2 and Cu2O enhances the photocatalytic activity of the material by generating a heterojunction capable of extending the light absorption in the visible and reducing the electron-hole recombination rate. Ball milling has been chosen as an alternative methodology for photocatalyst preparation, among the several techniques documented in the literature review. The results of a previously reported investigation enabled the identification of the most effective photocatalyst that can be prepared for hydrogen generation by combining Cu2O and TiO2 (i.e., 1%wt. Cu2O in TiO2 photocatalyst prepared by ball-milling method at 200 rpm and 1 min milling time). To optimize photocatalytic hydrogen generation in the presence of the greatest photocatalyst, the effects of (i) sacrificial species and their concentration, (ii) temperature, and (iii) pH of the system are taken into account, resulting in a light-to-chemical energy efficiency of 8% under the best-tested conditions. Last but not least, the possibility of using the present photocatalytic system under direct solar light irradiation is evaluated: the results indicate that nearly 60% of the hydrogen production recorded under sunlight can be attributed to the visible component of the solar spectrum, while the remaining 40% can be attributed to the UV component.

Sodium hypochlorite poses explosive hazards associated with its complex reactive chemistry. The production process of sodium hypochlorite consists of a first block where the chlorine, caustic soda and hydrogen are produced in an electrolytic cell from brine and a second block where chlorination of caustic soda to form hypochlorite is carried out. This process is characterized by several hazards such as chlorine gas toxicity, explosive hazards due to the presence of hydrogen and chlorine and corrosive hazards. Loss of control of such substances has the potential to cause high-consequence low-probability events. Thus, specific safety measures have to be designed to mitigate risk. In the present work, the risk assessment of the first block of the process is performed, focusing on hydrogen risks. To this end, HAZOP analysis was performed to identify the top events. For each top event, based on properly developed fault trees, the frequency analysis was performed. Eventually, the consequence analysis was carried out by the simulation of phenomena leading to dispersion and consequent ignition of the cloud as function of the distance from the source. Simulations were performed by means of the software PHAST.