DOI: https://doi.org/10.36347/sjet.2026.v14i05.004

Pages: 222-232

High-temperature chemical reactors are critical components in modern manufacturing systems, yet they pose significant safety challenges due to thermal instability and the risk of runaway reactions. This study presents an integrated framework for risk-resilient process safety design and operational optimization of high-temperature chemical reactors. The proposed methodology combines physicochemical reactor modeling, dynamic simulation, safety assessment, and constrained optimization into a unified approach. Key safety metrics, including processing safety time and safety index, are incorporated to quantify risk and define safe operating limits. The results demonstrate that reactor performance is highly sensitive to operating conditions, with elevated temperatures and concentrations significantly increasing the likelihood of thermal runaway. The analysis shows that improved heat transfer enhances thermal stability, although with diminishing returns at higher coefficients. Furthermore, the optimization framework successfully identifies operating conditions that balance product yield and safety, highlighting the trade-off between performance maximization and risk minimization. Overall, the study establishes that integrating safety constraints directly into the optimization process enables the development of resilient and efficient reactor systems. The proposed framework provides a systematic and reproducible approach for improving both safety and performance in high-temperature chemical reactor operations.