Study on Risk Analysis of a Rotary Kiln-Based Activated Carbon Manufacturing Process Using Fuzzy-FMEA

Abstract

Rotary kiln-based activated carbon production combines high-temperature operation with flammable/reducing gases, carbonaceous dust, and downstream off-gas treatment and acid/base washing, creating complex escalation pathways. This study prioritizes safety improvements by applying classical failure modes and effects analysis (FMEA) and a transparent Fuzzy-FMEA framework to 18 representative failure modes (six each for kiln/activation, acid/base handling, and atmosphere/control). Five experts evaluated Severity, Occurrence, and Detection on a 10-point scale. The fuzzy model used triangular membership functions (L/M/H), a monotonic 27-rule base, Mamdani max–min inference, and centroid defuzzification to compute a continuous fuzzy risk priority number (FRPN, 0–10). Classical FMEA identified dust explosion (RPN = 405), temperature control failure (RPN = 378), and off-gas leakage (RPN = 324) as the highest-ranked risks. Fuzzy-FMEA preserved the top-risk group while more strongly highlighting barrier-related risks, placing off-gas leakage, instrumentation/interlock failure, and electrostatic ignition control alongside dust explosion (FRPN 9.221–9.332). The rankings were strongly correlated (Spearman ρ = 0.871; Kendall τ = 0.752), yet mid-risk items were rearranged (mean |Δrank| = 2.06; max = 5), improving discrimination within tied RPN clusters. The five highest-priority scenarios were reconstructed into actionable engineering packages, including dust and ignition control, off-gas integrity linked to shutdown logic, interlock proof testing and bypass management, and independent protection layers for kiln temperature control.