There are different well-established strategies for making a process plant inherently safer. The benefits of applying these strategies on reducing the overall risk inside a plant are obvious.However, some of these changes are rejected many times because they appear to be too costly.But if the effects of applying inherently safer design strategies are investigated not only on the processing costs of a plant but also on the potential accident costs, the decision would in fact be different. In this paper an optimization procedure is proposed which integrates both processing and accident costs for different design schemes. In this procedure, some of the design variables are chosen with regard to inherently safer design strategies. The objective function is the sum of accident costs and plant lifecycle processing costs. For assessing accident costs, consequence modeling techniques and probit functions are applied. Consequence modeling formulas and an objective function are codified in an optimizer package (MATLAB) and to accomplish the optimization process a process simulator (called HYSYS) is coupled with this package. The application of the proposed procedure is demonstrated by selecting an optimum process scheme for a Refrigeration plant as a case study.

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