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Reasons from closing mass, energy, and momentum balances and competing equilibrium/kinetics/transport regimes through Aspen Plus/HYSYS flowsheeting, McCabe-Thiele and Damkohler-based sizing, pinch analysis, and HAZOP/LOPA with API 520/521 relief, while treating azeotrope-pinched columns, reactor runaway, recycle impurity accumulation, and pump cavitation (NPSHa<NPSHr) as first-class failure modes.