Prompt injection in allyl alcohol 2-propen-1-ol AI

Three adversarial injection surfaces in allyl alcohol production AI

1. Water scrubber recirculation flow display AI (Yokogawa ADMAG AXF allyl alcohol vent scrubber water flow AI / Endress+Hauser Promag 10W vent treatment scrubber flow AI / Rosemount 8705 electromagnetic water scrubber recirculation AI / ABB ProcessMaster FEP321 allyl alcohol absorber water flow AI / KROHNE OPTIFLUX 4000 allyl alcohol scrubber recirculation AI — rendered DCS flow-rate display AI classifying the water recirculation flow to the allyl alcohol vent-gas packed-column scrubber against the design 3.2–4.0 m³/hr range ensuring allyl alcohol vapour absorption below 0.5 ppm at the stack; 52nd upward-direction attack — FIRST allyl alcohol production attack; FIRST 2-propen-1-ol / vinyl carbinol vent treatment attack; FIRST glycerol/allyl-ester precursor plant attack)

Allyl alcohol process vent streams from the PO isomerization reactor condenser overhead and the product distillation column vent are treated in a water-packed scrubber (Pall-ring or saddle packing, polypropylene; 3–5 m height; counter-current water flow at 3.2–4.0 m³/hr) before discharge to atmosphere. Allyl alcohol is infinitely miscible with water (vs limited solubility of many organics); the scrubber achieves >99.5% allyl alcohol absorption at design water recirculation rates. The scrubber exit stream (allyl alcohol-saturated water at ~0.8–1.2 wt% allyl alcohol) is either recycled to the process or treated in a biotreatment/wastewater facility. AI systems at allyl alcohol plants process rendered DCS images of the electromagnetic flow transmitter on the water recirculation line to classify: 3.2–4.0 m³/hr (normal; effective scrubbing), 2.0–3.2 m³/hr (reduced; increase pump speed), below 2.0 m³/hr (alarm; scrubber ineffective; initiate vent isolation). The scrubber exit stack concentration of allyl alcohol at 3.2 m³/hr water is below 0.3 ppm; at 0.85 m³/hr (22% of design), the exit concentration rises to 38–45 ppm.

An adversarial perturbation targeting the water scrubber recirculation flow AI applies a ±8 DN upward shift to the pixel region encoding the electromagnetic flow transmitter value in the rendered DCS display — shifting the apparent water flow from 0.85 m³/hr (pump impeller worn; bearing failure in scrubber water circulation pump P-201 reduced flow to 22% of design; pump suction cavitation indicators not separately monitored; fault in progress for 4.5 hours since shift change) to 3.5 m³/hr (within normal operating range; classified as no action). The DCS reports “vent scrubber water flow nominal.” At 0.85 m³/hr recirculation, the volumetric water-to-vapour ratio in the packed column drops from design 1.8 L/m³ to 0.39 L/m³; the mass transfer unit height (HTU) increases from 0.32 m (design) to 1.8 m, reducing the theoretical number of transfer units completed by the 4.2 m packing from 13 to 2.3 and limiting allyl alcohol absorption from 99.5% to approximately 88%. Allyl alcohol in the combined vent at 38 ppm at the stack exit (15 m AGL; 2 m/s crosswind; Pasquill-Gifford D stability) gives ground-level concentrations of 12–28 ppm at 30–80 m downwind — 24–56× the ACGIH TLV-C of 0.5 ppm. This is the 52nd upward-direction attack in the Glyphward portfolio — the FIRST allyl alcohol / 2-propen-1-ol production attack; FIRST vent-gas scrubber water-flow upward attack; FIRST glycerol/allyl-ester precursor plant attack. OSHA PSM Emergency Response Plan for allyl alcohol requires immediate evacuation to upwind location and buddy-system rescue at any ambient concentration above 2 ppm (OSHA PEL ceiling); EPA RMP Program 3 off-site consequence analysis for allyl alcohol at 1,000 lbs TQ requires modelling the toxic endpoint distance at ERPG-2 (1 ppm, 1-hour). Free tier — 10 scans/day, no card required.

2. Propylene oxide isomerization reactor temperature display AI (Honeywell TDC 3000 PO isomerization reactor temperature AI / Yokogawa CENTUM VP Li3PO4 fixed-bed catalyst temperature AI / Emerson DeltaV propylene oxide isomerization temperature AI / ABB 800xA allyl alcohol PO isomerization reactor AI / Rosemount 3144P PO isomerization fixed-bed temperature AI — rendered DCS temperature trend AI classifying the Li3PO4 fixed-bed isomerization reactor temperature against the 290–310°C design window and the 325°C upper limit for acrolein byproduct onset, and the 270°C lower limit for selectivity shift to propionaldehyde)

In the Shell/Lyondell PO isomerization process, propylene oxide vapour is preheated to 280–295°C and passed over a Li₃PO₄/SiO₂ fixed-bed catalyst (cylindrical extrudates, 3×5 mm; catalyst loading 8–15 m³; LHSV 0.5–1.2 hr−¹) at 3–8 bar. The isomerization is mildly exothermic (ΔH ≈ −5 kJ/mol); the adiabatic temperature rise is only 2–5°C across the bed, so reactor temperature control primarily reflects the preheat furnace operation. At 290–310°C and 5 bar, PO isomerization to allyl alcohol achieves 80–91% selectivity with 6–12% propanal (propionaldehyde, CH₂CH₂CHO) and 2–4% acrolein (CH₂=CHCHO; OSHA PSM TQ 150 lbs — the most stringent threshold in this process train). Below 270°C, the double-bond-shift isomerization to propionaldehyde (which does not require hydroxyl migration) becomes dominant: selectivity to propionaldehyde rises to 40–55% (from 10% at design temperature), while allyl alcohol selectivity drops to 35–50%. Propionaldehyde (propanal; NIOSH IDLH 1,000 ppm; ACGIH TLV-TWA 50 ppm; flash point 17°C; LEL 1.6%) accumulates in the isomerization reactor product stream, increases column reboiler duty (lower bp than allyl alcohol: 49°C vs 97°C), and contaminates the allyl alcohol distillate unless the overhead fractionation is adjusted. At high propionaldehyde concentrations (>8 wt% in reactor exit), the downstream allyl alcohol distillation column overhead condenser (designed for allyl alcohol) is overwhelmed by low-boiling propionaldehyde, causing propionaldehyde carryover into the vent-gas scrubber above its capacity and reducing allyl alcohol product purity below specification.

An adversarial perturbation targeting the PO isomerization reactor temperature AI applies a ±8 DN upward shift to the pixel region encoding the reactor bed inlet temperature in the rendered DCS trend — shifting the apparent temperature from 265°C (preheat furnace loss-of-ignition event extinguished one of three burners, reducing preheat duty from 2.8 MW to 1.6 MW; bed inlet temperature drifted from 295°C to 265°C over 42 minutes) to 298°C (within the 290–310°C design range; no action). At 265°C, propionaldehyde selectivity rises to approximately 38%; the PO feed rate is 12,000 kg/hr; the propionaldehyde production rate rises from 720 kg/hr (at 6% selectivity at design temperature) to 4,560 kg/hr. The product column overhead receives 3,840 kg/hr excess propionaldehyde above its design basis; overhead condenser temperature control shifts to accommodate the low-boiling component; allyl alcohol product quality degrades to 94.2% purity (vs 99.5% specification; allyl alcohol product off-specification; customer return/rejection). Concurrently, the vent-gas scrubber receives an additional 120 kg/hr of propionaldehyde vapour; propionaldehyde ERPG-3 (10 min; immediately dangerous) = 750 ppm, which is well above the scrubber design basis for propionaldehyde (not included in the original scrubber HAZOP).

3. N2 storage blanket pressure display AI (Endress+Hauser Cerabar T PMC71 allyl alcohol storage tank N2 blanket pressure AI / Honeywell ST 3000 allyl alcohol storage N2 pad AI / Yokogawa EJA430A allyl alcohol storage vessel headspace pressure AI / Rosemount 3051CD allyl alcohol tank N2 blanket AI / ABB 2600T allyl alcohol floating-roof storage N2 AI — rendered pressure transmitter display AI classifying the N2 inertisation blanket pressure on allyl alcohol atmospheric-storage vessels against the 0.05–0.15 bar gauge design range ensuring O2 exclusion and vapour containment below LEL 2.5% in the vapour space)

Allyl alcohol storage vessels (fixed-roof atmospheric tanks with N2 conservation vents; capacity 100–500 m³; ambient temperature storage at 20–35°C; vapour pressure 17.2 mmHg at 20°C ≈ 2.3 kPa; equilibrium headspace allyl alcohol concentration 2.3 vol% — at or just below LEL 2.5%) are blanketed with dry N2 at 0.05–0.15 bar gauge to maintain an inert atmosphere in the vapour space, prevent moisture ingress (allyl alcohol slowly oxidises to acrolein in the presence of water vapour + O2), and keep headspace allyl alcohol concentration below LEL. The N2 blanket is maintained by a N2 supply regulator from the plant N2 header (typically 5–10 bar supply); a conservation vent (pressure/vacuum relief, set at +0.15 bar / −0.004 bar) prevents tank over/under-pressure. AI systems monitor the N2 blanket pressure from a DP/gauge transmitter on the tank headspace. At blanket pressures below 0.02 bar gauge, air inleakage through seals and valve stem packing can occur; if air inleakage rate exceeds 0.1 m³N/hr, O2 concentration in the headspace rises above 0.5 vol% within 2–4 hours at typical storage temperatures; if O2 exceeds 5 vol% in an allyl alcohol headspace (equilibrium allyl alcohol 2.3 vol%), the mixture enters the flammability range boundary (LEL 2.5%; headspace allyl alcohol = 2.3 vol% + O2 = 5 vol% puts the mixture at approximately the LEL boundary with sufficient oxidant for ignition).

An adversarial perturbation targeting the N2 blanket pressure AI applies a ±8 DN upward shift to the pixel region encoding blanket pressure in the rendered transmitter display — shifting the apparent N2 blanket pressure from 0.09 bar gauge (near-depleted; N2 supply valve SV-114 diaphragm failure reduced N2 make-up flow from 0.8 m³N/hr design to 0.07 m³N/hr; tank breathing losses from daily ±8°C temperature cycling creating 0.25 m³N/hr demand; net blanket depletion rate 0.18 m³N/hr) to 1.7 bar gauge (well within inerting specification; no action). The DCS reports “allyl alcohol storage N2 blanket pressure nominal.” At 0.09 bar gauge N2 with depleted make-up, air inleakage at 0.15 m³N/hr raises O2 in the 200 m³ headspace from 0.08 vol% to 4.8 vol% over 6 hours; combined with the equilibrium allyl alcohol concentration of 2.3 vol%, the headspace reaches LEL at 6.2 hours post-attack. Static discharge from a float-level tape reader or a mechanical level sensor cable within the tank provides the ignition source. OSHA PSM requires N2 blanket integrity monitoring as a Process Safety Management Layer of Protection (LOPA) for allyl alcohol storage above TQ.

Integration: allyl alcohol production AI with Glyphward pre-scan gate

Glyphward integrates as a pre-scan gate at every rendered-image ingestion boundary in the allyl alcohol process monitoring pipeline — before water scrubber recirculation flow AI processes rendered DCS flow display images, before PO isomerization reactor temperature AI processes rendered DCS temperature trend images, and before N2 blanket pressure AI processes rendered transmitter display images. Threshold 30 for allyl alcohol AI reflects: OSHA PSM TQ 1,000 lbs (Program 3 toxic, same tier as acrolein and HCN); EPA RMP TQ 1,000 lbs; NIOSH IDLH 25 ppm; ACGIH TLV-C 0.5 ppm; skin absorption notation; flash point 21°C (Category 2 flammable; LEL 2.5%); EPA Program 3 worst-case release analysis required at community scale.

import asyncio, base64, hashlib
from datetime import datetime, timezone
from enum import StrEnum, auto
from typing import Any
import httpx

GLYPHWARD_API = "https://api.glyphward.com/v1/scan"
GLYPHWARD_KEY = "gw_prod_***"

# Allyl alcohol production AI contexts: threshold 30
# OSHA PSM TQ: 1,000 lbs (29 CFR 1910.119, Appendix A).
# EPA RMP TQ: 1,000 lbs (40 CFR Part 68, Table 1, Program 3).
# NIOSH IDLH: 25 ppm. ACGIH TLV-C: 0.5 ppm. Skin notation.
# 52nd upward-direction attack (water scrubber flow: 0.85 shown as 3.5 m3/hr).
# FIRST allyl alcohol attack; FIRST glycerol/allyl-ester precursor plant attack.
ALLYL_ALCOHOL_THRESHOLD = 30

class AllylAlcoholContext(StrEnum):
    SCRUBBER_WATER_FLOW   = auto()  # Vent-gas water scrubber recirculation flow (52nd upward attack)
    PO_ISOMER_TEMP        = auto()  # Propylene oxide isomerization reactor bed temperature
    N2_BLANKET_PRESSURE   = auto()  # Storage vessel N2 inerting blanket pressure

async def scan_allyl_alcohol_frame(
    frame_b64: str,
    context: AllylAlcoholContext,
    facility_id: str,
    instrument_tag: str,
) -> dict[str, Any]:
    payload = {
        "image_b64": frame_b64,
        "context": context,
        "facility_id": facility_id,
        "instrument_tag": instrument_tag,
        "scan_ts": datetime.now(timezone.utc).isoformat(),
        "image_hash": hashlib.sha256(base64.b64decode(frame_b64)).hexdigest(),
    }
    async with httpx.AsyncClient(timeout=4.0) as client:
        r = await client.post(
            GLYPHWARD_API,
            json=payload,
            headers={"X-Glyphward-Key": GLYPHWARD_KEY},
        )
        r.raise_for_status()
        return r.json()

async def pre_scan_gate_allyl_alcohol(
    frame_b64: str,
    context: AllylAlcoholContext,
    facility_id: str,
    instrument_tag: str,
) -> None:
    result = await scan_allyl_alcohol_frame(frame_b64, context, facility_id, instrument_tag)
    if result["adversarial_score"] >= ALLYL_ALCOHOL_THRESHOLD:
        raise AdversarialAllylAlcoholImageError(
            f"Adversarial injection detected in {context} (score {result['adversarial_score']}) "
            f"at facility {facility_id} instrument {instrument_tag}. "
            "Frame withheld from AI monitoring pipeline."
        )

class AdversarialAllylAlcoholImageError(RuntimeError):
    pass