An alternative design approach to avoid or minimize the toxic release accidents using an inherent safety concept was presented. A process design tool was developed by the integration of process design simulator, iCON from PETRONAS with toxic release consequence model created in MS-Excel spreadsheet. The toxic release consequence was validated with case studies from established literatures and the results are in good agreement. The results of the case study demonstrated that the integrated consequence tool can evaluate the consequence of toxic release during preliminary design stage hence providing critical information that can be used to improve process plant safety. This is an abstract of a paper presented at the 19th International Congress of Chemical and Process Engineering and 7th European Congress of Chemical Engineering (Prague, Czech Republic 8/28/2010-9/1/2010).