The objective of this research was to design a pilot scale continuous supercritical fluid extraction (SFE) system for the treatment of drill cuttings.The design includes: • A Piping and instrumentation diagram (P&ID) • A control philosophy • An operation manual, and • A HAZOP analysis The pilot scale SFE system was designed using a HAZOP-inspired framework, which resulted in the inclusion of risk reducing measures. This design approach was appropriate for the design of a novel technology, as risk reduction was made the inherent priority throughout the process. No major changes were made to the design during the professionally conducted safety analysis (HAZOP), thus the design is considered to be well positioned to operate safely. Recommended, non-critical future design improvements include: • Separation of the process control from the safety control systems • Continuous reduction of “human factors”, and • Review of all changes to the design before implementation