Kcil Hazop Study Report

Prepared By M/s. Kutch Chemical Industries Limited Page : 1 HSE Department Rev. : 00

Kutch Chemical Industries Limited

Survey No 166/1,2,3, 171/1, 172,167,168, Village : Padana

Gandhidham, Dist. Kutch

Hazard & Operability Study

(FOR DESUR DEPOT EXISTING FACILITIES AND PROPOSED FACILITIES)

PREPARED BY

VAIBHU SAFETY CONSULTANTS FF-11, Akshat Complex,

Nr. Reliance Petrol Pump, High Tension Road, Subhanpura,

Vadodara-390 023 Phone: 9825756467/9427838021 (M)

Ph : 0265-2395798


ACKNOWLEDGEMENT

We express our sincere thanks to management of Kutch Chemical Industries Ltd

for providing unstinted support during the HAZOP Study without which the

HAZOP study could not have been possible. The courtesy extended to our team is

highly appreciated.


CERTIFICATE We are pleased to certify that this HAZOP Study Report of Company has been conducted by us. HAZOP STUDY is a legal requirement as per the rules 10 to 13 under Manufacture, storage and import of Hazardous chemicals rules, 2000 and environment (protection) Act, 1986. It is obligatory of the occupier to carry out a "HAZOP Study", as required under item no. (II) (2) of the format for application of the Site Appraisal Committee and as per the Schedule 1 of the Factories Act under Section 2(CB) - Item No. 11 of the Schedule. The Executive Summary is given in the beginning to highlight the important summary of our report and methodology of the HAZOP Study carried out. FOR VAIBHU SAFETY CONSULTANT

Authorized Signatory


CONTENTS

SECTION NO.

CONTENTS

NO. OF PAGES

1 Objective and Methodology of HAZOP Study

8

1.1 Objectives 8 1.2 Scope of The Work 8 1.3 Methodology 8 2 Introduction to HAZOP

10

2.0 Hazard and Operability Study 10 3 Introduction Of the Unit

13

3.1 Introduction of the unit 13 3.2 Details of Unit 13 3.3 Google map 20 3.4 Site Plan 21 3.5 Organisation chart 22 3.6 Details of storage of Hazardous Materials in Bulk 22 3.7 Facilities / System 28 3.8 Process Flow chart 29 4 HAZOP Sheets 49


LIST OF TABLES

TABLE NO.

CONTENTS

Page No.

Table- 4.1 Hazop Study Worksheet (Transferring of Chlorsulfonic Acid to service tank)

50

Table- 4.2 Hazop Study Worksheet (Charging of Acetanilide) 51 Table- 4.3 Hazop Study Worksheet (Reaction) 52 Table- 4.4 Hazop Study Worksheet (Dumping) 53 Table- 4.5 Hazop Study Worksheet (Reduction) 54 Table- 4.6 Hazop Study Worksheet (Condensation) 55 Table- 4.7 Hazop Study Worksheet (Esterification) 57 Table- 4.8 Hazop Study Worksheet (E. O. storage tank) 58 Table- 4.9 Hazop Study Worksheet (From outlet of storage

tank to inlet of batch tank) 61

Table- 4.10 Hazop Study Worksheet (Raw material to the storage tank ( Day Tank ))

63

Table- 4.11 Hazop Study Worksheet (Reaction Process) 64 Table- 4.12 Hazop Study Worksheet (Chilling of the HCL) 65 Table- 4.13 Hazop Study Worksheet (Gas cleaning) 66 Table- 4.14 Hazop Study Worksheet (Reaction) 67 Table- 4.15 Hazop Study Worksheet (Melting of Sulfur) 68 Table- 4.16 Hazop Study Worksheet (Burning of sulfur with

air) 69

Table- 4.17 Hazop Study Worksheet (Catalyst convertor) 70 Table- 4.18 Hazop Study Worksheet (Rector) 71 Table- 4.19 (Gas mixture) 72 Table- 4.20 Hazop Study Worksheet (High Boiler fractional

Distillation Column) 74

Table- 4.21 Hazop Study Worksheet (Final Product Distillation Column)

75

Table- 4.22 Hazop Study Worksheet (Reaction of Chlorine) 76 Table- 4.23 Hazop Study Worksheet (Reaction) 78 Table- 4.24 Hazop Study Worksheet (Reaction) 80 Table- 4.25 Hazop Study Worksheet (Distillation) 81


HAZOP SUMMARY

HAZOP SUMMARY

SR. NO. OBSERVATION AREA SUMMARY 1 UTILITY SERVICES Utility is the heart of the chemical process industries. All the

critical equipment shall be connected with the D. G. Set. Company has their own captive power plant. Overhead water tank for cooling operation shall be provided. Under worst case of GEB & DG failure cooling operation shall not be suffered. Stand by pump for cooling shall be provided . All the utilities line shall be provided with arrow indicators & content . this not only help of for better production but also help during the emergency it avoid the human error. A system shall be devised to maintain the sufficient quantity of water in the seal pot & scrubber to prevent escape of EO gas in the atmosphere. Common Dump tank shall be provided in the plant. The capacity of the same shall be the 1.10 times the biggest reactor in the plant. Written check procedures are not available for the checking the leak point in Vessel & piping system. Human errors may occurs during the verbal check. Written procedures shall be developed. Periodic inspection of the Sulfur burner to be ensured. To handle the chlorine emergency chorine kit to be ensured and maintained in tip top condition at all time. Flange guards needs to be provided on Acid lines. Non return Valve to be provided on pump discharge line. Arrow indicator to be provided on pipeline. Pump, storage tank & pipe line identification to be done. Color code for pipelines to be provided as per IS 2379. Periodic checking of the condenser to be followed

2 STORAGE OF CHEMICALS All the storage has been provided with the separate area. All statutory norms are followed. It should be made restricted entry. A register shall be maintained. Double Static earthing to be provided to flammable material storage tanks as well as pipelines and powder handling machines. Electrical earthing to be checked and record to be maintained and resistance to be maintained below 1 OHMs .


Safety valve Pressure gauges and other safety devises to be maintained in working condition and testing and calibration to be done once in a year. Thickness measurement to be done for all storage tanks and comparison records to be maintained. Tank ID, content and capacity to be displayed on each tanks and reactors.

3 INSTRUMENTATION Instrumentation has to play key role in the maintenance of process parameters. All the interlocks shall be tested every month. And the records shall be maintained. All the instruments shall be calibrated before the date expires. Calibration date for safety valve, shall be displays at site only. Functioning of Instrumentation depend on the well supply of air. Under no circumstances the air pressure shall be reduced. The DMS & H2SO4 plant are DCS operated. E. O. flow cutoff to be provided in connection with the temperature rise in VS plant.

4 ENVIRONMENTAL The organization has taken care of environment by converting all the by product into useful product. The concept of reduce, recycle & reuse has been vigorously followed. The generation of effluents is also well controlled.

5 ADMINISTRTION Standard Operating procedures to be prepared. Work permit procedures to be followed for the handling of hazardous chemicals.

6 GENERAL Use of Personal Protective Equipment (PPE ) are not found during the various plant operation. PPE matrix shall be defined for all the process activity. Alarms for vacuum failure in the dehydration shall be considered. Stand by pump for reflux system shall be provided in distillation section. Hot oil circulation line shall be inspected at least once in a month.


CHAPTER I

OBJECTIVE AND METHODOLOGY OF HAZOP STUDY 1.1 Objective :

The specific objectives of the study are- • Identification and assessment of major hazards potential in the storage and handling of

petroleum products inside the depot.

• Study of built- in- safety measures and operational safety precautions in practice.

• Identification and assessment of major hazards potential in the process equipment.

• Suggesting measures to reduce risk by reducing hazard and reducing probability.

1.2 SCOPE OF THE WORK

The principal objective of this study is to evaluate the potential hazards to the plant.

• To evaluate the process safety system of plant from the safety point of view

considering the structural / electrical / instrumentation aspects.

• To evaluate the system provided to protect fire & explosion in product pipe line and

system full proof.

• Evaluate the maintenance & operation system of the Terminal.

• Evaluate provided control parameters and instrumentation.

• Suggest better system for safe operation & maintaining plant in a safe manner.

1.3 METHODOLOGY

Design data, built in safety systems are studied. Discussions are held with Officials.

Safety related individual system is discussed with HAZOP team member.

HAZOP exercise is conducted taking into consideration of each and every equipments,

storage tanks, Tank truck filling gantry, pump house, pipe lines, operating procedures,


built in safety system, operating parameters and existing safety measures. Thus, this study

is mainly oriented towards actual risks rather than chromic risks.

Possible causes of the possible events will be derived and consequences effect of such

events will be discussed and required recommendation and follow-up sheet will be

generated for implementation purpose.


SECTION II

INTRODUCTION TO HAZOP 2.0 Hazard and Operability Studies(HAZOP)

2.1 The basic concept of HAZOP is to have an exhaustive review of the plant layout and P& ID

of KCIL. HAZOP study highlights the hidden operability problems and identifies hazards,

which are likely to result from the expected intention of seemingly safe components or

methods of operation.

2.2 This work utilizes imagination of team members to visualize ways in which a terminal can

malfunction or mal-operated. Each part of the plant is subjected to a number of questions

formulated around a number of guide words which are derived from method of study

technique. In effect, the guide words are used to ensure that the questions which are posed to

test integrity of each part of the design to explore every conceivable way in which that

design could deviate from the design intention. This usually produces a number of

theoretical deviations and each deviation is then considered how it could be caused and what

would be consequences.

2.3 HAZOP is a brainstorming approach, which stimulates creativity and procedure for

generating ideas. Possible results of this study are :-

(a) Identify and examining many types of risks.

(b) Identifying non-optimum system reliability.

(c) Suggestive qualitative recommendations regarding control, strategy, material properties,

material releases alternative design option, operation and maintenance.

2.4 The important terms pertaining to HAZOP study are:-

Intention : - The intention defines how the part is expected to operate. This can

take a number of forms and can be either descriptive or

diagrammatic. In many cases, it will be a flow sheet (P & ID)


Deviation : - These are departures from the intention which are discovered by

systematically applying the guide words.

Causes : - These are reasons why deviation might occur. Once a deviation has

been shown to have a conceivable or realistic cause, it can be treated

as meaningful.

Hazards : - These are the results of the deviations

Consequences : - These are the consequences, which can cause damage, injury or loss.

2.5 A list of guide words

Table- 3.1 list of guide words

Guide Words Meanings Comments None Complete negation of

the intention No part of the intention is achieved e.g. no flow or reverse flow.

More of Quantitative increase More of any relevant physical properties than there should be e.g. higher flow (rate or total quantity) higher temperature, higher pressure higher viscosity, more heat, more reaction etc.

Less of Quantitative decrease Less of any relevant physical property than there should be, e.g. Lower flow (rate or total quantity), lower temperature, lower pressure, less heat, less reaction etc.

Part of Quantitative decrease Composition of system different from what it should be e.g. Change in ration of components, component missing etc.

More than Qualitative increase More components present in the system that there should be e.g. extra phase present (Vapor, solid), impurities (air, water, acids, corrosion products etc.)

Other than Substitution What else can happen apart from normal operation e.g. Start up, shutdown, high/low rate running, alternative operation mode, failure of plant services, maintenance, catalyst change etc.

2.6 Guidewords are applied to the design intention. The design intention informs us what the

equipment is expected to do.


NO

Yes

NO

2.7 A flow chart giving HAZOP procedure is given below:-

NO NO Yes

Select Line

Select deviation Eg. More flow

Is more flow possible ?

Is it hazardous or does it prevent efficient

operation ?

Will the operator know that there is more flow ?

What change in plant or methods will prevent the deviation or make it less

likely or protect against the consequences.

Is the cost of change justified

Agree changes. Agree who is responsible for action.

Follow up to see that action has been taken.

Move onto next deviation

Consider other causes of more flow

Consider other changes or agree to accept

hazard.

What change in the plant will tell him


SECTION III

INTRODUCTION OF THE UNIT 3.1. COMPANY INTRODUCTION

M/s. Kutch Chemical Industries Ltd., is operating a manufacturing unit of various chemicals and dye intermediates at Survey No 166/1,2,3, 171/1, 172,167,168, Village : Padana, Gandhidham, Dist. Kutch Produce unit is classified as Major Accident Hazards unit ( MAH Installation ) based on the storage of the listed hazardous chemicals more than specified threshold quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-1963 (2004). Kutch Chemical Industries Ltd, with spot light on export market potential was founded in 2004 near the Global all weather ports of Kandla and Mundra. It consists of a well integrated chemical complex consisting of Chlorination, Nitration, Sulphonation and Dyes Intermediates products.

3.2. DETAILS OF UNITS

Sr. No. Particulars

1. Full Name & Address of Unit

: Kutch chemical Industries limited Plot no- 165,166/1&3,168,171/1&172 Village:Padana, Nr.Aquagel Chemicals, Gandhidham, Dist – Kutch Gujarat.

2. Telephone No. : 02836-28551-52, Fax-02836-285233 3. Month & Year of

Establishment

: 10th June 2002

4. Full name & Address of the occupier

: Sh. Shivlal Goyal ( Director) 2, Sri Ram Society, Gotri Road Baroda

5. Full name & Address of the Factory manager

: Sh. D.S.Purohit Plot no – 23, Ward -9B(D) New Bharat Nagar, Gandhidham Pin- 370201

6. Man Power

: 172 including all shift G Shift- 31 A Shift- 47 B Shift- 47 C Shift- 47

7. No. Of shift & Shift timing : Total no of shift :- 04 General shift :- 09AM To 06 PM First Shift “A”:- 07 AM To 03 PM


Second Shift “B”:- 03 PM To 11PM Night Shift “C”:- 11PM To 07AM

8. Environs (Nearest Facilities)

9. Meteorogical Data

Latitude 23º 10’N Longitude 70º 13’ E

Temperature

Maximum 48º C Minimum 7.2 º C

Relative Humadity :

Maximum 100 % Minimum 1 %

Annual Rain Fall :

Minimum 73.6 mm Maximum 1393 mm (1979)

Seasonal wind directions :

Jan- Feb N / NNW / ENE March – Sept SW / WSW Oct to Dec N / NNE

Wind Velocity :

Maximum 132 km/hr NNW (26.10.1975) Minimum 100 km/hr NNW (26.10.1975) Avg. Wind Speed 14 Km/hr

1. Railway Station : Gandhidham, Distance – 20 KM

2. Police Station : Anjar, Distance – 20 KM

3. Fire Station : Anjar , Distance- 20 KM

4. Hospitals : Anjar , Distance- 20KM

10. Total Land at Plant 50 ACRE


11. Total Built-up area at the Factory

30000 M2

12. Power connection Demand : 3000 KVA

13. DG Set KVA: 250 KVA

14. Power plant details : DG Set - 2.5 MW Turbine – 4.2 MW

15. Water Storage and source

Capacity in m3:20000 M3, Source – Gujarat water infrastructure limited (GWIL)

16. Boiler

Type

Model no

Capacity

Licence from Gujarat Govt.

Combi pack

CPB-80 8Ton/Hr GT 4879 IB-1478- 10 Ton/Hr GT 5516

Waste heat Recovery

Maker no-21943 AVU Make

25 Ton/Hr GT-5207

17. Chilled water plant

Particulars

Model No

Capacity

Location

VAM

------

150 TR

DMS Plant

VAM SD30BHX/1 200TR OLD VS

VAM SD30BHX/1 200 TR MCB & PNCB

Ammonia compr 2 nos

KC6-3 150 TR MCB

Ammonia compr 2 nos

KC6-3 150 TR PNCB

Ammonia compr 2 nos

KC6-3 150 TR PDCB

Ammonia compr 5 nos

KC6 300 TR New VS

Ammonia compr 3 nos

KC6 180 TR OLD VS

Total 1480 TR

18. Cooling Tower

Particulars

Flow rate

T R Plants

Process cooling water

4200M3/H 3260 Acid Division


1300M3/H 1000 DMS Plant


1200M3/H 1000 OLD VS



1200M3/H 1000 MCB Plant


1200M3/H 1000 Acetanilide plant


600m3/H 500 PNCB Plant


600M3/H 250 PDCB Plant


500M3/H 300 New VS plant


1350M3/H 1100 TC Plant

Total 9410 19. Effluent treatment

Plant Capacity: 50 M3

20. Fire water source Water reservoir (GWIL) 14 Fire Water Reservoir

capacity : M3 200M3

21. Department wise List of fire extinguishers with mapping if available

Departments Total nos of F/Extinguisher

Benzene storage 04 nos Power plant 12 nos PNCB Plant 16 nos MCB Plant 07 nos PDCB Plant 02nos Ice plant 01 no New VS Plant 09 nos ETP 01 no Acetanilide plant 06 nos EO Storage 05 nos Capacity-25 kg FO Storage 02 nos VS OLD 06 Nos CSA Plant 02nos DMS Plant 18 nos Methanol storage 04 nos SAP Plant 15 nos Boiler house 09 nos ECC Room 10 nos as spare Total 129 nos

22. SCBA sets availability and location mapping

Total Nos of SCBA Sets – 08 Nos Acid division C/R- 01No Chlorine Shed- 02 Nos DMS Plant- 01 Nos TC Plant- 02 Nos


Emergency Control centre- 02 nos

23. OHC facilities Occupational Health Centre is declared near main gate and factory medical officer visit schedule is once in a week. Well equipment Ambulence VAN. Stretcher-01 Oxygen cylinder with mask-01 First aid box- 10 nos in all departments

24. EMP Prepared as Per ISO-14000

25. EMP plan ( Action Plan) one page

Prepared and displayed in all department

26. List of emergency facilities

A. Dry powder (50% of fire extinguishers ) 50 nos

B. CO2 Cartridges ( 50% of fire extinguishers ) 200 gms (10 kg DCP

50 nos

C. As above 2 Kg ( 75 Kg DCP ) 06 nos

D. Sand scoops 50 nos

E. Safety helmets 500 nos

F. Water curtain nozzles 20 nos

G. Stretchers 01 nos

H. First aid box with anti snake serum 10 nos

I. Rubber hand gloves 200 nos

J. Explosive meter 01 no

K. Fire entry suit w/o breathing apparatus 01 no

L. Resuscitator 05 no

M. Electric siren with 3 km range 01 no

N. Hand operated siren Nil

O. Water gel blandest NA

P. Red/green flags for fire drill Nil

Q. Pressure type self contained breathing apparatus with spare cylinder (30 minutes)

08 nos.

R. Safety Shower 14 nos.

27. Fire Water Reservoir :- 200 M3

28. Other Source of Water :

Gujarat water infrastructure limited , Anjar


29. Fire Pump Details

Pump Detail Number of Pump

Head Capacity (Flow)

KW/HP

Jockey Pump 01 70 mtr 10.8 m3/h 10 Electrical Pump 01 70 mtr 270m3/h 120

Diesel Pump Nil Nil Nil Nil Total 02 Nil Nil Nil

30. Hydrant System Details

Area / Plant Nos. Of Hydrant with Hose Box

Nos. Of Monitors

PNCB Plant Hydrant – 07 nos Hose box- 01 nos

01 no

MCB Plant Hydrant – 01 nos Hose box- 01 nos

Acid Division Hydrant – 11 nos Hose box- 03 nos

Nil

Old VS plant Hydrant – 06 nos Hose box- 05 nos

01 no

New VS Plant Hydrant – 011nos Hose box- 05 nos

Acetanilide Plant Hydrant – 01no Hose box- 01 no

PDCB Plant Hydrant – 02 nos Hose box- 01 nos

Power Plant Hydrant – 05 nos Hose box- 02 nos

Canteen Hydrant – 01 no Hose box- 01 no

DMS Plant Hydrant – 02nos Hose box- 02 nos

Total Hydrant – 47 nos Hose box- 30 nos

31. License & Approval:

A. Factory Inspectorate

Licence No : 018712 Validity : 31/12/2010

B. GPCB Consent No: 5991/3/5/2005 Validity : 31/1/2010 Note – Application inward ID- 12531/Dated- 18/12/2009 for renewal of consent

C. Solid waste Disposal

Member ship : TSDF, Nandesari Baroda

D. Explosive licence No :

Particulars Licence no Validity Chlorine G/WC/GJ/06/109(G15607) 30/09/2011


Ethylene oxide old VS Plant

S/HO/GJ/03/718(SS5280) 31/03/2013

Ethylene oxide New VS Plant

S/HG/GJ/03/1066(S32386) 31/03/2011

Furnace oil P/WC/GJ/15/2380(PII9928) 31/12/2010 Methanol P/HQ/GJ/15/4682(P120542) 31/12/2010 Benzene& Toluene

P/HQ/GJ/15/4568(P20641) 31/12.2012


3.3. Google Map:


3.4. Site Plan:


3.5. ORGANIZATIONAL SET UP

Safety setup organisation chart

3.6. DETAILS OF STORAGE OF HAZARDOUS MATERIALS IN BULK

NAME OF

HAZARDOUS

SUBSTANCE

MAX. STORAGE

CAP.[Qty.]

PLACE

OF IT’S

STORAGE

OPERATING

PRESSURE

AND TEMP.

TYPE OF

HAZARD

CONTROL

MEASURE PROVIDED

Vinyl Sulphone Plant Ethylene Oxide

25 KL X 1 bullet 15 KL X 1 bullet

Licenced Premises A/G SS

10 Kg/ cm2 Ambient

Fire /Explosion/ Toxic

Double Safety Valve Nitrogen Blanketing Double Static earthing Dyke wall Scrubber provided Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking

and prohibited area. Tanker unloading procedure. Shed provided on bullets. Sprinkler provided on bullets. SCBA sets available. Safety shower.

Chloro Sulfonic Acid

45 KL X 6 Nos Tank

Tank farm area A/G MS

ATP Ambient

Corrosive Level gauge provided. Scrubber provided Required PPEs provided to

Advise Company of safety legislation & updates, safety awareness, carry out safety audits, update safety policy, provide training when required, to provide investigations and reports for any accidents.

Directors

Unit Head

VP Operation GM Operation Dy. Mgr ((Fire & Safety) (General Shift only)

Fire & Safety Supervisor (One in every shift)

Fireman Two in each shift


Chloro Sulfonic Acid (Proposed)

200 MT X 3 Nos. Do ATP Ambient

Corrosive all employees Double drain valve will be

provided to sulfuric Acid storage tank

Full body protection will be provided to operator.

Caution note and emergency first aid will be displayed and train for the same to all employees.

Safety shower and eye wash will be provided in storage tank area and plant area.

Total close process will be adopted for Sulfuric acid handling.

Dyke wall will be provided to storage tank

Caustic Lye 25 KL X 2Nos Tank


ATP Ambient

Corrosive

Caustic Lye 40 KL X6 Nos Tank

Do ATP Ambient

Corrosive

Sulfuric Acid 20 KL X 1Nos Tank

Do ATP Ambient

Corrosive

Hydrochloric Acid

30 KL X 3Nos Tank

Tank farm area A/G HDPE

ATP Ambient

Corrosive

Acetanilide Plant

Acetanilide 600 MT Godown ATP, Ambient

Combustible Flame proof plant, pumping transfer, close process, etc.

Double Static earthing Dyke wall Tanker unloading procedure. SCBA sets available . Flame proof plant, pumping

transfer, close process, etc. Jumper clips on flanges Fire extinguishers Fencing and No Smoking

and prohibited area. Tanker unloading procedure. Flame arrestor provided on

vent line of the tank

Aniline 100 KL X 1 No Tank


ATP, Ambient

Flammable

Aniline 200 KL X 1 No Tank

Do ATP, Ambient

Flammable

Acetic Acid 100 KL X 2 No Tank

Do ATP, Ambient

Corrosive/ Flammable

Dil. Acetic Acid

25 KL X 2 No Tank

Do ATP, Ambient

Corrosive

Ethyl Acetate 25 KL X 1 No Tank 15 KL X 1No Tank

Do ATP, Ambient

Flammable

MCB, ODCB, PDCB, DCB Plant Chlorine 209 Tonners Storage

Shed 10 Kg/cm2 Ambient

Toxic Chlorine Kit, Caustic Pit, SBA sets, Cl2 Shed, Cl2 Hood, EOT, etc. Provided. Chlorine 200 Tonners Storage

Shed 10 Kg/cm2 Ambient

Toxic

Benzene 40KLX4 Nos Tank Total : 160 KL

U/G Tank MS

ATP Fire Flame proof plant, pumping transfer, close process, etc.




vent line of the tank Hydrant system

Monochloro Benzene (MCB)

200KLX2Nos Tank


ATP Fire

PNCB 90KLX 2 Nos Tank

DO ATP Fire

ONCB 200KLX 1 No Tank

DO ATP Fire

Dichloro Benzene (DCB)

200KLX 1 No Tank


ATP Fire


NB, PNT, ONT, Plant

Toluene 40KLX4 Nos Tank Total : 160 KL

U/G Tank MS





vent line of the tank Hydrant system

Benzene 40KLX4 Nos Tank Total : 160 KL

U/G Tank MS

ATP Fire

Nitric Acid 20KLX3 Nos Tank

MS A/G Tank

ATP Corrosive Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to

all employees

Sulphuric Acid

20KLX 1 No Tank

MS A/G Tank

ATP Corrosive

PNT (P-NitroToluene)

200KLX1No Tank

MS A/G Tank


Double Static earthing Dyke wall Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking

and prohibited area. Tanker unloading procedure. Flame arrestor Provided.

ONT O- Nitro Toluene

200 KLX 1 No Tank

MS A/G(V) Tank

ATP Fire

MNT (Meta Nitro Toluene)

90KL X1 No Tank 200KLX 1 No Tank Total : 290 KL

MS A/G (H) Tank MS A/G(V) Tank

ATP Fire

NB (Nitro Benzene)

150KLX 1 No Tank

ATP Fire

Sulphuric Acid Plant Sulfur powder 5000 MT Storage

yard ATP Fire Separate storage area.

Monitors provided surrounding the storage area.

Automatic conveyer system for charging in melter.

Oleum 65 % 250 MT X2 Nos Tank

MS A/G Tank

Atmospheric Ambient


all employees Double drain valve will be



Oleum 23% 250 MT X 1No Tank

MS A/G Tank

Atmospheric Ambient

Corrosive

Oleum 65 % 100 MT X 2 Nos. MS A/G Tank

Atmospheric Ambient

Corrosive


Liq Sulphur Trioxide

MS A/G Tank

Atmospheric Ambient

Corrosive Caution note and emergency first aid will be displayed and train for the same to all employees.




Sulphuric Acid 98 %

1000 MT X 2 Nos. tank

MS A/G Tank

Atmospheric Ambient

Corrosive

CSA Plant Chloro sulphonic Acid

50 KLX 3 Nos Tank 140 KL X 01 Tank

MS A/G Tank

Atmospheric Ambient









Chloro sulphonic Acid

2000 MT X 2 Nos Tanks

MS A/G Tank

Atmospheric Ambient

Corrosive

Dimethyl Sulfate (DMS)

200 MTX 3 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Dimethyl Aniline (DMA)

100 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Diethyl Sulfate (DES)

200 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Benzene Sulphonyl Chloride

100 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

DASDA

100 MTX 2 Nos. MS A/G Tank

Atmospheric Ambient

Fire

Methanol 60KLX 4 Nos Tank

MS A/G Tank

Atmospheric Ambient

Fire Flame proof plant, pumping transfer, close process, etc.

Double Static earthing Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking


Ethanol 200 KL X 1 No. tank

MS A/G Tank

Atmospheric Ambient

Fire


Ammonia Anhydrous ( Liquefied )

50 MT X 1 No. Bullet

MS bullet 350 C 4 to 10 kg/cm2

Toxic Flame proof equipment, pumping transfer, close process, etc.

Double Static earthing Dyke wall Scrubber provided Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking

and prohibited area. Tanker unloading procedure. SCBA sets available . Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to

all employees Hydrochloric Acid

25 KL X 03 Nos A/G HDPE Tank

Atmospheric Ambient

Corrosive Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to

all employees TC plant (PROPOSED) Thyonile chloride

150KL X 03 Tank SS A/G Bullet

Atmospheric Ambient









Chlorine 140 Toner Storage Shed

10 Kg/cm2 Ambient

Toxic Chlorine Kit, Caustic Pit, SBA sets, Cl2 Shed, Cl2 Hood, EOT, etc. Provided.

Scrubber provided .


Sulpher trioxide

100 MT X 02 Tank

MS Tank Atmospheric Ambient


all employees Chlorinated Paraffin Wax CPW (PROPOSED) HNP 65KLX 04 TANK MS Tank Atmospheric

Ambient Flammable Safety Showers provided

Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to

all employees HCL 75KLX 6 TANK HDPE

TANK Atmospheric Ambient


all employees Chlorinated Paraffin oil

20 KLX 03 FRP Atmospheric Ambient


all employees

Furnace Oil/ LDO

27 KLX 2 Nos U/G tanks

MS Tank Atmospheric Ambient

Fire Flame proof plant, pumping transfer, close process, etc.

Double Static earthing Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking


HSD 21 KL Tank MS Tank Atmospheric Ambient

Fire

3.7. Facilities / System for process safety, transportation, fire fighting system and emergency capabilities to be adopted

Following facilities and system will be installed / implemented. 1. Total enclosed process system. 2. DCS operation plant. 3. Instrument & Plant Air System for control all parameters.


4. High level, low level, High pressure, low pressure, high temp, high flow, low flow indication and cut off interlocking provided on storage as well as process reactors.

5. Safety valve, rupture disk provided on reactor and pressure storage tanks.

6. Static earthing and electric earthing (Double) will be provided. 7. Jumpers for static earthing on pipeline flanges of flammable chemical

provided. 8. Flame proof light fitting installed where ever it is required. 9. Emergency handling equipments like SCBA sets, Fire extinguishers,

Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit , Air l ine respirator, provided.

10. Full fledge ETP plant made and it will take care of liquid effluent of the plant and final discharge parameter will be maintained as per GPCB norms.

11. Scrubbers provided on all process vent and air monitoring carried out and parameters will be maintained as per GPCB norms. Fire Water reservoir for fire hydrant and sprinkler system.

12. Storage tank area are away from the process plant and Separation Distance has been maintained.

13. Dyke wall provided to all above ground storage tanks, collection pit with valve provided.

14. Flame arrestor with breather valve is installed on flammable material storage tank vent.

15. Lightening arrestor on all chimneys and building provided. 16. Fencing and caution notes and hazard identification boards displayed. 17. Only authorized person are permitted in storage tank farm area. 18. Safety permit for hazardous material loading unloading is prepared

and implemented. 19. Static earthing provision is made at all loading unloading points of

flammable chemical storage tank farm area. 20. TREM CARD provided to all transporters and trained for

transportation Emergency of Hazardous chemicals. 21. Fire hydrant system and water sprinkler system installed at tank farm

area. 22. Caution note, safety posters, stickers and emergency preparedness

plan will be displayed. 23. Emergency facilities and medical emergency facilit ies are available at

site. Occupational Health centre facility generated at factory premises and paramedical staff is available round the clock.

24. Wind direction indicators are provided. 25. Safety Shower and eye wash are installed at acid/ alkali handling area. 26. Tele Communication system and mobile phone will be used in case of

emergency situations for communication. 27. Emergency siren installed at main gate as well as in all plant. 28. Training programme are being conducted regularly and induction

training are being provided to all employees on chemical safety and process safety.


NHCOCH3

+ 2Cl.SO3H

ACETANILIDE

NHCOCH3

+

SO2Cl

HCl + H2SO4

CHLORO SULPHONIC ACID

3.1 BRIEF DESCRIPTION OF PROCESS AND FLOW CHART

3.1.1 Vinyl Sulphone & Vinyl Sulphone Condense:

Chloro Sulphonation: Chloro Sulphonic Acid is charged into the sulphonation reactor. Acetanilide is then slowly added to maintain the temperature below 80° C. The temperature is then maintained between 50-60 °C. The batch thus prepared is transferred to the storage tank. Dumping: Sulphonated mass is charged into the Reactor cooled with brine. Ice water is then added slowly to remove all the HCl formed due to decomposition of excess Chloro Sulphonic Acid. The HCl is scrubbed and absorbed in water to make HCl. Further Ice water is added to dilute the concentrated Sulfuric Acid formed due to the decomposition of Chloro Sulphonic Acid. Here we get of Sulfuric Acid of strength 30-40%. The mass is then filtered out (ASC Cake). Reduction: Sodium Bi Sulphite slurry is added to the reactor. The pH is maintained neutral by adding Caustic Lye. The ASC wet cake is then charged under controlled temperature and pH. After addition is over the temperature is raised up to 50 °C. The mass is then filtered and transferred to condensation vessel. Condensation: The reduction mass in condensation vessel is maintained at 50°C. Ethylene Oxide is slowly added. The pH is maintained to 5-7 by adding dilute sulphuric acid. The material after condensation is transferred to the Nutsch Filter. The Mother liquor is stored in storage tank. The condensed product is then washed and dried. Esterification: The condensed product is charged in esterification reactor. Concentrated Sulphuric Acid is added. The temperature is then raised and maintained at 160°C for 4 hours. Vacumm is applied to take out acetic acid vapors and being condensed. The product is then collected a tank. The dried Vinyl Sulphone is pulverized and packed in PVC bags. Chlorosulphonation:


NHCOCH3

+

SO2Cl

NaOH + NaHSO3

NHCOCH3

+

SO2Na

Na2SO4 + NaCl

NHCOCH3

+

SO2Na

H2SO4 + H2O

O

H2C CH2

+

NHCOCH3

SO2CH2CH2OH

+ Na2SO4

ETHYLENE OXIDE

NHCOCH3

SO2CH2CH2OH

+ H2SO4

NH2

SO2CH2CH2OSO3H

+ CH3COOH

VINYL SULPHONE

Reduction:

Ethoxylation:

Esterification:


Process Flow Chart:

Acetanilide 2182CHLOROSULPHONIC ACID 10182

12364

Ice 14545 DUMPING(ICE)

26909

FILTERATION(Nutch) H2SO4 (35-40%)

12364 14545

SOD. BISULPHITE SLURRY(30%) 6545

CAUSTIC LYE 218221091

PRODUCT FROM FILT

ETHYLENE OXIDE 1018H2SO4 2269.00

24378.00

Salt

FILTER 17753SODIUM SULPHITE

SALT (BYPRODUCT)

8299

6625.00

ETP

CONDENSED PRODUCT 9454

6625.00

2262 MOISTURE LOSS

DRYER

4363.00

PRODUCT FROM Dryer

H2SO4 1455 ESTERIFICATION

5818.00ACETIC ACID

1818

VINYL SULPHONE

4000.0

CHLOROSULPHONATION

REDUCTION

ETHOXYLATION

MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE


3.1.2 Sulphuric Acid

The process for the manufacture of sulphuric acid comprise the following steps:

1. Solid Sulphur after weighment is fed to sulphur melter which is provided with steam coils. The ash content of the molten sulphur settles in the melter cum settler and molten sulphur free of impurities is pumped to the sulphur burner where it is burnt with air. Sulphur is converted in to SO2 in the sulphur burner as per the following reaction S + O2 SO2

2. SO2 is further converted to SO3 in presence of Vanadium Pentoxide catalyst in the converter as per the following reaction:

3. SO2 + ½ O2 SO3 The conversion of SO2 to SO3 is carried out in stages in all the five pass of the convertor. The conversion is optimized by intermediate cooling of gases between the different stages and also by interpass absorption of SO3 after 3rd pass of the convertor.

4. The gas from the 3rd & 5th pass of the convertor containing SO3 is cooled & then fed to the interpass & final absorption tower where SO3 is removed by circulating Sulphuric Acid in the absorption towers. The concentration of sulphuric acid is controlled by addition of water in the pump tank.

5. Air for sulphur burner is routed through Air Filter to drying tower and further to suction

side of Centrifugal Air Blower. 98.5% acid is circulated through drying tower at 70°C, thus heating to 125°C before entering sulfur burner. This system helps to increase generation of steam and hence power generation.

6. SO2 emission during start up of the plant is controlled by a Venturi Scrubber using alkali as scrubbing medium. The plant therefore does not cause any pollution either during start up or during normal operation. The process as described above has been divided into five main sections described as follows: • Sulphur Circuit

The weighed quantity of sulphur of about 99.5% purity is fed to the first compartment of sulphur melter. The heat for melting sulphur is provided through steam coils. The optimum pressure to be maintained for melting sulphur in the first compartment is upto 7 kg/cm2 G. The molten sulphur flows from compartment no. 1 to pumping compartment through underflows/overflows. The sulphur pumps for feeding sulphur are fitted in pumping compartment. The total time of retention in the compartments corresponds to more than 72 hrs at normal rated production capacity of the plant. In order to achieve


optimum results, it is necessary that the feeding of sulphur to the melter should be maintained at specified temperature of 135 °C. All compartments are fitted with steam coil to provide the necessary heat for maintaining the temperature of molten sulphur at the desired level. Molten sulphur from the pumping compartment is pumped to the sulphur burner through one of the submersible type sulphur pumps through specially designed sulphur feeding gun. The rate of feed of sulphur to the sulphur burner is controlled by operation of sulphur feed control valve. Drain lines have been provided in the molten sulphur discharge line at two different points. The optimum steam pressure for coils located in 2nd, 3rd , 4th through pumping compartments of the sulphur melter is around 4 kg/cm2 G. This regulated steam pressure is achieved through pressure reducing valve. Molten sulphur line starting from the discharge flange of the sulphur pump to the inlet of the sulphur burner is suitably steam jacketed to maintain correct temperature of molten sulphur fed to the sulphur burner.

• SO2 Scrubber It is very important that SO2 emission during plant startup is controlled within persmissible limits. This is achieved by use of a alkali scrubber located after the final absorption tower where gas is scrubbed with circulating alkali solution.

• DM and Water Softening Plants For generation of steam of high quality DM water is required for this purpose RO plant and DM plant will be installed.

• The plant is provided with data logging system through DCS control circuits for control of parameters like Acid concentration control, pump tank level control, Boiler feed water level control, boiler feed water from deaerator temperature control. All the output signals are fed to a computer and output data is collected based on reports to be prepared including log sheets.

Chemical Reaction:

S + O2 SO2

SO2 + 1/2O2 SO3

SO3 + H2O H2SO4

Overall S 3/2O2 + H2O H2SO4

M.W 32 48 18 98


3.1.3 Oleum & SO3

Oleum (23%) Oleum 23% is manufactured by absorbing SO3 gas with Sulphuric Acid. H2SO4 + SO3 H2S2O7 Oleum 23% means free SO3 in the product is 23%, which is equivivalent to 105.17% Sulphuric Acid. This way 23% Oleum is equivalent to 1.07 of 98% Sulphuric Acid. The sulphur required for 1 ton of 23% oleum is 0.326 x 1.07 = 0.349 ton. Oleum (65%) Oleum 65% means, the free SO3 in this product is 65% which is equivalent to 114.626% sulphuric acid. This way the oleum 65% is equivalent to 1.17 times of 98% sulphuric acid. The sulphur required for 1 ton of 65% Oleum 0.326 x 1.17 = 0.381 ton Liquid SO3 Liquid SO3 is = 1.25 times of 98% Sulphuric Acid. The Sulfur required for 1 ton of liquid SO3 = 0.326 x 1.25 = 0.41 ton.


Sulphur Metler (135°C)

163.25 MT

904341 M3 Air Drying Tower Furnace (1100°)

(Oxygen: 245 MT)

Water

WHB Steam Steam Turbine to Generate

4 MW Power

Convertor (upto 3rd pass)

100 MTDM Water

H2SO4 (98.5%)

Acid Pump Tank PIPAB(Inter Pass

Absorption Tower

99% H2SO4

Convertor (4th pass)

Oleum Storage

(23% or 65%)

99% H2SO4

H2SO4 (98.5%) Storage

Final Absorption Tower

Alkali Scrubbe

r

Vent to Atmosphere

Wastewater 500 MT/Day 0.8 KLD

Oleum Tower

Oleum Pump Tank (Oleum 23%

or 65%)

PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)

Prepared By Kutch Chemical Industries Ltd. Page : 36 HSE Department Rev. : 00

SO3 + HCl ClSO3H(l) (g) (l)80 36.5 116.5

1567 HCl Chilling

1567Chilled HCl

H2SO4 Gas Cleaning Bleed

1567Dry HCl 99.90%

3433 Liq SO3 Reactor

100.00% Gas to StackCaustic

Scrubber0.8 Castic Solution Wastewate To ETP

10% 0.8 KL/Month

5000Chlorosulphonic Acid

MASS BALANCE OF CHLOROSULPHONIC ACID

Condenser SO3 Liquid

7500

Oluem Pump Tank (23%)

8070

Oleum Tower (23%)

SO3 Convertor (132 °C)

PROCESS FLOW CHART OF SO3 LIQUID 3.1.4 Chloro Sulphonic Acid

The HCl gas is refrigerated and cleaned in gas cleaning tower. The dry HCl is reacted with liq SO3 to get Chloro Sulphonic Acid. The unconverted gas is scrubbed in caustic scrubber.

Chemical Reaction:

Mass Balance:


3.1.5 Sulfonation (of ONT/PNT, Tobias, VS)

Take ONT/PNT in as sulfonator and charge 98% Sulphuric Acid and 65% Oluem in it slowly. After completion of reaction blow sulfomass in another vessel containing water, charge common salt, mix it, cool it and filter in neutsch. Material is then centrifuge. Collect filterate as Spent Sulphuric Acid for sale. Sulphonated ONT/PNT from centrifuge is then packed in HDPE bags and sent for sale. For Tobias, Take Oleum (65%) in sulfonator, charge Tobias Acid slowly and after completion of charging raise temperature and maintain it. Now cool the sulphonated mass and blow it in Brine water. Allow for mixing, filter and give wash of brine water. Centrifuge the mass and collect the wet cake as product and packed in HDPE bags. Chemical Reaction (o-NT/p-NT):

98

178

o-Nitro Toluene Sulphonated Sulfuric Acido-NT

137 217 98

CH3NO2 H2SO4

H2S2O7

CH3NO2

SO3H

+ H2SO4

Chemical Reaction: (Tobias)

+ H2S2O7 + H2SO4

Tobias Acid (TA) STA (Sulfo Tobias Acid)223 178 303 98

NH2

SO3H SO3HNH2

SO3H

MASS BALANCE:

ONT 137H2SO4 98H2S2O7 178

413

Water 18Common Salt 117(NaCl) 548

Spent Acid (25%)Filteration (Water+Salt+Sulfuric Acid)

217 331

Centrifuge 2(Recycle to Drawning Vessel)

Wet Cake215

Sulfonator

Drawning Vessel

MASS BALANCE OF SULPHONATION ONT/PNT


3.1.6 BENZENE SULPHONYL CHLORIDE

Benzene is reacted with Chloro Sulphonic Acid in a agitated vessel at low temperature at about 20 -25 °C. Chloro Sulphonic Acid is used in excess for the reaction. The reacted mass is then kept under agitation for some time. It is then transferred to another vessel containing chilled water. During the addition, the vessel is cooled up to desire temperature till the addition complete. The contents are kept under agitation for some time. The mass is then separated. The acid layer is transferred to the storage tank for sale. The organic layer is washed, dried & distilled under vacuum to get the product. The HCl gas evolved during the reaction & isolation is send to CAS plant for making Chloro Sulphonic Acid.

Chemical Reaction:

C6H6 + HOSO2Cl C6H5SO2Cl + HCl

Benzene CSA BSC Hydrochloric Acid Gas(l) (l) (l) (g)

M.W 78 116.5 176.5 36.5 Mass Balance/Flow Chart:

663 Benzene HCl gas

1980 CSA 310

2333

Isolation Dilute H2SO4

1500 833

DistillationCrude

Dimethyl Sulphone

1485 15

Benzyl Sulphonyl Chloride

MASS BALANCE OF BENZYL SULPHONYL CHLORIDE

Reactor

3.1.7 Thionyl Chloride

Sulphur is charged in sulfur monochloride reactor along with chlorine in measured quantity and reacted over a period of 12 hours to Sulphur Monochloride (SMC), which is stored for further reaction. Thionyl Chloride reacted is fed with SMC, SO3 and Chlorine. Reactor is fitted with fractionating column. TC gas thus produced is passed through 3 condenser, out of which first condenser used cooling water and other two condenser use chilled water. Crude TC is then sent to Distillation column as reflux. A part of crude TC is reacted with sulfur to get pure Thionyl Chloride.


818 Sulphur890 Chlorine

17082044 SO3 To Sulfuric Acid & SBS plant (Recycle)890 Chlorine 1627

3015

2400Product

600Product

15Total Product 3000

MASS BALANCE OF THIONYL CHLORIDE

SMC Reactor

TC Reactor

Condenser

Distillation Column

Alkali Scrubber is provided to absorb SO2 when required; similarly chlorine scrubber removes traces of chlorine. Byproduct is recycled back to sulfuric acid plant, where it is converted to Sulphur Trioxide for reuse in TC Plant.

2S + Cl2 S2Cl2

Sulphur Chlorine Sulphur Monochloride (SMC)

64 70 134

S2Cl2 + 2SO3 + Cl2 2SOCl2 + 2SO2

134 160 70 236 128

SMC Sulphur Trioxide Chlorine TC

Overall Chemical Reaction:

2S + 2Cl2 + 2SO3 2SOCl2 + 2SO2

64 140 160 236 128

Chemical Reaction:

Mass Balance:

3.1.8 DASDA

Sulfuric Acid & Oluem (65%) are taken in Sulfonator, Para Nitro Toluene (PNT) is then charged. The mass in then dumped in to the water, cooled and filtered in Neutsch filter. The acid is then separated, The mass (PNTOSA) is then oxidized with sodium hypochloride. After completion of the reaction common salt is charged at the room temperature the mass is then filtered in Neutsch Filter . Then reduction of PNTOSA is carried out with Fe, HCl and NH4Cl. Filter the reduction mass & isolate the filterate using dilute H2SO4 & filter it in Neutsch filter. Material thus prepared is DASDA. Which is then centrifuged and packed in the HDPE bags.


PNT 63H2SO4 45Oleum 82

190Water 20Salt 15

225

Neutsch Filter 58 To ETP

167

Centrifuge 30 ML(Recycle)137 Drawning

Common Salt 15Soda Ash 18NaOCl 69Water 25

264

Neutsch Filter 58 To ETP206

Centrifuge 5 ML(Recycle)201 Drawning

Fe 5HCl 8NH4Cl 15

229

Filter Press 27 To ETP202

Isolation Vessel

202

Neutsch Filter 26 To ETP176

Centrifuge 6 ML(Recycle)170 Isolation Vessel

Product

DASDA

MASS BALANCE OF DASDA

Sulfonator

Drawning Vessel

Oxidation

Reduction Vessel

PNT(137) 98 178 PNTSA (217)

+ 2HCl + 3H2O2NaOCl +H2O

217 149 18 474 73 54

Fe/HCl

NH4Cl

(DNSDA) Di-Sodium Salt (Nitro form) Di-Sodium Salt (Amino form)414

+ H2SO4

414 370DASDA

CH3

+

NO2

H2SO 4 + H2S2O7 2H2SO4

CH3

NO2

+SO3H

O2N

SO3Na

- C = C

H H

SO3N

NO2 H2N

SO3Na

- C = C

H H

SO3N

NH2

H2N

SO3Na

- C = C

H H

SO3N

NH2 H2N

SO3H

- C = C

H H

SO3H

NH

CH3

NO2

+SO3H

2 O2N

SO3Na

- C = C

H H

SO3N

NO2

Chemical Reaction:

Mass Balance:


3.1.9 Power Generation of 10 MW (Coal)

For power generation steam will be generated from the boiler, which is then sent to steam turbine to generated the power. At the outlet of the turbine steam goes to condenser to recover the water utilized and further sent back to the boiler. The fuel utilized for the boiler will be Coal. To generated 10 MW, a steam of 40 MTD required, which is generated from the coal based boiler. The coal consumption for the required steam would be approximately 10 MTD. For Power plant, separate coal yard will be made in which coal will be stored, from coal yard the coal will be sent to crusher. The crushed coal is then sent to silo for ultimate feed in to the combustion chamber. Process Flow Chart:

High Pressure Steam45 kg/cm2

410°C

Exhaust0.1 kg/cm2

100 °CCondenser Condensate back to

Boiler feed water

Turbine GeneratorSet

3.1.10 Sodium Bi Sulphite

Sodium Carbonate and Water is charged in the reactor. Sulphur Dioxide is then passed slowly to the reactor. The mass is then allowed for continuous mixing. The material thus prepared is Sodium Bi Sulphite.

Na2CO3 + 2SO2 + H2O 2NaHCO3 + CO2106 64 18 208 28

Sodium SBSCarbonate

Chemical Reaction:

CO2Sodium Carbonate 106 28SO2 64Water 18

160

Reactor

MASS BALANCE OF SODIUM BI SULPHITE

Mass Balance:


1979 Liq SO3DME Gas

1138

1524 Methanol Day Tank Heat Exchanger

Reactor Containing

Al2O3 Catalyst(260°C)

Reactor

386 Water To ETP Condensation Tank

Pure Dimethyl Sulphate 3000 Distillation

11798% Spent Sulfuric Acid

MASS BALANCE OF DIMETHYL SULPHATE

3.1.11 Dimethyl Sulphate Methanol from day tank in the plant is taken through metering pump passed through heat exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum catalyst, further it is reacted with liquid SO3. The ration of consumption of methanol + SO3 for DMS produced is as follows:

SO3 = 0.70 MT Methanol = 0.55 MT.

The moisture shall be collected out of Methanol and sent to ETP. After reaction of SO3 + Methanol gas in a closed reaction , Which will have chilled water circulation in jacket. The crude DMS formed is having a high acidity. The distilled and acid thus produced is 98% Sulphuric Acid. This is a by product and will be sold.

260°C2 CH3OH CH3-O-CH3 + H2O

Catalyst(Al2O3)Methanol Dimethyl Ether

2 x 32 46 18

CH3-O-CH3 + SO3 (CH3)2SO4

Dimethyl Sulphate46 126

SO3 + H2O H2SO4

80 18 98

Chemical Reaction:

Mass Balance :


260°C2 CH3OH CH3-O-CH3 + H2O

Catalyst(Al2O3)Methanol Dimethyl Ether2 x 32 46 18

CH3-O-CH3 + C6H5NH2 (CH3)2C6H5NH2

Dimethly Aniline46 93 123

DME GasAniline1134

560

780 Methanol Day Tank Heat Exchanger

Reactor Containing Aluminium Catalyst

Reactor

220 Water To ETPCondensation

Tank

1694

1500 Pure Dimethyl Aniline Distillation

194Wastewate to ETP

MASS BALANCE OF DIMETHYL ANILINE

3.1.12 Dimethyl Aniline Methanol from day tank in the plant is taken through metering pump passed through heat exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum catalyst, further it is reacted with Aniline. The product is then distilled to get Dimethyl Aniline The moisture shall be collected out of Methanol and sent to ETP.

Chemical Reaction:

Mass Balance:

3.1.13 Diethyl Sulfate

Ethyl Alcohol and SO3 reacts in presence of catalyst Sodium Sulphate and Urea and formed Ethyl Hydrogen Sulfate (EHS). This EHS mass is ammoniated by ammonia and EHS gets converted into Diethyl Sulfate. Ammonia is passed in Ethyl Hydrogen Sulfate mass. The product thus formed is crude Diethyl Sulphate. Moisture content present in the Ethyl Alcohol reacts with SO3 and forms Sulphuric Acid. Distillation of crude EHS takes place under vacuum. The pure DES is produced and transported to the storage tanks.


2C2H5OH + 2SO3 2C2H5OSO3HCatalyst

Ethyl Alcohol Ethyl Hydrogen Sulfate92 160 228

2C2H5OSO3H + NH3 (C2H5)2SO4 + NH4SO4

EHS Ammonia Diethyl Sulfate Ammonium Sulfate228 17 154 114

896 Ethyl Alcohol

1558 SO3

3542100

NH3166

2266

Spent ST Tank766

1500Pure Diethyl Sulfate

MASS BALANCE OF DIETHYL SULFATE

Reactor (Catalyst: Urea+Sod. Sulfate)

Cooler

Ammoniation Reactor

Distillation

Chemical Reaction:

Mass Balance:

3.1.14 Calcium Chloride

Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride.

2CaCO3 +4 HCl 2CaCl2 + 2 HCO3

Chemical Reaction:


0.2Water

5 Lime Stone Ventury Scrubber (Alkali)ETP

4 HCl 0.29

Sludge to ETP1

8 CaCl2 Clear Liquid

Mosture Loss

5Dry CaCl2

Product

Reactor

Filter Press

MASS BALANCE OF CALCIUM CHLROIDE

Evaporator

Mass Balance:

3.1.15 Di Calcium Phosphate

Rock Phosphate is reacted with Hydrochloric Acid to generated Phosphoric Acid, which is further reacted with Lime stone to get DCP which separated and crystallized.

Ca F2 3 ( Ca3(PO4)2) + 14 HCl 7 CaCl2 + 3Ca H(PO4)2 + 2HF

Chemical Reaction:

3Ca (OH)2 6CaHPO4 DCP

Rock Phosphate 1800

HCl (30%) 36005400

Lime 200

5600

Hydrated Lime 200

Sodium Silicate 105810

Filteration Process Sludge5310 500

Recycle to Reactor to recover DCP 1500 Centriguge

3810

Dryer Mositure Loss3000 810

Finished Product

Reactor

Neutralisation

Separation

MASS BALANCE OF DI CALCIUM PHOSPHATE

Mass Balance:


3.1.16 Sulphur Mono Chloride Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a reactor.

2S + Cl2 S2Cl2

Sulphur Chlorine Sulphur Monochloride (SMC)

64 70 134

Chemical Reaction:

95.5 Sulphur104.5 Chlorine

200

MASS BALANCE OF SULPHUR MONOCHLORIDE

SMC Reactor

Mass Balance:

3.1.17 Sulphuryl Chloride

Sulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl Chloride. Chemical Reaction

S

:

+ 3Cl2 + 2SO3

3SO2Cl2

32 210 160 402

Sulphuryl Chloride

16 Sulphur17.5 Chlorine

33.580 SO3

89.5 Chlorine203

190Product

13

Residue Product 103

Reactor

Reactor

Condenser

Distillation Column

MASS BALANCE OF SULPHURYL CHLORIDE

Mass Balance:


Water

860 Alumina Hydrate/Bauxite

456 Sulphuric Acid1316

1316

456 Sulphuric Acid

Mouldingin to Slab

Reactor

Settling Tank

Reactor

MASS BALANCE OF ALUM

3.1.18 Aluminium Sulphate (Alum) Aluminium Sulphate is manufactured by the reaction of Aluminia Hydrate and Bauxite with Sulphuric Acid. Bauxite is ground in the pulveriser to 90% passing through 200 mesh and elevated to batch hopper through bucket elevator. Measure quantity of water is added in the lead bonded reactor and slowly sulphuric acid is to be added in the reactor.. After getting the required temperature in the reactor, slowly ground bauxite i.e added. After the addition of measure quantity of bauxite/alumina hydrate, the agitator is kept on for about 45 minutes, solution is then dumped in to the settling tank. The decanted solution of Aluminium Sulphate is then taken to the reactor and the required quantity of sulphuric acid is added after getting the required temperature Hydrated Alumina is added slowly. After addition, Aluminum Sulphate is moulded in the trays with the help of tray filling arrangements. The slabs after cooling are to be taken out from the trays and stacked in the store.

2Al(OH)3 + 3H2SO4 Al2(SO4)3 + 6H2O 156 294 342 108

Chemical Reaction:

Mass Balance:


350 Urea Reactor3300 SO3/Oleum

(23-25%) 3650R/C Mother Liquor

Mixing

5150

Separation Spent Acid2400 2750

100 Water Make -Up

2500

Cyrstallisation1500

1000

Packing/Bagging

Figure are in Ton/Month

MASS BALANCE OF SULFAMIC ACID

3.1.19 Sulfamic Acid

Urea & 23-25% Oleum are fed at controlled rates to reactor, which is cooled by chilled water/brine and cooling water. The reaction products are diluted by mixing with recycled mother liquor (available after separation of crystals of sulfamic acid). Temperature is controlled during mixing by chilled water/brine. Dilute acid streams (70% sulfuric acid) is separated after the mixing operation and is sold to SSP/Alum manufacturer.

NH2CONH2 + SO3 NH2CONHSO3H + CO2

Chemical Reaction:

NH2CONHSO3H + H2SO4 2NH2SO3H + CO2

Overall Reaction

NH2CONH2 + SO3 + H2SO4 2NH2SO3H + CO2

60 80 98 2 x 97 44

Mass Balance:


SECTION IV

HAZOP SHEET

HAZOP SHEET


VS PLANT Table: 4.1 HAZOP STUDY WORKSHEET Study Title Transferring of Chlorsulfonic Acid to service tank. Drawing No. Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Storage tank, Pump Activity Transferring of Chloro Sulfonic Acid to Service Tank. Design intent PRES. TEMP FLOW VACU. Material : Chloro Sulfonic Acid Amb Amb ---- Source : Form the storage Tank

Parameter Guide

Words Possible causes Possible

consequences Measures/Existing facilities safeguard

Action Required

Flow No 1. No material in the storage tank.

2. Pump tripped. 3. Pump valve closed.

No material to service tank.

Pressure gauge provided on the pump discharge valve.

1. Level indicator to be provided on service tank.

2. Arrow indicators to be provided on pipeline

Less 1. Valve partially closed. 2. Leakage in the pipe line. 3. Less material in the

storage tank.

More time taken to fill the service tank.

More 1. Pump Ampere more. 2. Discharge valve fully

open than required set value.

Early filling of Service tank

1. Level indicator provided. 2. Vents are connected to

scrubber.


Table: 4.2 HAZOP STUDY WORKSHEET Study Title Charging of Acetanilide Drawing No. Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered -- Activity Charging of acetanilide Design intent PRES. TEMP FLOW VACU. Material : Acetanilide Nil Amb NA -- Source : Bag packing

Parameter Guide



Action Required

Charging No No material No process will take place.

Material is charge under the supervision.

Separate storage to be identified with the marking

Less 1. Human error. 2. Material weight is less

than what is mentioned on the bag.

1. Disturbance in the process.

2. More

More 1. Human Error 2. Material packing weight

is more than what is printed on it.

1. Disturbance in the process.

2. Product quality may detoriate.

1. Charge batch to be earmarked.

2. Identification of bag to be done in local language.

Wrong 1. Human error. 2. Wrong labeling. 3. Wrong supply of

material from supplier.

Disturbance in the process.


Table: 4.3 HAZOP STUDY WORKSHEET Study Title Reaction Drawing No. Revision No. NIL Date 08.07.2010 Hazop Team Part Considered Rector Activity Reaction Design intent PRES. TEMP FLOW VACU. Material : Acetanilide + Chlorosulfonic. ----- 80 ---- ----- Source : From the storage tank & Manual charging of bag.

Parameter Guide



Action Required

Pressure More 1. Chilled water supply low.

2. More quantity of CSA. 3. No stirrer operation. 4. Entry of water in the

reactor 5. No scrubbing of HCL

water, Accumulation of vapor in the reactor.

6. Choking in the scrubber.

Pressure & temperature will go on increasing. Exothermic Reaction will take place.

1. Vent provided to scrubber. 2. Pressure gage provided on

Reactor. 3. Temperature gauge provided

on reactor. 4. Safety valve & pressure gauge

are provided on reactor cooling jacket.

5. Sight glass provided.

1. Standard operating procedure to be prepared.

2. Arrow indicators to be provided on pipe line.

Less 1. Good cooling 2. Control Rate of Raw

material addition.

No process hazards

Temperature More As per pressure Less Good cooling water flow No process hazards. It

is process requirement.

Water Entry in the reactor

Leakage Temperature & Pressure will go on increasing.

1. Thickness monitoring of the reactor is carried out.

2. Hydro testing of the jacket at periodic interval.


Table: 4.4 HAZOP STUDY WORKSHEET Study Title Dumping Drawing No. Revision No. Nil Date 08.07.2010 Hazop Team Part Considered Dumping vessel Activity Dumping of sulphonated mass. Design intent PRES. TEMP FLOW VACU. Material : Sulphonated mass. Gravity 5 ---- ---- Source : From sulfonator

Parameter Guide



Action Required

Temperature More

1. No addition of ICE water. 2. Poor cooling of the

reactor. 3. Choking in the HCL

scrubber line.

1. Maximum temperature will be the ambient.

1. Temperature Gauge 2. Pressure gauge provided. 3. Total closed process 4. Safety valve provided on

Chilled water cooling line.

1. Only administrative checks to be ensured.

2. SOP to be prepared.

Less Good cooling 1. It is good for the process

2. No safety & health hazards.

Pressure More Increase in temperature due to above hazards.

No process & safety hazards

Less Flow More Not Applicable There is no flow

measurement as sulphonated reaction mass is directly dumped in the dumping vessel.

Less Not applicable Other than Part of No full charging Process delayed Physical inspection


Table: 4.5 HAZOP STUDY WORKSHEET Study Title Reduction Drawing No. Revision No. Nil Date 08.07.2010 Hazop Team Part Considered Reduction Activity Reduction Design intent PRES. TEMP FLOW VACU. Material SBS + Caustic Lye 50 Source From

Parameter Guide



Action Required

Temperature More 1. Poor/No cooling. 2. Damaged insulation 3. Stirrer not

moving/stopped 4. More addition of

caustic. 5. Charging of normal

water.

1. Desired process will not achieved.

2. Temperature will rise.

1. Temperature Gauge 2. Pressure gauge provided. 3. Total closed process 4. Safety valve provided on

Chilled water cooling line.

Visual check by the operator

Less 1. Good cooling. 2. Controlled addition of

material in controlled way.

No process & safety hazards as it is requirement of the process.

Pressure More No effect on pressure rise as it is only neutralization & reduction by adding caustic lye.

No process & safety hazards

Less Not possible.


Table: 4.6 HAZOP STUDY WORKSHEET Study Title Condensation Drawing No. Revision No. Nil Date 08.07.2010 Hazop Team Part Considered Condensation Rector Activity Design intent PRES. TEMP FLOW VACU. Material : Reduction Mass + Ethylene Oxide 50 --- ---- ---- Source : Reduction & EO form storage tank

Parameter Guide



Action Required

Temperature More 1. Hot oil circulation is more.

2. More hot material from the reduction it self.

3. Flow of EO in case above desired level.

Increase in temperature & pressure.

1. Safety valve provided on reactor & day tank

2. Rupture disc provided on reactor & day tank.

3. Temperature & Pressure gauge provided.

4. Stand by pump for the cooling have been provided.

5. Safety valve provided on Chilled water cooling line.

6. Temperature control at50 C by providing chilling cooling & hot oil circulation in reactor jacket.

7. Dump vessel provided to transfer reaction mass in case pressurize & increase in temperature.

8. Load shell tank provided 9. Nitrogen PRV skid provided

for the Nitrogen blanketing.

1. Visual check by the operator

2. E. O. flow cutoff to be provided in connection with the temperature rise.

3. Arrow indicators to be provided on pipeline.

4. Nitrogen blanketing to during reaction to be provided.


Parameter Guide Words

Possible causes Possible consequences

Measures/Existing facilities safeguard

Action Required

Temperature Less Human error- Chilled water circulation valve is open.

Desired process will not achieve.

BMR is prepared & followed. Physical checks are required.

Pressure More Increase in temperature due to above mentioned causes

Temperature Increase. Pressure Gauge provided on reactor & operator will take action accordingly.

Less Not possible

Flow ( EO ) More 1. Human Error 2. Valve passed.


1. Sight glass 2. Line Sight Glass Provided. 3. Flow meter provided on Inlet

of reactor. 4. Double mechanical seal in

stirrer 5. Total closed process 6. Flameproof fitting provision. 7. Double static earthing

provided. 8. Jumpers provided on flange

joint. 9.

No/Less 1. No material 2. Valve jammed 3. Wrong setting of the

valve

Delayed in the process.


Table: 4.7 HAZOP STUDY WORKSHEET Study Title Esterification Drawing No. Revision No. Date 08.07.2010 Hazop Team Part Considered Esterification Reactor Activity Esterification Design intent PRES. TEMP FLOW VACU. Material : Sulfuric Acid + Condensed product. ---- 160 Yes Source : From Condensation

Parameter Guide

Words Possible causes Possible consequences Measures/Existing facilities

safeguard Action Required

Temperature More 1. Increase in flow of Sulfuric acid.

2. Jacket temperature is more.

3. Less quantity of condensed material.

1. Pressure will increase.

2. PH may affected.

1. Temperature & pressure gauge provided.

2. Safety valve & Pressure gauge provided on Reactor jacket.

3. Sight glass provided. 4. Vent are connected to

scrubber.

Physical & administrative checks to be ensured.

Less 1. No heating in the jacket. 2. No flow of sulfuric acid.

1. No safety & health hazards.

2. Desired process temperature will not achieved.

3. Delayed in the batch cycle.

Pressure More As per the temperature

Less As per the temperature


Table: 4.8 HAZOP STUDY WORKSHEET Study Title E. O. storage tank Drawing No. NIL Revision No. NIL Date 28-06-2008 Hazop Team Deepak Chanchad Part Considered Storage Tank Activity Storing of E. O. Design intent PRES. TEMP FLOW VACU. Material : E. O. N. A. N.A. Source : E. O. Storage tank

Parameter Guide



Temperature

More

1. No chilled water supply. 2. Ambient temp high. 3. Poor insulation (water

entry inside insulation). 4. E. O. not consumed for

some days.

1. Development of pressure in Ethylene Oxide tank.

2. Blow off from Safety Valve.

3. Toxic & Fire Hazards. Explosion Hazards. Air pollution. Leakage from flange may occur.

4. Metallic impurities.

5. In case temperature is more than 20 C then polymerization may occur.

1. PSV provided. 2. Chilled water cooling

provided. Safety Valve provided.

3. Rupture disc provided. 4. Insulation to tank provided. 5. Magnetic level type flow

indicator provided. 6. Ethylene Oxide gas sensor

monitoring system provided. 7. Pressure Gauge provided. 8. Fix Fire water monitor system

provided. 9. Sprinkle on System on EO

tank provided. 10. Hi temperature alarms

provided. 11. Chilling coil provided. To

storage tank covers 90 % in the bottom 2-3 tons E. O. left without chilling.

1. To dilute the 1 liter of EON, 18 liters water is required. Considering this sufficient quantity of water shall be ensured.

2. All flange joints shall be checked regularly.



Possible causes Possible consequences Measures/Existing facilities safeguard

Action Required

Temperature Less 1. Good Chilling. 2. Too cold atmosphere

during the winter.

1. Decrease in E. O. Pressure.

1. Temperature Gauge provided. 2. Insulation provided.

Pressure More 1. N2 valve passing. 2. More temperature in the

storage tank.

1. Leakage from flange may occur

2. Blow off from Safety Valve.

3. Toxic & Fire Hazards. Explosion Hazards. Air pollution.

1. Pressure switch provided on E. O. tank.

2. Inbuilt N2 pressure is 5.8 kg/cm2 so by human error N2 valve remains open than also it will not rise up to 5.8 kg/came. Safety valve of Storage tank set at 6.5 Kg/cm2

1. During the pop of Safety valve it shall be ensured the sufficient quantity of water for dilution.

2. In case Safety valve do not set to its back position after venting the extra pressure (this scenarios shall be considered.)

3. Foam type monitor shall be considered.

4. Calibration for all instruments shall be done vigorously.

Less 1. Leakage from flange joints,

2. Pump discharges less. 3. Mal functioning FCV 4. Valve partially closed.

In case activation of any interlock than also the flow will be low.



Possible causes Possible consequences Measures/Existing facilities safeguard

Action Required

Flow More Covered under pressure 1. During the pop of Safety valve it shall be ensured the sufficient quantity of water for dilution.

2. In case Safety valve do not set to its back position after venting the extra pressure (this scenarios shall be considered.)

3. Foam type monitor shall be considered. Calibration for all instruments shall be done vigorously.

Less

Covered under pressure Process disturbance. Spillage hazards

Reverse

Not Possible

No Safety hazards

Auto shut off valve provided.

Leakage of water in storage tank.

Other than Leakage from cooling coil

Moisture in E.O. quality problem in EO. Wastage of material

Pressure gauge on the outer side of the cooling coil shall be provided.


Table: 4.9 HAZOP STUDY WORKSHEET Study Title From outlet of storage tank to inlet of batch tank. Drawing No. 0 Revision No. NIL Date 28-06-2008 Hazop Team Mr Deepak Chanchad Part Considered Storage tank & pump Activity Transferring of Raw material Design intent PRES. TEMP FLOW VACU. Material : E. O. Amb Source : From storage tank

Parameter Guide



Action Required

Temperature More

1. Seasonal effect 2. Poor insulation of

pipeline. 3. Falling of hot water on

uninsulated line. 4. Incoming E. O. from

storage tank itself has high temperature.

1. More pressure in the pipeline may give rise to leakage.

2. From poor flange joints, valve. Fire & health hazards.

Insulation on pipeline & batch tank provided.

1. To dilute the 1 liter of EON, 18 liters water is required. Considering this sufficient quantity of water shall be ensured.

2. All flange joints shall be checked regularly.

Less

1. Seasonal effect 2. lekage of chilled water

in E.O. from tank.

No workplace Hazards. It the basic requirement but High moisture in E.O. Wastage of E. O.

Safety valve provided on batch tank.

Pressure More Covered under flow

Less Covered under flow





Action Required

Flow More

1. N2 pressures more. 2. Valve failure 3. FIC mal function. 4. Human error.

1. Pressure rise in batch tank.

2. Leakage in flange joint.

3. Safety valve of batch tank may popup.

4. Tank filling operation completed in less time.

Pressure gauge shall be provided on batch tank.

Less

1. Choking in the excess flow valve. (Holes are choked.)

2. Low pressure of N2 itself.

3. Valve choked.

No safety hazards but it will take more time for filling operation.

Reverse No chances 1. NRV provided. 2. Auto shut off valve provided.


ACETALININDE PLANT Table 4.10 HAZOP STUDY WORKSHEET Study Title Raw material to the storage tank ( Day Tank ) Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Storage tank & pump Activity Transfer Design intent PRES. TEMP FLOW VACU. Material : Acetic Acid Am Am Source : From storage tank.

Parameter Guide



Action Required

Flow Pressure

No

1. No material in the storage tank.

2. Pump tripped. 3. Pump discharge valve

closed. 4. Heavy leakage in pipe line.

No material to service tank.

Pressure gauge provided on the pump discharge valve.

1. Non-returnable Valve to be provided.

2. Arrow indicator to be provided on pipeline.

3. Stand by pump to be provided.

4. Pump, storage tank & pipe line identification to be done.

5. Color code to be provided.

6. Work permit procedure to be followed for handling of hazardous chemicals.

7. PPE compliance to be followed during handling of acid.

More 1. Valve opened more than set value

2. Human Error.

More material to the service tank.

Reverse Not possible Less SOP to be prepared.


Table 4.11 HAZOP STUDY WORKSHEET Study Title Reaction Process Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Storage tank & pump Activity Reaction Design intent PRES. TEMP FLOW VACU. Material : Acetic Acid & Aniline + Acetic anhydride. Am 130 Source : From the storage tank.

Parameter Guide



Action Required

Temperature More 1. Hot oil circulation temperature is more.

2. Choking of pipeline of inlet & out let of condenser.

3. Poor cooling in condenser.

1. Process Disturbance.

2. (Reaction time will be more.)

3. Product will char.

1. Pressure gauge & temperature gauge to be provided.

2. Safety valve provided on reactor’s jacket.

1. Arrow indicator to be provided.

2. Sand tray to be provided for the collection of storage.

3. SOP to be prepared.

Less 1. Ambient temperature is low.

2. Good cooling. 3. Hot oil circulation

temperature is low.

Efficient process will not take place.

Pressure More Atmospheric pressure reaction

SOP to be prepared.

Less

Not possible

Power failure

No process will take place.

DG set provided.


CHLORO SULPHONIC ACID PLANT

Table 4.12 HAZOP STUDY WORKSHEET Study Title Chilling of the HCL Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr Deepak Chanchad Part Considered Storage tank & pump Activity Chilling Design intent PRES. TEMP FLOW VACU. Material : HCL ---- ---- ---- Source : Form MCB plant

Parameter Guide



Action Required

Chilling No

1. No supply of chilling media.

2. Power failure 3. Insulation damaged. 4. Seasonal effect 5. HCL flow is low. 6. More impurities of

organics from the other plant.

1. Poor chilling of the HCL.

2. Process delayed.

1. Temperature controller is provided.

2. Insulation provided on the chiller.

More Not possible.

Reverse Not possible.


Table 4.13 HAZOP STUDY WORKSHEET Study Title Gas cleaning Drawing No. Revision No. NIL Date 08.07.2010 Hazop Team Mr Deepak Chanchad Part Considered Activity Cleaning of HCL Design intent PRES. TEMP FLOW VACU. Material : HCL Source : From chilling section

Parameter Guide



Action Required

Cleaning No

1. No supply of HCL. 2. Cleaning media

circulation stopped. 3. Poor circulation. 4. H2SO4 exhausted.

1. No Health & Safety hazards.

2. Quality of cleaning of the HCL will be affected. (Moister will not removed and due to moisture wet gas will carry over in the reaction.

1. Physical check for the cleaning media which is to be changed after certain cycle.

2. Pump stop alarm to be provided.

More Good quality of cleaning media.

No process & safety hazards.

Temperature More Choking in scrubber & vapor. Accumulation in gas phase.


Table 4.14 HAZOP STUDY WORKSHEET Study Title Reaction Drawing No. Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Activity Reaction Design intent PRES. TEMP FLOW VACU. Material : Dry HCL & SO# 3-5 kg

/cm2 Am As per

blower --- Source : From the storage tank.

Parameter Guide



Action Required

Flow More 1. HCL flow as per blower. 2. SO3 flow more than set

value. 3. Human error.

1. No process disturbance.

2. Un reacted sulfur trioxide generation will be more.

1. Temperature indicator provided.

2. Pressure gauge provided.

Arrow indicators & pipeline color code to be provided.

Less/ No 1. Blower amp low. 2. Blower stopped

Process Delayed.

Temperature More Flow of HCL & SO3 are more.


Less Flow of HCL & SO3 are less.

Decrease in pressure & temperature

Power failure

--- 1. Un-reacted gas will come out from the scrubber.

2. Circulation will be stopped & reaction will take place.

Captive Power plant.


SULFURIC ACID PLANT Table 4.15 HAZOP STUDY WORKSHEET Study Title Melting of Sulfur Drawing No. 0 Revision No. NIL Date 07.07.2010 Hazop Team Mr Deepak Chanchad Part Considered Storage tank & pump Activity Melting Design intent PRES. TEMP FLOW VACU. Material : Sulfur 135 Source : From the Sulfur storage tank.

Parameter Guide



Action Required

Temperature More 1. Low quantity of sulfur (Sulfur fed poorly.

2. Steam temperature high. 3. Ambient temperature high.

Good for the process.

1. DSC operated plant. 2. Pressure indicator provided. 3. Temperature gauge provided. 4. Level indicator provided. 5. Closed process 6. Controls on flow. Temperature &

pressure are provided.

Interlocks between the Burner temperature & steam flow is suggested.

Less 1. Incoming steam temperature low.

2. Ambient temperature low. 3. More quantity of sulfur fed

in the burner.

Pressure More

1. Temperature is very high. 2. Choking in the upward

stream.

Over pressurization may affect on there factory wall over a long run.

Pressure indicator provided. Temperature gauge provided.

1. Physical checks to be ensured.

2. Periodic inspection of the Sulfur burner to be ensured.

Less As per low temperature. Sulfur & Steam Mixing Leakage in the steam coil. Material will spoil. Temperature gauge & pressure gauge

provided.

Power failure

---- Sulfur May jammed Captive Power Plant. Critical equipment should be connected with the DG supply.


Table 4.16 HAZOP STUDY WORKSHEET Study Title Burning of sulfur with air. Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Sulfur Burner Activity Pumping Design intent PRES. TEMP Sulfur VACU. Material : Sulfur 1100 - ---- Source : From the Sulfur storage tank.

Parameter Guide



Action Required

Temperature More 1. Incoming air temperature is high.

2. Efficient operation of furnace.

No process hazards as it is the process requirement.

1. Temperature controller provided. 2. Glass window provided.

Arrow indicators to be provided on fuel line.

Less 1. Poor incoming air temperature

2. Poor flow of fuel.

Conversion process of the SO2 will not take place.

Pressure More 1. Incoming air flow is more than set value.

2. Discharge of SO2 gas restricted due to choking.

3. Rupture of partition wall. 4. More incoming pressure

from the sulfur melter.

Heavy leakage may started form the panel door & also some time rupture of furnace.

Less 1. No flow of air. 2. No sulfur from the melter.

No Health & safety hazards.

Flow More As per more pressure. Low As low pressure.

Power failure.

Jamming of sulfur In burner.

DG set provided.


Table 4.17 HAZOP STUDY WORKSHEET Study Title Catalyst convertor Drawing No. 0 Revision No. Nil Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Sulfur Burner Activity Design intent PRES. TEMP FLOW VACU. Material : SO3, Vanadiumpentoxide. Source :

Parameter Guide



Action Required

Temperature More 1. Incoming air temperature is high.

2. Efficient operation of furnace.

No process hazards as it is the process requirement.

1. Temperature controller provided. 2. Glass window provided.

Less 1. Poor incoming air temperature

2. Poor flow of fuel.

Conversion process of the SO2 will not take place.

Pressure More 1. Incoming air flow is more than set value.

2. Discharge of SO2 gas restricted due to choking.

3. Rupture of partition wall. 4. More incoming pressure

from the sulfur smelter. 5.

Heavy leakage may started form the panel door & also some time rupture of furnace.

Less 1. No flow of air. 2. No sulfur from the melter.

No Health & safety hazards.

Flow More As per more pressure. Low As low pressure.

Power failure.

Jamming of sulfur In burner.

DG set provided.


THYONYL CHLORIDE PLANT Table 4.18 HAZOP STUDY WORKSHEET Study Title Rector Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr Deepak Chanchad Part Considered Activity Reaction process Design intent PRES. TEMP FLOW VACU. Material : Chlorine & Sulfur 105 Source : From Storage

Parameter Guide



Action Required

Temperature More 1. More quantity of Catalyst, 2. More Charge quantity of

either Chlorine & Sulfur 3. Hot oil temperature is more.

Pressure & temperature will go on increasing.

1. Temperature gauge & pressure gauge provided.

2. Rotometer provided for the chlorine control.

3. Sight glass provided. 4. Safety valve provided. 5. Cooling & chilling arrangement

with alternative provided. 6. Chlorine PRV station provided. 7. In case of increase of

temperature chlorine charging supply will closed.

8. In case of increase of pressure raw material charging supply will closed.





5. Work permit procedure to be followed for handling of hazardous chemicals.


Less 1. Less quantity of catalyst. 2. Hot oil temperature is less

or less quantity of HO is fed due to leakage valve partially closed.

Reaction time will increase.





Action Required

Pressure More

As per temperature

Less

Flow More Human error. More charging of material.


Power failure

No GEB supply. Captive power plant provided.


Table 4.19 HAZOP STUDY WORKSHEET Study Title Gas mixture Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr Deepak Chanchad Part Considered Activity Gas Mixing Design intent PRES. TEMP FLOW VACU. Material : Chlorine, SO2 & SDC Source : From Storage

Parameter Guide



Action Required

Temperature More 1. More quantity of Catalyst, 2. More Charge quantity of eithe

Chlorine & Sulfur 3. Hot oil temperature is more. 4. More SO2 from the holder

tank.



2. Rotometer provided for the chlorine control.

3. Sight glass provided. 4. Safety valve provided . 5. Cooling & chilling arrangement

with alternative provided. 6. Chlorine PRV station provided.

1. Non returnable Valve to be provided.




5. Color code to be provided. 6. Work permit procedure to

be followed for handling of hazardous chemicals.


8. Periodic checking of the condenser to be followed.

Less 1. Less quantity of catalyst. 2. Hot oil temperature is less

or less quantity of HO is fed due to leakage, valve partially closed.

Reaction time will increase.

Pressure More As per temperature Less 1. Human error.

2. More charging of material. Pressure & temperature will go on increasing.

Flow More No GEB supply. Pump circulation will stop.

Power failure Captive power plant provided.


Table 4.20 HAZOP STUDY WORKSHEET Study Title High Boiler fractional Distillation Column Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered HBFC, Condenser, Heat Exchanger & Carbon bed. Activity Distillation Design intent PRES. TEMP FLOW VACU. Material : Crude TC Source : From the Crude TC Reciever.

Parameter Guide



Temperature More Good Heating

1. No process hazards. It is part of the requirement.

2. It will accelerate the distillation process


2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling

arrangement with alternative provided.

5. Chlorine PRV station provided.

1. Non return Valve to be provided.






Less Poor Heating No distillation will take place. Process delayed.

Pressure More Not possible ----- Less Not Possible -----

Flow More Not possible ----- Power

failure No GEB supply. Distillation will not

achieve. Captive power plant provided.


Table 4.21 HAZOP STUDY WORKSHEET Study Title Final Product Distillation Column Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr Deepak Chanchad Part Considered HBFC, Condenser, Heat Exchanger &

Carbon bed. Activity TC Distillation

Design intent PRES. TEMP FLOW VACU. Material : Crude TC Yes Yes Source : From HBFC.

Parameter Guide



Action Required













Pressure More Not possible ----- Less Not Possible -----

Flow More Not possible ----- Power

failure No GEB supply. Distillation will not

achieved. Captive power plant provided.


MONOCHLORO BENEZEN PLANT

Table 4.22 HAZOP STUDY WORKSHEET Study Title Reaction of Chlorine Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Activity Reaction Design intent PRES. TEMP FLOW VACU. Material : Chlorine & Benzene Source : From the storage tank

Parameter Guide



Action Required

Temperature More 1. More quantity of chlorine due to wrong setting of Rotometer.

2. Rotometer malfunction 3. Poor cooling of reactor. 4. Ambient temperature is

high. 5. More flow of benzene

due to human error.

1. Flame Proof fitting are provided.

2. Rota Meter is provided. 3. Double static earthing

provided to all equipment. 4. Jumpers are provided on all

the pipe line joint. 5. Benzene flow cut off at high

temperature in reactor have been provided.

6. Temperature controllers are provided in front of Operators cabin.

1. To handle the chlorine emergency chorine kit to be ensured.

2. Chlorine detectors to be provided.

Less 1. Flow of chlorine is less. 2. Rotometer malfunctions. 3. No benzene flow or

choking in spray nozzles.

4. Chlorine sprayer got choked.





Action Required

Pressure More As per flow

Less As per flow

Flow More 1. Rotometer failure 2. More flow from the

chlorine header itself.

Temperature will go on increasing

Less 1. Rotometer malfunction. 2. Less flow from the

chlorine itself. 3. Valve closed.

Process delayed.

Power failure

1. No supply due to electrical fault

2. & also the captive power plant not running.

Captive power plant provided. 1. Chlorine supply to be closed immediately as it leads to environmental hazards. Un reacted chlorine will go to the atmosphere.

2. DG set to be provided & all critical equipment shall be connected with the DG supply.


DMS PLANT

Table 4.23 HAZOP STUDY WORKSHEET Study Title Reaction Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr Deepak Chanchad Part Considered Activity Reaction Design intent PRES. TEMP FLOW VACU. Material : Methanol Yes 260 No Source : From the Heat exchanger & condenser

Parameter Guide



Action Required

Temperature More 1. Hot oil circulation is more.

2. More temperature of the methanol gas.

3. More charging of the catalyst.

4. Ambient temperature is more.

1. Pressure will go on increasing.

2. No process hazards.

3. It is the part of requirement.

1. DSC Plant operation 2. Flow control valve provided

on the methanol. 3. Flame Proof fitting are

provided. 4. Double static earthing

provided to all equipment. 5. Jumpers are provided on all

the pipe line joint. 6. Safety Valve & Pressure

gauge are provided on Hot oil circulation circuit.

1. Calibration of all instruments to be carried out.

2. SOP to be prepared. 3. Annual shut down to

be carried out and corroded plant to be replaced.

4. Thickness monitoring of the vessels to be carried out.

Less Low catalyst quantity of catalyst due to human error.

1. Process delayed. 2. DMS gas will not

produced.

Pressure More As per flow

Less As per flow





Action Required

Flow More 1. Pump Ampere more. 2. Valve fully open 3. In the system. 4. Human error.

Less 1. Pump amp low 2. Leakage in the pipe line. 3. Valve partially closed in

the HE & condenser system.

4. No material in the storage tank.

Power failure

1. No GEB supply. 2. Sudden failure in the

electrical system.

Process disturbance. Captive power plant provided.


Table 4.24 HAZOP STUDY WORKSHEET Study Title Reaction Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Activity Chilling Reaction Design intent PRES. TEMP FLOW VACU. Material : SO3 & Methanol Yes No Source : From the reactor.

Parameter Guide



Action Required

Temperature More 1. Not Possible. 2. Chilling process

1. DCS operated plant. 2. Closed process 3. Pressure gauge provided on

the chilled water jacket. 4.

Less 1. Good chilling effect. 2. Winter days. 3. Good insulation

1. Good for the process.

2. No safety hazards

Pressure More Not possible

Less Not possible

Flow More Not possible

Less Not possible.

Power failure

1. No GEB supply. 2. Sudden failure in the

electrical system.

Process Disturbance Captive power plant provided.


Table 4.25 HAZOP STUDY WORKSHEET Study Title Distillation Drawing No. 0 Revision No. NIL Date 08.07.2010 Hazop Team Mr. Deepak Chanchad Part Considered Activity Distillation Design intent PRES. TEMP FLOW VACU. Material : DMS vapour. Yes No Source : From the reactor.

Parameter Guide



Action Required







5. Chlorine PRV station provided.








Pressure More Not Possible Less Not Possible Flow More Not Possible Less Not Possible. Captive power plant provided. Power

failure 1. No GEB supply. 2. Sudden failure in the

electrical system.

Process Disturbance

Kcil Hazop Study Report

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