HAZOP STUDY Report (Kutch Chemical Industries Limited)

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
Prepared By HSE Department
M/s. Kutch Chemical Industries Limited
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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.
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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
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CONTENTS
SECTION NO. 1 1.1 1.2 1.3 2 2.0 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4
CONTENTS Objective and Methodology of HAZOP Study Objectives Scope of The Work Methodology Introduction to HAZOP Hazard and Operability Study Introduction Of the Unit Introduction of the unit Details of Unit Google map Site Plan Organisation chart Details of storage of Hazardous Materials in Bulk Facilities / System Process Flow chart HAZOP Sheets
NO. OF PAGES
8 8 8 8 10 10 13 13 13 20 21 22 22 28 29 49
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LIST OF TABLES
TABLE NO. Table- 4.1 Table- 4.2 Table- 4.3 Table- 4.4 Table- 4.5 Table- 4.6 Table- 4.7 Table- 4.8 Table- 4.9 Table- 4.10 Table- 4.11 Table- 4.12 Table- 4.13 Table- 4.14 Table- 4.15 Table- 4.16 Table- 4.17 Table- 4.18 Table- 4.19 Table- 4.20 Table- 4.21 Table- 4.22 Table- 4.23 Table- 4.24 Table- 4.25
CONTENTS Hazop Study Worksheet (Transferring of Chlorsulfonic Acid to service tank) Hazop Study Worksheet (Charging of Acetanilide) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Dumping) Hazop Study Worksheet (Reduction) Hazop Study Worksheet (Condensation) Hazop Study Worksheet (Esterification) Hazop Study Worksheet (E. O. storage tank) Hazop Study Worksheet (From outlet of storage tank to inlet of batch tank) Hazop Study Worksheet (Raw material to the storage
tank ( Day Tank ))
Page No. 50 51 52 53 54 55 57 58 61 63 64 65 66 67 68 69 70 71 72 74 75 76 78 80 81
Hazop Study Worksheet (Reaction Process) Hazop Study Worksheet (Chilling of the HCL) Hazop Study Worksheet (Gas cleaning) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Melting of Sulfur) Hazop Study Worksheet (Burning of sulfur with air) Hazop Study Worksheet (Catalyst convertor) Hazop Study Worksheet (Rector) (Gas mixture) Hazop Study Worksheet (High Boiler fractional Distillation Column) Hazop Study Worksheet (Final Product Distillation Column) Hazop Study Worksheet (Reaction of Chlorine) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Distillation)
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HAZOP SUMMARY
HAZOP SUMMARY SR. NO. 1 OBSERVATION AREA UTILITY SERVICES SUMMARY 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 .
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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. 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. Standard Operating procedures to be prepared. Work permit procedures to be followed for the handling of hazardous chemicals. 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.
ENVIRONMENTAL
ADMINISTRTION
GENERAL
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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,
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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.
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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 Intention
HAZOP study are:-
: - 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)
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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 Consequences
: - These are the results of the deviations : - 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 None More of Meanings Complete negation of the intention Quantitative increase Comments No part of the intention is achieved e.g. no flow or reverse flow. 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 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. Composition of system different from what it should be e.g. Change in ration of components, component missing etc. More components present in the system that there should be e.g. extra phase present (Vapor, solid), impurities (air, water, acids, corrosion products etc.) 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.
Less of
Quantitative decrease
Part of
Quantitative decrease
More than
Qualitative increase
Other than
Substitution
2.6
Guidewords are applied to the design intention. The design intention informs us what the equipment is expected to do.
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2.7
A flow chart giving HAZOP procedure is given below:Select Line
Select deviation Eg. More flow Move onto next deviation NO
Is more flow possible ? Consider other causes of more flow
Is it hazardous or does it prevent efficient operation ?
NO
What change in the plant will tell him
NO
Yes Will the operator know that there is more flow ?
Yes
What change in plant or methods will prevent the deviation or make it less likely or protect against the consequences.
Consider other changes or agree to accept hazard.
Is the cost of change justified
NO
Agree changes. Agree who is responsible for action.
Follow up to see that action has been taken. Prepared By HSE Department
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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. 1. Particulars Full Name & Address of : Kutch chemical Industries limited Unit Plot no- 165,166/1&3,168,171/1&172 Village:Padana, Nr.Aquagel Chemicals, Gandhidham, Dist Kutch Gujarat. Telephone No. : 02836-28551-52, Fax-02836-285233 Month & Year of : 10th June 2002 Establishment Full name & Address of : Sh. Shivlal Goyal ( Director) the occupier 2, Sri Ram Society, Gotri Road Baroda Full name & Address of : Sh. D.S.Purohit the Factory manager Plot no 23, Ward -9B(D) New Bharat Nagar, Gandhidham Pin- 370201 Man Power : 172 including all shift G Shift- 31 A Shift- 47 B Shift- 47 C Shift- 47 No. Of shift & Shift timing : Total no of shift :- 04 General shift :- 09AM To 06 PM First Shift A:- 07 AM To 03 PM
2. 3.
4. 5.
6.
7.
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Second Shift B:- 03 PM To 11PM Night Shift C:- 11PM To 07AM 8. 9. Environs (Nearest Facilities) Meteorogical Data Latitude Longitude Temperature Maximum Minimum Relative Humadity Maximum Minimum Annual Rain Fall Minimum Maximum Seasonal wind directions : Jan- Feb March Sept Oct to Dec Wind Velocity Maximum Minimum Avg. Wind Speed 1. Railway Station 2. Police Station 3. Fire Station 4. Hospitals N / NNW / ENE SW / WSW N / NNE : 132 km/hr NNW (26.10.1975) 100 km/hr NNW (26.10.1975) 14 Km/hr : Gandhidham, Distance 20 KM : Anjar, Distance 20 KM : Anjar , Distance- 20 KM : Anjar , Distance- 20KM 48 C 7.2 C : 100 % 1% : 73.6 mm 1393 mm (1979) 23 10N 70 13 E
10.
Total Land at Plant
50 ACRE
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11. 12. 13. 14. 15.
Total Built-up area at the Factory Power connection DG Set Power plant details :
30000 M2 Demand : 3000 KVA KVA: 250 KVA
16.
17.
DG Set - 2.5 MW Turbine 4.2 MW Water Storage and source Capacity in m3:20000 M3, Source Gujarat water infrastructure limited (GWIL) Boiler Type Model no Capacity Licence from Gujarat Govt. Combi pack CPB-80 8Ton/Hr GT 4879 IB-147810 Ton/Hr GT 5516 Waste heat Maker no- 25 Ton/Hr GT-5207 Recovery 21943 AVU Make Chilled water plant Particulars Model No Capacity Location VAM VAM VAM Ammonia compr 2 nos Ammonia compr 2 nos Ammonia compr 2 nos Ammonia compr 5 nos Ammonia compr 3 nos -----150 TR DMS Plant OLD VS MCB & PNCB MCB PNCB PDCB New VS OLD VS
SD30BHX/1 200TR SD30BHX/1 200 TR KC6-3 KC6-3 KC6-3 KC6 KC6 Total 150 TR 150 TR 150 TR 300 TR 180 TR 1480 TR TR 3260 1000 1000
18.
Cooling Tower
Particulars
Flow rate
Plants Acid Division DMS Plant OLD VS
Process 4200M3/H cooling water Process 1300M3/H cooling water Process 1200M3/H cooling water Prepared By HSE Department
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Process 1200M3/H cooling water Process 1200M3/H cooling water Process 600m3/H cooling water Process 600M3/H cooling water Process 500M3/H cooling water Process 1350M3/H cooling water Total Capacity: 50 M3 Water reservoir (GWIL) 200M3 Departments
1000 1000 500
MCB Plant Acetanilid e plant PNCB Plant PDCB Plant New VS plant TC Plant
250 300 1100 9410
19. 20. 14 21.
Effluent treatment Plant Fire water source Fire Water Reservoir capacity : M3 Department wise List of fire extinguishers with mapping if available
22.
SCBA sets availability and location mapping
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 Total Nos of SCBA Sets 08 Nos Acid division C/R- 01No Chlorine Shed- 02 Nos DMS Plant- 01 Nos TC Plant- 02 Nos Page Rev. : : 16 00
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 Prepared as Per ISO-14000
24. 25. 26. A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q. R. 27. 28.
EMP
EMP plan ( Action Prepared and displayed in all department Plan) one page List of emergency facilities Dry powder (50% of fire extinguishers ) CO2 Cartridges ( 50% of fire extinguishers ) 200 gms (10 kg DCP As above 2 Kg ( 75 Kg DCP ) Sand scoops Safety helmets Water curtain nozzles Stretchers First aid box with anti snake serum Rubber hand gloves Explosive meter Fire entry suit w/o breathing apparatus Resuscitator Electric siren with 3 km range Hand operated siren Water gel blandest Red/green flags for fire drill Pressure type self contained breathing apparatus with spare cylinder (30 minutes) Safety Shower Fire Water Reservoir :Other Source of Water : 50 nos 50 nos 06 nos 50 nos 500 nos 20 nos 01 nos 10 nos 200 nos 01 no 01 no 05 no 01 no Nil NA Nil 08 nos. 14 nos. 200 M3 Gujarat water infrastructure limited , Anjar Page Rev. : : 17 00
29.
Fire Pump Details Pump Detail Head 70 mtr 70 mtr Nil Nil Capacity (Flow) 10.8 m3/h 270m3/h Nil Nil Nos. Of Hydrant with Hose Box Hydrant 07 nos Hose box- 01 nos Hydrant 01 nos Hose box- 01 nos Hydrant 11 nos Hose box- 03 nos Hydrant 06 nos Hose box- 05 nos Hydrant 011nos Hose box- 05 nos Hydrant 01no Hose box- 01 no Hydrant 02 nos Hose box- 01 nos Hydrant 05 nos Hose box- 02 nos Hydrant 01 no Hose box- 01 no Hydrant 02nos Hose box- 02 nos Hydrant 47 nos Hose box- 30 nos KW/HP 10 120 Nil Nil Nos. Of Monitors 01 no
Number of Pump Jockey Pump 01 Electrical Pump 01 Diesel Pump Nil Total 02 30. Hydrant System Details Area / Plant PNCB Plant MCB Plant Acid Division Old VS plant New VS Plant Acetanilide Plant PDCB Plant Power Plant Canteen DMS Plant Total 31. A. B. License & Approval: Factory Inspectorate GPCB
Nil 01 no
C. D.
Solid waste Disposal Explosive licence No : Particulars Chlorine
Licence No : 018712 Validity : 31/12/2010 Consent No: 5991/3/5/2005 Validity : 31/1/2010 Note Application inward ID12531/Dated- 18/12/2009 for renewal of consent Member ship : TSDF, Nandesari Baroda Licence no Validity G/WC/GJ/06/109(G15607) 30/09/2011 Page Rev. : : 18 00
Ethylene oxide old VS Plant Ethylene oxide New VS Plant Furnace oil Methanol Benzene& Toluene
S/HO/GJ/03/718(SS5280) S/HG/GJ/03/1066(S32386)
31/03/2013 31/03/2011
P/WC/GJ/15/2380(PII9928) 31/12/2010 P/HQ/GJ/15/4682(P120542) 31/12/2010 P/HQ/GJ/15/4568(P20641) 31/12.2012
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3.3.
Google Map:
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3.4.
Site Plan:
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3.5.
ORGANIZATIONAL SET UP
Safety setup organisation chart

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
Dy. Mgr ((Fire & Safety) (General Shift only)
GM Operation
Fire & Safety Supervisor (One in every shift)
Fireman Two in each shift
3.6.
NAME
DETAILS OF STORAGE OF HAZARDOUS MATERIALS IN BULK

OF MAX. STORAGE PLACE OF ITS OPERATING PRESSURE AND TEMP. TYPE HAZARD OF CONTROL MEASURE PROVIDED
HAZARDOUS SUBSTANCE
CAP.[Qty.]
STORAGE
Vinyl Sulphone Plant Ethylene 25 KL X 1 bullet Oxide 15 KL X 1 bullet
Licenced Premises A/G SS
10 Kg/ cm2 Ambient
Fire /Explosion/ Toxic
Chloro Sulfonic Acid
45 KL X 6 Nos Tank
Tank farm area A/G MS
ATP Ambient
Corrosive
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. Level gauge provided. Scrubber provided Required PPEs provided to
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Chloro Sulfonic Acid (Proposed) Caustic Lye
200 MT X 3 Nos.
Do
ATP Ambient ATP Ambient ATP Ambient ATP Ambient ATP Ambient
Corrosive
25 KL X 2Nos Tank 40 KL X6 Nos Tank 20 KL X 1Nos Tank 30 KL X 3Nos Tank
Caustic Lye Sulfuric Acid Hydrochloric Acid
Tank farm area A/G MS Do Do Tank farm area A/G HDPE
Corrosive
Corrosive Corrosive 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 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 Chlorine Kit, Caustic Pit, SBA sets, Cl2 Shed, Cl2 Hood, EOT, etc. Provided. 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 Hydrant system
Acetanilide Plant Acetanilide Aniline 600 MT 100 KL X 1 No Tank Godown Tank farm area A/G MS Do Do Do Do ATP, Ambient ATP, Ambient ATP, Ambient ATP, Ambient ATP, Ambient ATP, Ambient Combustible Flammable
Aniline
200 KL X 1 No Tank Acetic Acid 100 KL X 2 No Tank Dil. Acetic 25 KL X 2 No Acid Tank Ethyl Acetate 25 KL X 1 No Tank 15 KL X 1No Tank MCB, ODCB, PDCB, DCB Plant Chlorine 209 Tonners Chlorine Benzene 200 Tonners 40KLX4 Nos Tank Total : 160 KL 200KLX2Nos Tank 90KLX 2 Nos Tank 200KLX 1 No Tank 200KLX 1 No Tank
Flammable Corrosive/ Flammable Corrosive Flammable
Storage Shed Storage Shed U/G Tank MS Tank farm area A/G MS DO DO Tank farm area A/G MS
10 Kg/cm2 Ambient 10 Kg/cm2 Ambient ATP
Toxic Toxic Fire
Monochloro Benzene (MCB) PNCB ONCB Dichloro Benzene (DCB)
ATP
Fire
ATP ATP ATP
Fire Fire Fire
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NB, PNT, ONT, Plant Toluene 40KLX4 Nos Tank Total : 160 KL 40KLX4 Nos Tank Total : 160 KL U/G Tank MS U/G Tank MS ATP Fire 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 Hydrant system Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees Flame proof plant, pumping transfer, close process, etc. 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.
Benzene
ATP
Fire
Nitric Acid Sulphuric Acid
20KLX3 Nos Tank 20KLX 1 No Tank
MS A/G Tank MS A/G Tank
ATP ATP
Corrosive Corrosive
PNT (PNitroToluene) ONT ONitro Toluene MNT (Meta Nitro Toluene)
200KLX1No Tank 200 KLX 1 No Tank 90KL Tank X1 No
MS A/G Tank MS A/G(V) Tank MS A/G (H) Tank MS A/G(V) Tank
ATP
Fire
ATP
Fire
ATP
Fire
NB (Nitro Benzene) Sulphuric Acid Plant Sulfur powder 5000 MT
200KLX 1 No Tank Total : 290 KL 150KLX 1 No Tank
ATP
Fire
Storage yard
ATP
Fire
Oleum 65 %
250 MT X2 Nos Tank 250 MT X 1No Tank 100 MT X 2 Nos.
MS A/G Tank MS A/G Tank MS A/G Tank
Atmospheric Ambient Atmospheric Ambient Atmospheric Ambient
Corrosive
Oleum 23%
Corrosive
Oleum 65 %
Corrosive
Separate storage area. Monitors provided surrounding the storage area. Automatic conveyer system for charging in melter. Level gauge provided. Scrubber provided Required PPEs provided to all employees Double drain valve will be provided to sulfuric Acid storage tank Full body protection will be provided to operator.
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Liq Sulphur Trioxide Sulphuric Acid 98 % 1000 MT X 2 Nos. tank
MS A/G Tank MS A/G Tank
Atmospheric Ambient Atmospheric Ambient
Corrosive
Corrosive
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 Level gauge provided. Scrubber provided Required PPEs provided to 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
CSA Plant Chloro sulphonic Acid Chloro sulphonic Acid Dimethyl Sulfate (DMS) Dimethyl Aniline (DMA) Diethyl Sulfate (DES) Benzene Sulphonyl Chloride DASDA
50 KLX 3 Nos Tank 140 KL X 01 Tank 2000 MT X 2 Nos Tanks 200 MTX 3 Nos.
MS A/G Tank
Atmospheric Ambient
Corrosive
MS A/G Tank MS A/G Tank MS A/G Tank
Atmospheric Ambient Atmospheric Ambient Atmospheric Ambient
Corrosive
Fire
100 MTX 2 Nos.
Fire
200 MTX 2 Nos.
MS A/G Tank MS A/G Tank MS A/G Tank MS A/G Tank MS A/G Tank
Atmospheric Ambient Atmospheric Ambient Atmospheric Ambient Atmospheric Ambient Atmospheric Ambient
Fire
100 MTX 2 Nos.
Fire
100 MTX 2 Nos.
Fire
Methanol
60KLX Tank
Nos
Fire
Ethanol
200 KL X 1 No. tank
Fire
Flame proof plant, pumping transfer, close process, etc. Double Static earthing Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking and prohibited area. Tanker unloading procedure. Flame arrestor Provided.
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Ammonia Anhydrous ( Liquefied )
50 MT X 1 No. Bullet
MS bullet
350 C 4 to kg/cm2
Toxic 10
Hydrochloric Acid
25 KL X 03 Nos
A/G HDPE Tank
Atmospheric Ambient
Corrosive
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 Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees Level gauge provided. Scrubber provided Required PPEs provided to 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 Chlorine Kit, Caustic Pit, SBA sets, Cl2 Shed, Cl2 Hood, EOT, etc. Provided. Scrubber provided .
TC plant (PROPOSED) Thyonile 150KL X 03 Tank chloride
SS A/G Bullet
Atmospheric Ambient
Corrosive
Chlorine
140 Toner
Storage Shed
10 Kg/cm2 Ambient
Toxic
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Sulpher trioxide
100 MT X 02 Tank
MS 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 Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees
Chlorinated Paraffin Wax CPW (PROPOSED) HNP 65KLX 04 TANK MS Tank
Atmospheric Ambient
Flammable
HCL
75KLX 6 TANK
HDPE TANK
Atmospheric Ambient
Corrosive
Chlorinated Paraffin oil
20 KLX 03
FRP
Atmospheric Ambient
Corrosive
Furnace LDO HSD
Oil/
27 KLX 2 Nos U/G tanks 21 KL Tank
MS Tank MS Tank
Atmospheric Ambient Atmospheric Ambient
Fire Fire
Flame proof plant, pumping transfer, close process, etc. Double Static earthing Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking and prohibited area. Tanker unloading procedure. Flame arrestor Provided.
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. 2. 3.
Total enclosed process system. DCS operation plant. Instrument & Plant Air System for control all parameters.
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4.
5. 6. 7. 8. 9.
10.
11.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
24. 25. 26. 27. 28.
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. Safety valve, rupture disk provided on reactor and pressure storage tanks. Static earthing and electric earthing (Double) will be provided. Jumpers for static earthing on pipeline flanges of flammable chemical provided. Flame proof light fitting installed where ever it is required. Emergency handling equipments like SCBA sets, Fire extinguishers, Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit, Air line respirator, provided. 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. 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. Storage tank area are away from the process plant and Separation Distance has been maintained. Dyke wall provided to all above ground storage tanks, collection pit with valve provided. Flame arrestor with breather valve is installed on flammable material storage tank vent. Lightening arrestor on all chimneys and building provided. Fencing and caution notes and hazard identification boards displayed. Only authorized person are permitted in storage tank farm area. Safety permit for hazardous material loading unloading is prepared and implemented. Static earthing provision is made at all loading unloading points of flammable chemical storage tank farm area. TREM CARD provided to all transporters and trained for transportation Emergency of Hazardous chemicals. Fire hydrant system and water sprinkler system installed at tank farm area. Caution note, safety posters, stickers and emergency preparedness plan will be displayed. Emergency facilities and medical emergency facilities are available at site. Occupational Health centre facility generated at factory premises and paramedical staff is available round the clock. Wind direction indicators are provided. Safety Shower and eye wash are installed at acid/ alkali handling area. Tele Communication system and mobile phone will be used in case of emergency situations for communication. Emergency siren installed at main gate as well as in all plant. Training programme are being conducted regularly and induction training are being provided to all employees on chemical safety and process safety.
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3.1 3.1.1
BRIEF DESCRIPTION OF PROCESS AND FLOW CHART 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 50C. 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 160C 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 + 2Cl.SO 3H SO 2Cl ACETANILIDE CHLORO SULPHONIC ACID NHCOCH3 + HCl + H2SO 4
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Reduction:
NHCOCH3 + SO 2Cl NaOH + NaHSO 3 SO 2Na NHCOCH3 + Na2SO 4 + NaCl
Ethoxylation:
NHCOCH3 H2 C + H2SO4 + H2O SO2Na + O ETHYLENE OXIDE CH2 + Na2SO4 SO2CH2CH2OH NHCOCH3
Esterification:
NHCOCH3 + H2SO 4 SO 2CH2CH2OH NH2 + CH3COOH SO 2CH2CH2OSO 3H VINYL SULPHONE
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Process Flow Chart:

Acetanilide 2182 CHLOROSULPHONIC 10182 ACID CHLOROSULPHONATION 12364
Ice
14545
DUMPING(ICE) 26909
FILTERATION(Nutch) 12364
H2SO4 (35-40%) 14545
SOD. BISULPHITE SLURRY(30%) CAUSTIC LYE
6545 REDUCTION 2182 21091
PRODUCT FROM FILT ETHYLENE OXIDE H2SO4 1018 2269.00 ETHOXYLATION 24378.00 Salt FILTER 6625.00 ETP CONDENSED PRODUCT 6625.00 2262 DRYER 4363.00 PRODUCT FROM Dryer H2SO4 1455 ESTERIFICATION 5818.00 ACETIC ACID 1818 VINYL SULPHONE 4000.0 MOISTURE LOSS 9454 17753 SODIUM SULPHITE SALT (BYPRODUCT) 8299
MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE
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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 + 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 70C, thus heating to 125C 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 Prepared By HSE Department
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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 M.W 32 3/2O2 48 + H2O 18 H2SO4 98
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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.
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Sulphur 163.25 MT 904341 M3 (Oxygen: 245 MT) Water Air Drying Tower
Metler (135C)
Furnace (1100)
WHB
Steam
Steam Turbine to Generate 4 MW Power
Convertor (upto 3rd pass)
100 MT DM Water IPAB(Inter Pass Absorption Tower 99% H2SO4 Oleum Tower H2SO4 (98.5%) Oleum Pump Tank (Oleum 23% or 65%)
Acid Pump Tank
Convertor (4th pass)
Oleum Storage (23% or 65%)
99% H2SO4 H2SO4 (98.5%) Storage 500 MT/Day Final Absorption Tower
Alkali Scrubbe r Vent to Atmosphere
Wastewater 0.8 KLD
PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)
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SO3 Convertor (132 C)
Condenser
SO3 Liquid 7500
Oluem Pump Tank (23%) 8070
Oleum Tower (23%)
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:
SO3 (l) 80 + HCl (g) 36.5 ClSO3H (l) 116.5
Mass Balance:
1567 HCl Chilling 1567 Chilled HCl H2SO4 Gas Cleaning Bleed 1567 Dry HCl Reactor Gas to Stack Caustic Scrubber 0.8 Castic Solution Wastewate To ETP 10% 0.8 KL/Month 5000 Chlorosulphonic Acid
99.90%
3433 Liq SO3 100.00%
MASS BALANCE OF CHLOROSULPHONIC ACID
Kutch Chemical Industries Ltd.
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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):
CH3 NO2
98
CH3
H2SO4 H2S2O7
178
NO2
+
H2SO4
SO3H
Sulphonated o-NT 217 Sulfuric Acid 98
o-Nitro Toluene 137
Chemical Reaction: (Tobias)

SO3H NH2 + H2S2O7 SO3H SO3H NH2 + H2SO4
Tobias Acid (TA) 223
178
STA (Sulfo Tobias Acid) 303
98
MASS BALANCE:
ONT H2SO4 H2S2O7 137 98 178
Sulfonator 413
Water Common Salt (NaCl)
18 117
Drawning Vessel 548 Filteration 217 Centrifuge Spent Acid (25%) (Water+Salt+Sulfuric Acid) 331 2 (Recycle to Drawning Vessel)
Wet Cake 215 MASS BALANCE OF SULPHONATION ONT/PNT
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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 Benzene (l) 78 + HOSO2Cl CSA (l) 116.5 C6H5SO2Cl + BSC (l) 176.5 HCl Hydrochloric Acid Gas (g) 36.5
M.W
Mass Balance/Flow Chart:

663 1980 Benzene CSA HCl gas 310
Reactor
2333 Isolation 1500 Dilute H2SO4 833 Crude Dimethyl Sulphone 15
Distillation 1485 Benzyl Sulphonyl Chloride
MASS BALANCE OF BENZYL SULPHONYL CHLORIDE
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.
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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. Chemical Reaction:
2S Sulphur 64 + Cl2 Chlorine 70 S2Cl2 Sulphur Monochloride (SMC) 134
S2Cl2 134 SMC
2SO3 160
Cl2 70 Chlorine
2SOCl2 236 TC
2SO2 128
Sulphur Trioxide
Overall Chemical Reaction: 2S 64 + 2Cl2 140 + 2SO3 160 2SOCl2 236 + 2SO2 128
Mass Balance:
818 Sulphur 890 Chlorine SMC Reactor
1708 2044 SO3 890 Chlorine TC Reactor 3015 Condenser 2400 Product To Sulfuric Acid & SBS plant (Recycle) 1627
Distillation Column 15 Total Product
600 Product 3000
MASS BALANCE OF THIONYL CHLORIDE
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.
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Chemical Reaction:
CH3 + NO 2 PNT(137) 98 178 H 2 SO 4 + H2S2O7 NO 2 PNTSA (217) CH3 SO3H + 2H2SO4
CH3 2 NO 2 217 SO3H + 2NaOCl +H2O O2N
SO3Na - C = C H 149 18 H
SO3N
+ NO2
2HCl + 3H2O
474
73
54
SO3N
SO3Na O2N - C = C H (DNSDA) H
SO3Na Fe/HCl NO2 NH4Cl H H H2N - C = C
SO3N
NH2
Di-Sodium Salt (Nitro form)
Di-Sodium Salt (Amino form) 414
SO3N
SO3Na H2N - C = C H 414 H
SO3H NH2 + H2SO4 H2N - C = C H DASDA H
SO3H
NH
370
Mass Balance:
PNT H2SO4 Oleum 63 45 82 Sulfonator
190 Water Salt 20 15 Drawning Vessel 225 Neutsch Filter 167 Centrifuge 137 Common Salt Soda Ash NaOCl Water 15 18 69 25 30 ML(Recycle) Drawning 58 To ETP
Oxidation 264 Neutsch Filter 206 Centrifuge 201 58 To ETP
ML(Recycle) Drawning
Fe HCl NH4Cl
5 8 15
Reduction Vessel 229 Filter Press 202 Isolation Vessel 202 Neutsch Filter 176 Centrifuge 170 Product 26 To ETP 27 To ETP
ML(Recycle) Isolation Vessel
DASDA MASS BALANCE OF DASDA
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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 Steam 45 kg/cm2 410C
Turbine Generator Set
Exhaust 0.1 kg/cm2 100 C Condenser Condensate back to Boiler feed water
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. Chemical Reaction:
Na2CO3 + 106 Sodium Carbonate 2SO2 + 64 H2O 18 2NaHCO3 + CO2 208 SBS 28
Mass Balance:
Sodium Carbonate SO2 Water 106 64 18 CO2 28 Reactor
160
MASS BALANCE OF SODIUM BI SULPHITE
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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. Chemical Reaction:
260C 2 CH3OH Catalyst(Al2O3) Methanol 2 x 32 Dimethyl Ether 46 18 CH3-O-CH3 + H2O
CH3-O-CH3 +
SO3
(CH3)2SO4 Dimethyl Sulphate 126
46
SO3 80
H2O 18
H2SO4 98
Mass Balance :
DME Gas 1138 Reactor Containing Al2O3 Catalyst(260C) Condensation Tank
1979
Liq SO3
1524
Methanol Day Tank
Heat Exchanger
Reactor
386
Water To ETP
Pure Dimethyl Sulphate
3000
Distillation
117 98% Spent Sulfuric Acid
MASS BALANCE OF DIMETHYL SULPHATE
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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:
260C 2 CH3OH Catalyst(Al2O3) Methanol 2 x 32 Dimethyl Ether 46 18 CH3-O-CH3 + H2O
CH3-O-CH3 +
C6H5NH2
(CH3)2C6H5NH2 Dimethly Aniline 123
46
93
Mass Balance:
DME Gas Aniline 1134
780
Methanol Day Tank
Heat Exchanger
560 Reactor Containing Aluminium Catalyst Condensation Tank
Reactor
220 Water To ETP
1694 1500 Pure Dimethyl Aniline Distillation 194 Wastewate to ETP
MASS BALANCE OF DIMETHYL ANILINE
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.
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Chemical Reaction:
2C2H5OH Ethyl Alcohol 92 2C2H5OSO3H + EHS 228 + 2SO3 Catalyst 160 NH3 Ammonia 17 Ethyl Hydrogen Sulfate 228 (C2H5)2SO4 Diethyl Sulfate 154 + NH4SO4 Ammonium Sulfate 114 2C2H5OSO3H
Mass Balance:
896 Ethyl Alcohol 1558 SO3 Cooler 354
Reactor (Catalyst: Urea+Sod. Sulfate)
2100 NH3 166 Ammoniation Reactor 2266
Distillation
Spent ST Tank 766
1500 Pure Diethyl Sulfate MASS BALANCE OF DIETHYL SULFATE
3.1.14
Calcium Chloride
Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride. Chemical Reaction: 2CaCO3 +4 HCl 2CaCl2 + 2 HCO3
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Mass Balance:
0.2 Water 5 Lime Stone Reactor 4 HCl 9 0.2 Ventury Scrubber (Alkali) ETP
Filter Press 8 CaCl2 Clear Liquid
Sludge to ETP 1
Mosture Loss Evaporator
5 Dry CaCl2 Product MASS BALANCE OF CALCIUM CHLROIDE
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. Chemical Reaction: Ca F2 3 ( Ca3(PO4)2) + 14 HCl
7 CaCl2 + 3Ca H(PO4)2 + 2HF
3Ca (OH)2 Mass Balance:

Rock Phosphate HCl (30%) 1800 Reactor 3600 5400
6CaHPO4 DCP
Lime
200 Neutralisation 5600
Hydrated Lime Sodium Silicate
200 10 Separation 5810
Filteration 5310 Recycle to Reactor to recover DCP 1500 Centriguge 3810 Dryer 3000 Finished Product
Process Sludge 500
Mositure Loss 810
MASS BALANCE OF DI CALCIUM PHOSPHATE
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3.1.16 Sulphur Mono Chloride Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a reactor. Chemical Reaction:
2S Sulphur 64 + Cl2 Chlorine 70 S2Cl2 Sulphur Monochloride (SMC) 134
Mass Balance:
95.5 Sulphur 104.5 Chlorine SMC Reactor
200 MASS BALANCE OF SULPHUR MONOCHLORIDE
3.1.17
Sulphuryl Chloride Sulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl Chloride. Chemical Reaction:
S 32
3Cl2 210
2SO3 160
3SO2Cl2 402 Sulphuryl Chloride
Mass Balance:
16 Sulphur 17.5 Chlorine Reactor
33.5 80 SO3 89.5 Chlorine Reactor 203 Condenser 13 Residue 3 Distillation Column Product 10 190 Product
MASS BALANCE OF SULPHURYL CHLORIDE
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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. Chemical Reaction: 2Al(OH)3 156 Mass Balance:
Water 860 Alumina Hydrate/Bauxite Reactor 456 Sulphuric Acid 1316
3H2SO4 294
Al2(SO4)3 + 342
6H2O 108
Settling Tank 1316 456 Sulphuric Acid Reactor
Moulding in to Slab
MASS BALANCE OF ALUM
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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. Chemical Reaction: NH2CONH2 + SO3 H2SO4 NH2CONHSO3H 2NH2SO3H + CO2
NH2CONHSO3H + Overall Reaction
+ CO2
NH2CONH2 + SO3 + H2SO4 60 Mass Balance:

350 Urea 3300 SO3/Oleum (23-25%) Reactor 3650
2NH2SO3H 2 x 97
CO2 44
80
98
R/C Mother Liquor Mixing 5150 Separation 2400 100 Water Make -Up 2500 Cyrstallisation 1500 1000 Packing/Bagging Spent Acid 2750
Figure are in Ton/Month MASS BALANCE OF SULFAMIC ACID
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SECTION IV HAZOP SHEET
HAZOP SHEET
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VS PLANT
Table: 4.1 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Transferring of Chlorsulfonic Acid to service tank. Revision No. Mr. Deepak Chanchad Storage tank, Pump Activity PRES. TEMP FLOW VACU. Material : Amb Amb ---Source : Guide Words No Possible causes 1. No material in the storage tank. 2. Pump tripped. 3. Pump valve closed. NIL Date 08.07.2010
Transferring of Chloro Sulfonic Acid to Service Tank. Chloro Sulfonic Acid Form the storage Tank Measures/Existing facilities Action Required safeguard Pressure gauge provided on the 1. Level indicator to be pump discharge valve. provided on service tank. 2. Arrow indicators to be provided on pipeline
Parameter Flow
Possible consequences No material to service tank.
Less
1. Valve partially closed. 2. Leakage in the pipe line. 3. Less material in the storage tank. 1. Pump Ampere more. 2. Discharge valve fully open than required set value.
More time taken to fill the service tank.
More
Early filling of Service tank
1. Level indicator provided. 2. Vents are connected to scrubber.
Page Rev.
: :
50 00
Table: 4.2 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Charging of Acetanilide Revision No. Mr. Deepak Chanchad -PRES. TEMP FLOW Nil Amb NA Guide Words No Possible causes No material Activity Material : Source : NIL Charging of acetanilide Acetanilide Bag packing Measures/Existing facilities safeguard Material is charge under the supervision. Action Required Separate storage to be identified with the marking Date 08.07.2010
VACU. --
Parameter Charging
Possible consequences No process will take place.
Less
1. Human error. 2. Material weight is less than what is mentioned on the bag. 1. Human Error 2. Material packing weight is more than what is printed on it.
1. Disturbance in the process. 2. More
More
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.
Page Rev.
: :
51 00
Table: 4.3 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reaction Revision No. Rector PRES. ----Guide Words More Activity Material : Source : NIL Date 08.07.2010
TEMP 80
FLOW ----
VACU. -----
Reaction Acetanilide + Chlorosulfonic. From the storage tank & Manual charging of bag. Measures/Existing facilities safeguard 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. Action Required 1. Standard operating procedure to be prepared. 2. Arrow indicators to be provided on pipe line.
Parameter Pressure
Possible causes 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. 1. Good cooling 2. Control Rate of Raw material addition. As per pressure Good cooling water flow
Possible consequences Pressure & temperature will go on increasing. Exothermic Reaction will take place.
Less
No process hazards
Temperature
More Less
Water Entry in the reactor
Leakage
No process hazards. It is process requirement. Temperature & Pressure will go on increasing.
1. Thickness monitoring of the reactor is carried out. 2. Hydro testing of the jacket at periodic interval. : : 52 00
Page Rev.
Table: 4.4 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Dumping Revision No. Dumping vessel PRES. TEMP Gravity 5 Guide Words More Activity Material : Source : Nil Date 08.07.2010
FLOW ----
VACU. ----
Dumping of sulphonated mass. Sulphonated mass. From sulfonator Measures/Existing facilities safeguard 1. Temperature Gauge 2. Pressure gauge provided. 3. Total closed process 4. Safety valve provided on Chilled water cooling line. Action Required 1. Only administrative checks to be ensured. 2. SOP to be prepared.
Parameter Temperature
Possible causes
Less
Pressure
More Less More
Possible consequences 1. No addition of ICE water. 1. Maximum 2. Poor cooling of the temperature will reactor. be the ambient. 3. Choking in the HCL scrubber line. Good cooling 1. It is good for the process 2. No safety & health hazards. Increase in temperature due No process & safety to above hazards. hazards Not Applicable There is no flow measurement as sulphonated reaction mass is directly dumped in the dumping vessel.
Flow
Less Other than Part of Prepared By HSE Department
Not applicable No full charging Process delayed Page Rev. Physical inspection : : 53 00
Table: 4.5 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reduction Revision No. Reduction PRES. TEMP 50 Guide Words More Activity Material Source Nil Reduction SBS + Caustic Lye From Measures/Existing facilities safeguard 1. Temperature Gauge 2. Pressure gauge provided. 3. Total closed process 4. Safety valve provided on Chilled water cooling line. Action Required Visual check by the operator Date 08.07.2010
FLOW
VACU.
Possible causes 1. Poor/No cooling. 2. Damaged insulation 3. Stirrer not moving/stopped 4. More addition of caustic. 5. Charging of normal water. 1. Good cooling. 2. Controlled addition of material in controlled way.
Possible consequences 1. Desired process will not achieved. 2. Temperature will rise.
Less
Pressure
More
Less
No process & safety hazards as it is requirement of the process. No effect on pressure rise as it is only neutralization & reduction by adding caustic lye. Not possible.
No process & safety hazards
Page Rev.
: :
54 00
Table: 4.6 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Condensation Revision No. Condensation Rector PRES. TEMP FLOW 50 -----Guide Words More Possible causes 1. Hot oil circulation is more. 2. More hot material from the reduction it self. 3. Flow of EO in case above desired level. Activity Material : Source : Possible consequences Increase in temperature & pressure. Nil Date 08.07.2010
VACU. ----
Reduction Mass + Ethylene Oxide Reduction & EO form storage tank Measures/Existing facilities safeguard 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. Page Rev. : : 55 00 Action Required 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.
Guide Words Less
Possible causes Human error- Chilled water circulation valve is open. Increase in temperature due to above mentioned causes
Possible consequences Desired process will not achieve. Temperature Increase.
Measures/Existing facilities safeguard BMR is prepared & followed.
Action Required Physical checks are required.
Pressure
More
Pressure Gauge provided on reactor & operator will take action accordingly.
Less Flow ( EO ) More 1. Human Error 2. Valve passed.
Not possible Increase in temperature & pressure. 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.
Page Rev.
: :
56 00
Table: 4.7 HAZOP STUDY WORKSHEET
Study Title Drawing No. Hazop Team Part Considered Design intent
Esterification Revision No. Esterification Reactor PRES. TEMP FLOW ---160

Guide Words Possible causes
Date Esterification Sulfuric Acid + Condensed product. From Condensation

Measures/Existing facilities safeguard
08.07.2010
VACU. Yes
Activity Material : Source :
Parameter
Possible consequences
Action Required
Temperature
More
1. Increase in flow of Sulfuric acid. 2. Jacket temperature is more. 3. Less quantity of condensed material. 1. No heating in the jacket. 2. No flow of sulfuric acid.
1. Pressure will increase. 2. PH may affected.
1. Temperature & pressure gauge Physical & administrative provided. checks to be ensured. 2. Safety valve & Pressure gauge provided on Reactor jacket. 3. Sight glass provided. 4. Vent are connected to scrubber.
Less
1. No safety & health hazards. 2. Desired process temperature will not achieved. 3. Delayed in the batch cycle.
Pressure
More Less
As per the temperature As per the temperature
Page Rev.
: :
57 00
Table: 4.8 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent E. O. storage tank NIL Deepak Chanchad Storage Tank PRES. TEMP FLOW N. A.
Guide Words Possible causes
Revision No. Activity Material : Source :

NIL Storing of E. O. E. O. E. O. Storage tank
Date
28-06-2008
VACU. N.A.
Parameter
Action Required
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. Page Rev.
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. : : 58 00
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.
Parameter
Guide Words
Possible causes
Action Required
Temperature
Less
1. Good Chilling. 2. Too cold atmosphere during the winter. 1. N2 valve passing. 2. More temperature in the storage tank.
1. Decrease in E. O. Pressure.
1. Temperature Gauge provided. 2. Insulation provided.
Pressure
More
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 1. During the pop of E. O. tank. Safety valve it shall be 2. Inbuilt N2 pressure is 5.8 ensured the sufficient kg/cm2 so by human error N2 quantity of water for dilution. valve remains open than also 2. In case Safety valve do it will not rise up to 5.8 not set to its back kg/came. Safety valve of position after venting Storage tank set at 6.5 Kg/cm2 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.
Page Rev.
: :
59 00
Parameter
Guide Words
Possible causes
Action Required
Flow
More Less Reverse
Covered under pressure Covered under pressure Not Possible
Process disturbance. Spillage hazards 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
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. Pressure gauge on the outer side of the cooling coil shall be provided.
Page Rev.
: :
60 00
Table: 4.9 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent From outlet of storage tank to inlet of batch tank. 0 Revision No. Mr Deepak Chanchad Storage tank & pump Activity PRES. TEMP FLOW VACU. Material : Amb Source : Guide Words More Possible causes 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. Seasonal effect 2. lekage of chilled water in E.O. from tank. Possible consequences 1. More pressure in the pipeline may give rise to leakage. 2. From poor flange joints, valve. Fire & health hazards.
NIL
Date
28-06-2008
Transferring of Raw material E. O. From storage tank Measures/Existing facilities safeguard Insulation on pipeline & batch tank provided. Action Required 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
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
Page Rev.
: :
61 00
Parameter Flow
Guide Words More
Possible causes 1. 2. 3. 4. N2 pressures more. Valve failure FIC mal function. Human error.
Less
1. Choking in the excess flow valve. (Holes are choked.) 2. Low pressure of N2 itself. 3. Valve choked. No chances
Possible consequences 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. No safety hazards but it will take more time for filling operation.
Action Required Pressure gauge shall be provided on batch tank.
Reverse
1. NRV provided. 2. Auto shut off valve provided.
Page Rev.
: :
62 00
ACETALININDE PLANT
Table 4.10 HAZOP STUDY WORKSHEET
Study Title Drawing No. Hazop Team Part Considered Design intent Raw material to the storage tank ( Day Tank ) 0 Mr. Deepak Chanchad Storage tank & pump PRES. TEMP FLOW VACU. Am Am Revision No. Activity Material : Source : NIL Transfer Acetic Acid From storage tank. Date 08.07.2010
Parameter
Flow Pressure
Guide Words
No
Possible causes

Pressure gauge provided on the pump discharge valve.
Action Required
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.
1. No material in the storage No material to service tank. tank. 2. Pump tripped. 3. Pump discharge valve closed. 4. Heavy leakage in pipe line.
More
Reverse Less
1. Valve opened more than set value 2. Human Error. Not possible
More material to the service tank.
SOP to be prepared.
Page Rev.
: :
63 00
Table 4.11 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reaction Process 0 Mr. Deepak Chanchad Storage tank & pump PRES. TEMP FLOW Am 130 Guide Words More Possible causes 1. Hot oil circulation temperature is more. 2. Choking of pipeline of inlet & out let of condenser. 3. Poor cooling in condenser. 1. Ambient temperature is low. 2. Good cooling. 3. Hot oil circulation temperature is low. Atmospheric pressure reaction Not possible
Revision No. Activity Material : Source : Possible consequences 1. Process Disturbance. 2. (Reaction time will be more.) 3. Product will char.
NIL
Date
08.07.2010
VACU.
Reaction Acetic Acid & Aniline + Acetic anhydride. From the storage tank. Measures/Existing facilities safeguard 1. Pressure gauge & temperature gauge to be provided. 2. Safety valve provided on reactors jacket. Action Required 1. Arrow indicator to be provided. 2. Sand tray to be provided for the collection of storage. 3. SOP to be prepared.
Less
Efficient process will not take place.
Pressure
More Less Power failure
SOP to be prepared.
No process will take place.
DG set provided.
Page Rev.
: :
64 00
CHLORO SULPHONIC ACID PLANT

Table 4.12 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Chilling of the HCL 0 Mr Deepak Chanchad Storage tank & pump PRES. TEMP FLOW ------Guide Words No Possible causes 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. Not possible.
Revision No. Activity Material : Source : Possible consequences 1. Poor chilling of the HCL. 2. Process delayed.
NIL Chilling HCL Form MCB plant
Date
08.07.2010
VACU. ----
Parameter Chilling
Measures/Existing facilities safeguard 1. Temperature controller is provided. 2. Insulation provided on the chiller.
Action Required
More
Reverse
Not possible.
Page Rev.
: :
65 00
Table 4.13 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Gas cleaning Revision No. Mr Deepak Chanchad PRES. TEMP FLOW VACU. Activity Material : Source : Possible consequences 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. No process & safety hazards. Cleaning of HCL HCL From chilling section Measures/Existing facilities safeguard Action Required 1. Physical check for the cleaning media which is to be changed after certain cycle. 2. Pump stop alarm to be provided. NIL Date 08.07.2010
Parameter Cleaning
Guide Words No
Possible causes 1. No supply of HCL. 2. Cleaning media circulation stopped. 3. Poor circulation. 4. H2SO4 exhausted.
More
Good quality of cleaning media. Choking in scrubber & vapor. Accumulation in gas phase.
Temperature
More
Page Rev.
: :
66 00
Table 4.14 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reaction Revision No. Mr. Deepak Chanchad PRES. 3-5 kg /cm2 Guide Words More TEMP Am FLOW As per blower VACU. --Activity Material : Source : Reaction Dry HCL & SO# From the storage tank. NIL Date 08.07.2010
Parameter Flow
Possible causes
Less/ No Temperature More
Less Power failure
Possible consequences 1. HCL flow as per blower. 1. No process 2. SO3 flow more than set disturbance. 2. Un reacted sulfur value. trioxide generation 3. Human error. will be more. 1. Blower amp low. Process Delayed. 2. Blower stopped Flow of HCL & SO3 are Increase in more. temperature & pressure. Flow of HCL & SO3 are Decrease in pressure less. & temperature --1. Un-reacted gas will come out from the scrubber. 2. Circulation will be stopped & reaction will take place.
Measures/Existing facilities safeguard 1. Temperature indicator provided. 2. Pressure gauge provided.
Action Required Arrow indicators & pipeline color code to be provided.
Captive Power plant.
Page Rev.
: :
67 00
SULFURIC ACID PLANT

Table 4.15 HAZOP STUDY WORKSHEET
Study Title Drawing No. Hazop Team Part Considered Design intent Melting of Sulfur 0 Mr Deepak Chanchad Storage tank & pump PRES. TEMP FLOW 135 Revision No. Activity Material : Source : NIL Date 07.07.2010
VACU.
Melting Sulfur From the Sulfur storage tank.
Parameter
Temperature
Guide Words
More
Possible causes
1. Low quantity of sulfur (Sulfur fed poorly. 2. Steam temperature high. 3. Ambient temperature high.
Good for the process.

1. 2. 3. 4. 5. 6. DSC operated plant. Pressure indicator provided. Temperature gauge provided. Level indicator provided. Closed process Controls on flow. Temperature & pressure are provided.
Action Required
Interlocks between the Burner temperature & steam flow is suggested.
Less
Pressure
More
1. Incoming steam temperature low. 2. Ambient temperature low. 3. More quantity of sulfur fed in the burner. 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.
Sulfur & Steam
Less Mixing Power failure
As per low temperature. Leakage in the steam coil. ----
Material will spoil. Sulfur May jammed
Temperature gauge & pressure gauge provided. Captive Power Plant.
Critical equipment should be connected with the DG supply.
Page Rev.
: :
68 00
Table 4.16 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Burning of sulfur with air. 0 Mr. Deepak Chanchad Sulfur Burner PRES. TEMP Sulfur 1100 Guide Words
More
Revision No. Activity Material : Source : Possible consequences
NIL
Date
08.07.2010
VACU. ----
Pumping Sulfur From the Sulfur storage tank. Measures/Existing facilities safeguard
1. Temperature controller provided. 2. Glass window provided.
Parameter
Temperature
Possible causes
1. Incoming air temperature is high. 2. Efficient operation of furnace. 1. Poor incoming air temperature 2. Poor flow of fuel. 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. 1. No flow of air. 2. No sulfur from the melter. As per more pressure. As low pressure. Jamming of sulfur In burner.
Action Required
Arrow indicators to be provided on fuel line.
No process hazards as it is the process requirement. Conversion process of the SO2 will not take place. Heavy leakage may started form the panel door & also some time rupture of furnace.
Less
Pressure
More
Less Flow More Low Power failure.
No Health & safety hazards.
DG set provided.
Page Rev.
: :
69 00
Table 4.17 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Catalyst convertor 0 Mr. Deepak Chanchad Sulfur Burner PRES. TEMP FLOW
Nil
Date
08.07.2010
VACU.
SO3, Vanadiumpentoxide.
Parameter
Temperature
Guide Words
More
Possible causes
1. Incoming air temperature is high. 2. Efficient operation of furnace. 1. Poor incoming air temperature 2. Poor flow of fuel. 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. 1. No flow of air. 2. No sulfur from the melter. As per more pressure. As low pressure. Jamming of sulfur In burner.

1. Temperature controller provided. 2. Glass window provided.
Action Required
No process hazards as it is the process requirement. Conversion process of the SO2 will not take place. Heavy leakage may started form the panel door & also some time rupture of furnace.
Less
Pressure
More
Less Flow More Low Power failure.
No Health & safety hazards.
DG set provided.
Page Rev.
: :
70 00
THYONYL CHLORIDE PLANT

Table 4.18 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Rector 0 Mr Deepak Chanchad PRES. TEMP 105 FLOW VACU.
NIL Reaction process Chlorine & Sulfur From Storage
Date
08.07.2010
Parameter
Temperature
Guide Words
More
Possible causes

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.
Action Required
1. Arrow indicator to be provided on pipeline. 2. Stand by pump to be provided. 3. Pump, storage tank & pipe line identification to be done. 4. Color code to be provided. 5. Work permit procedure to be followed for handling of hazardous chemicals. 6. PPE compliance to be followed during handling of acid.
1. More quantity of Catalyst, Pressure & temperature 2. More Charge quantity of will go on increasing. either Chlorine & Sulfur 3. Hot oil temperature is more.
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.
Page Rev.
: :
71 00
Parameter Pressure
Guide Words More Less
Possible causes As per temperature
Action Required
Flow
More
Human error. More charging of material. No GEB supply.
Pressure & temperature will go on increasing. Captive power plant provided.
Power failure
Page Rev.
: :
72 00
Table 4.19 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Gas mixture 0 Mr Deepak Chanchad PRES. TEMP FLOW VACU.

Pressure & temperature will go on increasing.
NIL Gas Mixing Chlorine, SO2 & SDC From Storage
Date
08.07.2010
Parameter
Temperature
Guide Words
More
Possible causes
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. 1. Less quantity of catalyst. 2. Hot oil temperature is less or less quantity of HO is fed due to leakage, valve partially closed.

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.
Action Required
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. 8. Periodic checking of the condenser to be followed.
Less
Reaction time will increase.
Pressure
More Less More Power failure
Flow
As per temperature 1. Human error. 2. More charging of material. No GEB supply.
Pressure & temperature will go on increasing. Pump circulation will stop. Captive power plant provided.
Page Rev.
: :
73 00
Table 4.20 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent High Boiler fractional Distillation Column 0 Revision No. Mr. Deepak Chanchad HBFC, Condenser, Heat Exchanger & Carbon bed. PRES. TEMP FLOW VACU.
NIL Activity Material : Source :
Date
08.07.2010
Distillation Crude TC From the Crude TC Reciever. Action Required 1. Non return 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. Periodic checking of the condenser to be followed.
Guide Words More
Possible causes Good Heating
Possible consequences 1. No process hazards. It is part of the requirement. 2. It will accelerate the distillation process
Measures/Existing facilities safeguard 1. Temperature gauge & pressure gauge provided. 2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling arrangement with alternative provided. 5. Chlorine PRV station provided.
Less Pressure Flow More Less More Power failure
Poor Heating Not possible Not Possible Not possible No GEB supply.
No distillation will take place. Process delayed. ------------Distillation will not achieve. Page Rev.
Captive power plant provided.
: :
74 00
Table 4.21 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Final Product Distillation Column 0 Mr Deepak Chanchad HBFC, Condenser, Heat Exchanger & Carbon bed. PRES. TEMP FLOW VACU. Yes Yes Guide Words More Possible causes Good Heating
NIL TC Distillation Crude TC From HBFC.
Date
08.07.2010
Possible consequences 1. No process hazards. It is part of the requirement. 2. It will accelerate the distillation process
Measures/Existing facilities safeguard 1. Temperature gauge & pressure gauge provided. 2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling arrangement with alternative provided.
Action Required 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. Periodic checking of the condenser to be followed.
Less
Poor Heating
Pressure Flow
More Less More Power failure
Not possible Not Possible Not possible No GEB supply.
No distillation will take place. Process delayed. ------------Distillation will not achieved. Page Rev.
: :
75 00
MONOCHLORO BENEZEN PLANT

Table 4.22 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reaction of Chlorine 0 Mr. Deepak Chanchad PRES. TEMP FLOW VACU.
NIL Reaction Chlorine & Benzene From the storage tank
Date
08.07.2010
Guide Words More
Possible causes 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. Flow of chlorine is less. 2. Rotometer malfunctions. 3. No benzene flow or choking in spray nozzles. 4. Chlorine sprayer got choked.
Less
Measures/Existing facilities safeguard 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.
Action Required 1. To handle the chlorine emergency chorine kit to be ensured. 2. Chlorine detectors to be provided.
Page Rev.
: :
76 00
Parameter Pressure
Guide Words More Less
Possible causes As per flow As per flow
Action Required
Flow
More
Less
Power failure
1. Rotometer failure Temperature will go 2. More flow from the on increasing chlorine header itself. 1. Rotometer malfunction. Process delayed. 2. Less flow from the chlorine itself. 3. Valve closed. 1. No supply due to electrical fault 2. & also the captive power plant not running.
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.
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DMS PLANT
Table 4.23 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reaction 0 Mr Deepak Chanchad PRES. Yes Guide Words More TEMP FLOW VACU. 260 No Possible causes 1. Hot oil circulation is more. 2. More temperature of the methanol gas. 3. More charging of the catalyst. 4. Ambient temperature is more.
Revision No. Activity Material : Source : Possible consequences 1. Pressure will go on increasing. 2. No process hazards. 3. It is the part of requirement.
NIL
Date
08.07.2010
Reaction Methanol From the Heat exchanger & condenser Measures/Existing facilities safeguard 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. Action Required 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. As per flow As per flow
1. Process delayed. 2. DMS gas will not produced.
Pressure
More Less
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78 00
Parameter Flow
Guide Words More
Possible causes 1. 2. 3. 4. 1. 2. 3. Pump Ampere more. Valve fully open In the system. Human error. Pump amp low Leakage in the pipe line. Valve partially closed in the HE & condenser system. 4. No material in the storage tank. 1. No GEB supply. 2. Sudden failure in the electrical system.
Action Required
Less
Power failure
Process disturbance.
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: :
79 00
Table 4.24 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Reaction 0 Mr. Deepak Chanchad PRES. Yes TEMP FLOW VACU. No
NIL Chilling Reaction SO3 & Methanol From the reactor.
Date
08.07.2010
Guide Words More
Possible causes 1. Not Possible. 2. Chilling process
Measures/Existing facilities safeguard 1. DCS operated plant. 2. Closed process 3. Pressure gauge provided on the chilled water jacket. 4.
Action Required
Less
1. Good chilling effect. 2. Winter days. 3. Good insulation Not possible Not possible Not possible Not possible. 1. No GEB supply. 2. Sudden failure in the electrical system.
1. Good for the process. 2. No safety hazards
Pressure
More Less
Flow
More Less Power failure
Process Disturbance
Page Rev.
: :
80 00
Table 4.25 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent Distillation 0 Mr. Deepak Chanchad PRES. Yes Guide Words More TEMP FLOW VACU. No Possible causes Good Heating
NIL Distillation DMS vapour. From the reactor.
Date
08.07.2010
Less
Poor Heating
Possible consequences 1. No process hazards. It is part of the requirement. 2. It will accelerate the distillation process No distillation will take place. Process delayed.
Measures/Existing facilities safeguard 1. Temperature gauge & pressure gauge provided. 2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling arrangement with alternative provided. 5. Chlorine PRV station provided.
Action Required 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. Periodic checking of the condenser to be followed.
Pressure Flow
More Less More Less Power failure
Not Possible Not Possible Not Possible Not Possible. 1. No GEB supply. 2. Sudden failure in the electrical system.
Captive power plant provided. Process Disturbance
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: :
81 00
Page Rev.
: :
82 00

HAZOP STUDY Report (Kutch Chemical Industries Limited)

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Kutch Chemical Industries Limited

Survey No 166/1,2,3, 171/1, 172,167,168, Village : Padana Gandhidham, Dist. Kutch

Hazard & Operability Study

PREPARED BY VAIBHU SAFETY CONSULTANTS

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

FOR VAIBHU SAFETY CONSULTANT

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

CHAPTER I OBJECTIVE AND METHODOLOGY OF HAZOP STUDY

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

SECTION II INTRODUCTION TO HAZOP

Hazard and Operability Studies(HAZOP)

The important terms pertaining to Intention

HAZOP study are:-

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

A flow chart giving HAZOP procedure is given below:Select Line

Select deviation Eg. More flow Move onto next deviation NO

Is more flow possible ? Consider other causes of more flow

Is it hazardous or does it prevent efficient operation ?

What change in the plant will tell him

Yes Will the operator know that there is more flow ?

Consider other changes or agree to accept hazard.

Is the cost of change justified

Agree changes. Agree who is responsible for action.

M/s. Kutch Chemical Industries Limited

SECTION III INTRODUCTION OF THE UNIT

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Total Land at Plant

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

11. 12. 13. 14. 15.

30000 M2 Demand : 3000 KVA KVA: 250 KVA

Plants Acid Division DMS Plant OLD VS

M/s. Kutch Chemical Industries Limited

1000 1000 500

250 300 1100 9410

19. 20. 14 21.

SCBA sets availability and location mapping

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

24. 25. 26. A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q. R. 27. 28.

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

Solid waste Disposal Explosive licence No : Particulars Chlorine

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited