PROCESS HAZARD ANALYSIS OF ETHYL ACETATE PLANT USING HAZOP

Abstract

Hazard and Operability study (HAZOP) study is the most widely used and preferred•approach in the chemical plant to accomplish hazard assignment qualitatively and quantitatively. This study is typically performed by a team of experts having specialized knowledge expertise in design, operation, and maintenance of the plant. The HAZOP team members examine the process P & ID systematically, identify every deviation from design intent in the plant using a "guideword " approach; determine all possible abnormal causes and the adverse consequences of the deviation. - The present dissertation work has been carried out in Ethyl Acetate plant at Bharuch, where Ethyl Acetate is the main product. The HAZOP study is carried out from Ethanol Unloading to Reactor in Ethyl Acetate plant. Ethyl Acetate is a hazardous material in terms of toxicity, Flammable liquid and vapors, is harmful if swallowed or inhaled directly affect central nervous system, causes irritation to skin, eyes and respiratory tract. If it contacts with nitrates, strong oxidizers, strong alkalis, or strong acids may cause fire and explosions. The main raw materials such as Ethanol, Acetic Acid and catalyst PTSA (Paratoluene Sulfonic Acid) are used in the manufacturing process of Ethyl Acetate. The operating units involved for the production of Ethyl Acetate in the plant are Reactor, Reactive Distillation Column, Decanter, wash Column, final/ product column, Ethyl Acetate storage tank. Deviation in the process parameter (such as temperature, pressure, level, flow etc.) may lead to serious accident (over pressurization of tank, high pressure in the tank, occurrence of flammable condition etc.); therefore qualitative and manual HAZOP study has been carried out for a better performance of the process system as well as safety. The present HAZOP study shows the possible abnormal causes and consequence of hazard in the plant. A brief result and discussion is also performed based on the present HAZOP study and also preventive corrective measures - and recommendation have been made to improve the safety performance of the process and production line as well.