Professional Documents
Culture Documents
Summary
In this memo, detail process of VCM has been simulated using HYSYS and it is found out
that the number of distillation column can be reduced as one distillation column are able to achieve
99% VCM purity. A manual mass and energy balance calculations has been performed for the major
equipment. It is found that the results agree with the simulation value with slight variation. Heat
integration conducted proves to reduce the energy consumption of hot and cold utilities of 41.6 % and
20.3 % respectively. The utilities required for this plant are 6 heat exchangers, 7 cooler and 2 heaters.
Major equipments used are reactors and distillation column with carbon steel and stainless steel 304
used as the material. Pipe sizing is conducted for major pipelines connecting and the industrial
diameter for each pipeline is obtained. Environmental Impact Assessment (EIA) is done to assess the
potential environmental impact the plant may experience and taking necessary mitigation to reduce
the impact. The effluents produced by VCM process are properly treated and disposed according to
the standards. Analysis of the process material hazards has been studied for its magnitude of risk in
order to take prevention method. The likelihood of hazards is presented in the contingency plan and
detail HAZOP study and its mitigation measures are also listed.
Process Flow Diagram
The modified process flow diagram for production of VCM from base case flow sheet is showed
in Appendix A with the stream composition. One distillation column is removed in EDC purification
section since one distillation column is sufficient enough to purify EDC to 99% for thermal cracking
process. .
Manual Mass and Energy Balance
Manual mass and energy balances are conducted to compare the calculated results with the results
obtained from HYSYS simulation, and it is observed that there are deviations between the two. Huge
variations exist for distillation columns as the calculated number of stages is unable to achieve the
desired purity of product, hence the number of stages is increased and consequently, the outlet flow
will deviate. For other components, the results are rather compatible. Hence, the results generated
from HYSYS simulation are valid. Appendix B shows the steps for manual mass and energy balances
conducted for major equipments.
Heat Integration (Targeting and Network Design) and Utilities Specifications
Process integration is conducted in the flowsheet to reduce plant energy consumption by designing a
network for heat exchange between the streams. One of the targeting tools used in this design is the
problem table algorithm (PTA) and the procedure can be shown in Appendix C. After cascading, the
total hot and cold utilities needed are 51.19 MW and 143.32 MW which shows a total savings of 44.6%
and 24.3% of utilities respectively compared to the design before performing heat integration, which
are QH,min= 92.47 MW and QC,min=189.44 MW. The hot and cold pinch temperatures obtained are
261.6C and 251.6C correspondingly. From heat exchange network (HEN) as seen in Appendix C as
well , a total of six heat exchangers, two heaters and 7 coolers are required for effective heat transfer.
Although the utilities achieved are considerably higher compared to the values obtained in PTA
method which are QH,min=53.92 MW and QC,min=151.0 MW, it is still acceptable as 41.6% of hot
utility and 20.3% of cold utility can be saved after targeting. The results of utility consumption are
shown in Appendix D.
Confidential
Confidential
To Wastetreatment
Vent_1
H2O
Chlorine
V-102
3-phase
Separator
CombinedFeed_1
Vent_3
Vent-2
E-100
Heater
VCM
To wastewater
treatment
MIX-100
Mixer
Ethylene_1
EDC2
EDC recycle
to Light
Column
Ethylene
Cstr-101
Oxychlorinator
10
9
NaOH
TEE-100
Splitter
Light End
P-100
Pump
MIX -102
Mixer
Ethylene_2
Vent_4
V-100 Crude
EDC Storage
Tank
Combined EDC
CombinedFeed_2
11
T-105 Light
Column
PFR-100
Pyrolysis
Reactor
EDC1
Flue Gas Product
T-101 VCM
Column
Oxygen
E-103 Cooler
V-101Caustric
Scrubber
CombinedFeed_3
E-105 Heater
T-100 HCL
Coumn
P-101
Pump
Bot_1
HCL Removed
MIX-101
Mixer
Heated HCl to
reactor
12
FH-100
Furnace
Fuel
HCl in
CombinedFeed_4
Air
K-100
Expander
E-101
Heater
Recycled EDC_1
Project A001
Plant Design for Vinyl Chloride
Monomer Production Plant
Confidential
Prepared by:
Lai Jia Yen
Checked by:
Michele Wee Sing Yee
Client: Mesfin Getu
Date: 10th September
2013
Stream Table
Table A1 :Stream Table of VCM Plant
Vap. Frac
Temp (Celcius)
Pressure (Kpa)
Mass Flow (Kg/h)
Heat Flow (KJ/h)
Comp Mole Frac (12-ClC2)
Comp Mole Frac (Ethylene)
Comp Mole Frac (Cl2)
Comp Mole Frac (112-ClC2)
Comp Mole Frac (Oxygen)
Comp Mole Frac (Nitrogen)
Comp Mole Frac (CO2)
Comp Mole Frac (Methane)
Comp Mole Frac (Ethane)
Comp Mole Frac (HCl)
Comp Mole Frac (H2O)
Comp Mole Frac (CO)
Comp Mole Frac (n-Butane)
Comp Mole Frac (VinylCl)
Comp Mole Frac (NaCl*)
Comp Mole Frac (NaOH)
Comp Mole Frac (Propane)
Comp Mole Frac (Acetylene)
Chlorine
1
25
101.324997
55585.7027
-994137.2429
0
0
0.9855
0
0.0075
0.004
0.003
0
0
0
0
0
0
0
0
0
0
0
CombinedFeed_1
1
24.976892
101.324997
78023.54585
40694857.94
0
0.502491
0.489651
0
0.003726
0.001987
0.001491
0.000327
0.000327
0
0
0
0
0
0
0
0
0
To Wastetreatment
1
50
151.987495
1415.946949
-675292.0791
0.185995
0.471376
0
0.000028
0.169628
0.092835
0.049303
0.014456
0.010647
0.005732
0
0
0
0
0
0
0
0
2
0
50
151.987495
76607.8318
-125436170
0.9913
0.00649
0
0.000394
0.000367
0.000095
0.000939
0.000051
0.000213
0.000151
0
0
0
0
0
0
0
0
CombinedFeed_2
1
50
151.987495
78023.54585
42235955.32
0
0.502491
0.489651
0
0.003726
0.001987
0.001491
0.000327
0.000327
0
0
0
0
0
0
0
0
0
3
0.2758
54.266594
151.987495
146608.117
-390625940
0.54282
0.126704
0
0.000136
0.013467
0.000033
0.057342
0.000248
0.000304
0.000057
0.258221
0
0
0.000402
0
0.000013
0
0.000253
4
1
47.455044
101.324997
0
0
0.223951
0.427515
0
0.000022
0.045896
0.000112
0.191262
0.000844
0.00102
0.000189
0.107212
0
0
0.001129
0
0
0
0.000848
5
0
47.455044
101.324997
109328.7531
-213042921
0.883565
0.002898
0
0.00024
0.00006
0
0.002484
0.000002
0.00001
0.000003
0.110572
0
0
0.000133
0
0.000025
0
0.000009
Ethylene
1
25
101.325
44875.69
83377990
0
0.9987
0
0
0
0
0
0.00065
0.00065
0
0
0
0
0
0
0
0
0
Ethylene_1
1
25
101.324997
22437.84315
41688995.19
0
0.9987
0
0
0
0
0
0.00065
0.00065
0
0
0
0
0
0
0
0
0
Ethylene_2
1
25
101.324997
22437.84315
41688995.19
0
0.9987
0
0
0
0
0
0.00065
0.00065
0
0
0
0
0
0
0
0
0
6
0
48.917685
3500
109328.7531
-212629318
0.883565
0.002898
0
0.00024
0.00006
0
0.002484
0.000002
0.00001
0.000003
0.110572
0
0
0.000133
0
0.000025
0
0.000009
HCl Recycle_2
0
-26.552983
1200
33172.24442
-98322446.48
0
0
0
0
0
0
0
0
0
0.998373
0
0
0
0.000999
0
0
0
0.000629
Oxygen
1
25
101.324997
14400
-4294.219232
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
CombinedFeed_3
1
24.941762
101.324997
70010.08757
-42038576.71
0
0.370005
0
0
0.208399
0
0
0.000241
0.000241
0.420429
0
0
0
0.000421
0
0
0
0.000265
Vap. Frac
Temp (Celcius)
Pressure (Kpa)
Mass Flow (Kg/h)
Heat Flow (KJ/h)
Comp Mole Frac (12-ClC2)
Comp Mole Frac (Ethylene)
Comp Mole Frac (Cl2)
Comp Mole Frac (112-ClC2)
Comp Mole Frac (Oxygen)
Comp Mole Frac (Nitrogen)
Comp Mole Frac (CO2)
Comp Mole Frac (Methane)
Comp Mole Frac (Ethane)
Comp Mole Frac (HCl)
Comp Mole Frac (H2O)
Comp Mole Frac (CO)
Comp Mole Frac (n-Butane)
Comp Mole Frac (VinylCl)
Comp Mole Frac (NaCl*)
Comp Mole Frac (NaOH)
Comp Mole Frac (Propane)
Comp Mole Frac (Acetylene)
CombinedFeed_4
1
200
405.299986
70010.08757
-27856437.74
0
0.370005
0
0
0.208399
0
0
0.000241
0.000241
0.420429
0
0
0
0.000421
0
0
0
0.000265
11
1
220
405.299986
70009.59071
-219913302.1
0.306739
0.189991
0
0
0.020363
0
0.087035
0.000352
0.000352
0.000393
0.393775
0
0
0.000614
0
0
0
0.000386
12
0
220
405.299986
0
0
0.014477
0.00012
0
0
0.000241
0
0.00207
0
0
0.000025
0.983052
0
0
0.000014
0
0
0
0
7
1
715.517045
3120
141685.612
-73371186
0.996293
0
0
0.00272
0
0
0
0
0
0
0.000948
0
0
0
0
0.000039
0
0
FlueGasProduct
1
1188.262576
101.324997
85599.77041
-126689087.8
0
0
0
0
0
0.730961
0.119573
0
0
0
0.149466
0
0
0
0
0
0
0
Air
1
25
101.324997
80368.6104
-22795.6537
0
0
0
0
0.21
0.79
0
0
0
0
0
0
0
0
0
0
0
0
Fuel
1
25
101.324997
5231.160049
-11373939.49
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
H2O
0
25
101.324997
3603.020099
-57244133.3
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
Vent_1
1
47.45504
101.325
30477.03
-7.1E+07
0.223951
0.427515
0
0.000022
0.045896
0.000112
0.191262
0.000844
0.00102
0.000189
0.107212
0
0
0.001129
0
0
0
0.000848
CombinedEDC
0
47.455044
101.324997
109328.7531
-213042921.2
0.883565
0.002898
0
0.00024
0.00006
0
0.002484
0.000002
0.00001
0.000003
0.110572
0
0
0.000133
0
0.000025
0
0.000009
AqueousWaste
0
47.455044
101.324997
10405.3578
-164231573.5
0.000082
0
0
0
0
0
0.000059
0
0
0
0.999858
0
0
0
0
0
0
0
Vent_2
1
190.686955
3110
0.000659
-2.218782
0.282113
0.209826
0
0.000304
0.006469
0.000012
0.103438
0.00018
0.00064
0.000099
0.394065
0
0
0.002282
0
0
0
0.000573
Bot_1
0
251.633726
3120
141685.6119
-188127229.4
0.996293
0
0
0.00272
0
0
0
0
0
0
0.000948
0
0
0
0
0.000039
0
0
Light End
0
190.686955
3110
18834.75042
-59534569.54
0.534314
0.011593
0
0.000968
0.000239
0
0.009939
0.000006
0.000039
0.000013
0.442014
0
0
0.000829
0
0.000009
0
0.000037
8
1
364.950076
3120
141679.2807
-73371697.78
0.21941
0
0
0.001661
0
0
0
0
0
0.389283
0.000579
0
0
0.388801
0
0.000024
0
0.000241
Vent_3
HCL Recycle_1
10
Vent_4
VCM
HCl removed
EDC1
NaOH
EDC2
Recycled EDC_2
HCl in
0.38378
50
1480
-150837831.5
141679.2807
0.21941
0
0
0.001661
0
0
0
0
0
0.389283
0.000579
0
0
0.388801
0
0.000024
0
0.000241
1
-26.552949
1200
-2.203026
0.000851
0
0
0
0
0
0
0
0
0
0.999234
0
0
0
0.000079
0
0
0
0.000687
0
-26.552949
1200
-98651993.29
33282.59403
0
0
0
0
0
0
0
0
0
0.998382
0
0
0
0.000999
0
0
0
0.000619
0
91.856951
1210
-61969133
108396.686
0.35923
0
0
0.00272
0
0
0
0
0
0.001135
0.000948
0
0
0.635928
0
0.000039
0
0
1
30.702142
471
0.470721
0.000884
0
0
0
0
0
0
0
0
0
0.013822
0.000034
0
0
0.986139
0
0
0
0.000005
0
30.702142
471
14284363.5
56951.0437
0
0
0
0
0
0
0
0
0
0.001781
0.000102
0
0
0.998116
0
0
0
0.000001
0
476.28633
101.324997
-26300083.2
33.301773
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
1
476.2863
101.325
-1.9E+08
70000.29
0.306733
0.189987
0
0
0.020362
0
0.087033
0.000352
0.000352
0.000008
0.394152
0
0
0.000614
0
0.00002
0
0.000386
0
25
101.324997
-102396.3768
23.998201
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0.446804
57.35
151.987495
-265189770
70000.28559
0.306733
0.189987
0
0
0.020362
0
0.087033
0.000352
0.000352
0.000008
0.394152
0
0
0.000614
0
0.00002
0
0.000386
0
145.091382
477
-77490625.89
51191.60993
0.989791
0
0
0.007537
0
0
0
0
0
0
0.002442
0
0
0.000175
0
0.000055
0
0
1
25
101.324997
-83723277.67
33172.24442
0
0
0
0
0
0
0
0
0
0.998373
0
0
0
0.000999
0
0
0
0.000629
Heated HCl to
reactor
1
25
101.324997
-83723277.67
33172.24442
0
0
0
0
0
0
0
0
0
0.998373
0
0
0
0.000999
0
0
0
0.000629
EDC recycle to
Light Column
0
147.319301
3500
-77293877.76
51191.60993
0.989791
0
0
0.007537
0
0
0
0
0
0
0.002442
0
0
0.000175
0
0.000055
0
0
Vap. Frac
Temp (Celcius)
Pressure (Kpa)
Heat Flow (KJ/h)
Mass Flow (Kg/h)
Comp Mole Frac (12-ClC2)
Comp Mole Frac (Ethylene)
Comp Mole Frac (Cl2)
Comp Mole Frac (112-ClC2)
Comp Mole Frac (Oxygen)
Comp Mole Frac (Nitrogen)
Comp Mole Frac (CO2)
Comp Mole Frac (Methane)
Comp Mole Frac (Ethane)
Comp Mole Frac (HCl)
Comp Mole Frac (H2O)
Comp Mole Frac (CO)
Comp Mole Frac (n-Butane)
Comp Mole Frac (VinylCl)
Comp Mole Frac (NaCl*)
Comp Mole Frac (NaOH)
Comp Mole Frac (Propane)
Comp Mole Frac (Acetylene)
Confidential
Recycled
EDC_1
0.000002
145.09316
477
-77876378.24
51445.64124
0.98979
0
0
0.007493
0
0
0
0
0
0
0.002433
0
0
0.000177
0
0.000107
0
0
Confidential
720.5
C2
-0.069
249.2
111.3
102.9
-73
0.5
41.6
106.814
0.5
2.8
1.378
6.7
19.3
0.093
35.6
-11.823
0.6
52.6
-0.454
9.6
32.3
2.6
0.029
7.4
H6
93.487
0.5
14.5
-1.101
0.1
3.8
14.34
0.5
47.2
9.6
15.886
0.5
7.943
-31.2
H3
38.982
90.178
43.874
95.070
39.515
90.711
42.519
93.715
42.717
93.913
42.931
94.128
89.675
140.871
89.095
140.291
88.985
140.181
88.685
139.881
95.855
147.051
92.126
143.322
92.126
143.322
Surplus
Deficit
Surplus
Deficit
Surplus
Surplus
Surplus
Surplus
Deficit
Deficit
Deficit
Surplus
-3.7288
-21.6
C3
97.272
7.17
25.6
-0.079
46.076
Surplus
-0.3002
26.1
H5
93.961
-0.1101
29.9
-0.079
42.765
Surplus
-0.58
30
C4
67.790
46.7435
44.5
-0.04
16.594
Surplus
0.2146
45
H2
58.558
0.1976
52.4
H1
7.361
Surplus
3.0039
55
0.076
58.233
-4.3584
87.3
0.093
7.037
Surplus
4.8918
96.9
C5
4.826
-7.0938
149.5
0.093
-46.370
Deficit
PINCH
3.3108
150.1
C7
0.000
26.1708
185.7
H4
-51.196
Surplus
9.2326
205
1.356
36.500
0.3248
211.7
C1
-14.696
Deficit
53.407
214.5
0.116
31.664
4.8256
215
H7
-19.532
Deficit
-36.5
256.6
0.116
34.001
4.8363
257.1
C6
-17.195
Qh (min)
-2.3373
360
0.047
51.196
-17.1948
471.3
-0.021
Surplus /deficit
Deficit
Qc (min)
Surplus
-31.7
Cold Utility
ABOVE PINCH
CP (MW/C)
0.047
0.068
H (MW)
10.09
7.03
H1
H2
H2
261.6
476.3
H1
CP (MW/C)
167.4:
261.6
H2
0.069
32
715.5
252.1
73.056
C2
36.53
21.92 MW
10.3MW
10.09 MW
14.4
1.263
32.8
1.4418
7.2
15.886
7.9
93.526
46.8
106.698
53.3
25.6MW
C6
7.03 MW
0.068
190.7
H4
251.7:C
251.8:C
9.6
50.0
c
211:C
216.7
0.047
5.17MW
261.6
251.6
32 MW
H (MW)
57.4
201.3:C
261.6
365.0
BELOW PINCH
252.5:C
31.1
30.6
H5
7.2MW
251.6
-26.2
H3
-26.7
7.9MW
50.0
219.95:C
220.0
49.5
H6
46.8MW
219.5
H7
48.05MW
50.0
25.0
C4
0.017
0.43
C1
0.023
C3
0.079
4.1
C5
0.547
5.3
C7
11.917
7.2
0.43MW
200.0
25.0
91.9
24.9
4.0MW
-26.6
4.1MW
82.3
5.3MW
145.1
144.5
7.2MW
32
Reboiler for
Light Column
21.92
C2
C6
H1
H2
HP Steam
Refrigerant 2
Refrigerant 2
250
249
5.23
-40
-39
14805.56
-40
-39
16047.20
Furnace
Fired Heat
(1000)
1000
400
39.36
Uility Consumption
Inlet Temperature (C)
Outlet Temperature (C)
Flowrate (kg/s)
Light Column
T-100
Confidential
Condenser for
HCl Column
7.9
H4
H5
HP Steam
Generation
249
250
14.55
MP Steam
Generation
174
175
3.64
5.17
Oxychlorinator
CSTR-101
Condenser for
VCM Column
7.2
E-103
Pyrolysis Reactor
PFR-100
10.3
Condenser for
Light Column
25.6
E-102
Material of
Construction
Stainless Steel Type
304
Stainless Steel Type
316
CSTR-100
CSTR-101
46.8
48.05
H3
H6
H7
LP Steam
Generation
124
125
3.62
Cooling
Water
20
25
2235.83
HP Steam
Generation
249
250
31.33
Remarks(Special features)
Ferric chloride is used as catalyst to increase
selectivity of main reaction.
Conversion of EDC is more than 99%.
Copper (II) chloride is used as a catalyst.
Exothermic reaction.
Conversion of HCl is 94 97%.
Carbon Steel
Endothermic reaction.
Butane is used as the fuel.
Conversion of EDC is 55%.
Confidential
Schedule No.
40S
40
40
40
40
40
40S
40
40
40
40
40
80S
40S
40S
10S
40S
Pipe thickness(Inch)
0.38
0.44
0.41
0.69
0.59
0.00
0.50
0.36
0.36
0.44
0.11
0.28
0.56
0.32
0.38
0.38
0.06
No.of pipes
4
1
1
3
4
1
1
1
1
1
1
1
13
2
2
1
1
Mitigation Measures
Rehabilition programme can be organized to replant and preserve mangrove in the
area. Unused area can be used as a growth site. The release of hydrochloric gas
should follow the guide and permitted amount which is 5-10ppm in most country
(Vinyl Chloride 2013). The gas could be pre-treated before being released to
air.The sites will have empty areas which can be used to plant green trees to reduce
the effect of soil salinity to take place.
Wastewater treatment implemented and amount of gas released will follows the
environmental regulation limits. Construction work will only be done during day
time and weekdays. The plant wall will be concealed to absorb industrial activity
sound. Trees will be planted in the empty areas site of the plant.
Dam or reservoir can be built to store water for future production or local usage.
Workers should attend safety and health training so that they are more alert and
aware of the usage of mask during the production. Proper emergency plan will be
conducted to ensure workers and residents are not in danger in the case of
emergency.
The pipelines should be monitored regularly to prevent leakage.
Source
Amount
Flow rate : 85599.77
kg/h Nitrogen 0.7310
Carbon Dioxide 0.1196
Steam 0.1495
0.1 wt %
Water 0.9998
EDC 0.0001
Carbon Dioxide 0.001
Hydrochloric Acid 0.997
Standards
0.12 ppm
Treatments
The amount of flue gas release by fire heater is in small amount. Therefore no pre-treatment needed.
Copper 0.1
gm/Nm3
Ferric
0.2gm/Nm3
The catalyst life before disposal could be prolonged through regeneration and rejuvenation. The catalyst metal can be recovered
for other raw material before being disposed in an approved chemical landfill. The recovery of metal will reduce the amount of
waste being disposed. (Marafi , Stanislaus and Kam 2006)
0.2 gm of
HCL/Nm3
All liquid disposals will be sent to wastewater treatment unit. Chlorinated hydrocarbon waste will be removed through distillation
and Hydrogen chloride will be neutralized with the aid of caustic soda.
Dissolved solid carried by water will be filtered , flocculated and sedimentated
Hazards Identification
Ethylene
Chlorine
Ethylene
dichloride (EDC)
Hydrogen
chloride
Vinyl chloride
monomer (VCM)
Pure Oxygen
Health Effect
Harmful to target organ such as lungs, heart, muscle tissue.
Burns or frostbite effect to skin and eyes.
Inhalation of ethylene causing simple asphyxiant. (Airgas 2011)
Using water spray curtain and stop the leak immediately. (Sciencelab
2013)
Store the tanks in refrigerated room and keep away from sources of
ignition. (Sciencelab 2013)
Economic
Recycle of effluent reduces cost of raw material
HCL is recycle back as raw material during oxy-chlorination process. This reduces the need to
further invest on the raw material
Reuse of By products for manufacturing of other industrial products
VCM process produced 112- trichloroethane and acetylene which as a byproduct are used in
chemical making, solvents, cleaning agent and etc. This will help to increase the profit of the
plant as the by product can be sold to other industry.
(Ethylene Dichloride (1,2-Dichloroethane) 2008)
Energy Saving
Usage of cracking gas heat and flue gas for
pre-evaporation and preheat of combustion air help to save energy consumption
(ThyssenKrup2013
Social
Job Opportunities
Construction stage will require workers for the road construction, vessel transportation
and etc.The VCM production will require more engineers to monitor and conduct the
production process.According to Azapagic and Verdan (2011) , a VCM plant will
requirefulltime employment of 20 operators , approximately 25 contractors during the
construction process that will take about 3 years.
More Housing Areas
More housing areas will be built to accommodate the workers.
Development of rural areas
The industrial area will be developed such that there will be more connecting roads ,
local markets and etc.
Environmental
Ferric Chloride and Copper Chloride as catalyst reduce toxic
generation
Use of this catalyst reduces formation of toxic and waste compared to usage
of mercury catalyst in acetylene based process ThyssenKrup (2013) states
that catalyst used in this process does not being discharge at the end of the
process. Therefore, minimal waste disposal.
Reduction of fresh water usage
The recycling of certain effluents from the process reduces the usage of
fresh water and pollution.This method is proven to reduce up to half of the
fresh water usage (Australian Vinyls Corporation Ltd. 2009)
Likelihood
Back-up Plan
Possible
Using spill pads backed with vapour barriers to remove flammable liquids. (ACS 2013)
Leakage of gas
Possible
Power outages
Likely
Installation of uninterruptible power supply (UPS) system as standby power source (Solidstate 2013)
Likely
Factory collapse
Unlikely
Likely
Possible
Confidential
Event Recovery
Checking and maintenance of equipment should be done regularly.
Knowledge of the use and handling of hazardous chemicals should be applied by each
worker.
Identify the causes of gas leakage and monitor the gas supply day by day.
Regular checking and maintenance of pipeline and vessel.
Conducting an annual inspection of any generators and possible upgrade of power
system.
Testing of back-up generator should be done regularly under load of 24 hours.
Find out the sources of ignition and checking of the current condition of plants.
Conduct inspection of factory structures regularly.
Robust and secure factory construction.
Detect the source of the release of chlorine by using chlorine gas detector. (wiseGeek
2013)
Regular checking and maintenance of pipeline and chlorine storage tank.
Identify the causes of EDC leakage by using gas detector to evaluate the airbourne
concentrations of EDC.
Guide word /
Deviation
No flow
Low flow
High temperature
Runaway reaction.
Insufficient cooling of reaction.
High concentration of catalyst.
Low pressure
No flow
Low flow
High flow
Low temperature
High temperature
Low pressure
High pressure
PFR-101
Plug Flow Reactor
(EDC pyrolysis)
High flow
Low temperature
High pressure
Possible Causes
No flow
Low flow
High flow
Low temperature
High temperature
Low pressure
High pressure
Consequences
Safeguard
Action Required
Monitoring of temperature.
Perform maintenance frequently.
Observe and alert to the operating pressure of reactor to ensure
the pressure is beyond safe limit.
Regular checking and maintenance.
Monitor the flow rate of inlet stream frequently.
References
Airgas Inc. 2013. Hydrogen Chloride. Material Safety Data Sheet. http://www.airgas.com/documents/pdf/001028.pdf.
Australian Vinyls Corporation Pty Ltd.2009. Sustainability Report.http://www.av.com.au/Assets/228/1/SR0809publish.pdf
Atlas Steels.2012. Pressure Rating Table for Stainless Steel Pipe. http://www.atlassteels.com.au/documents/St_St_Pipe_Pressure_Rating_Charts_rev_Sep_2010.pdf
Atlas Steels.2012. Pressure Rating Table Carbon Steel Pipe. http://www.atlassteels.com.au/documents/C_St_A106_GrB_Pipe_Pressure_Rating_Charts_rev_Dec_2012.pdf
Azapagic, Adisa., Slobodan Perdan, and Roland Clift. 2004. Sustainable Development in Practice. John Wiley & Sons, Ltd.
Cause and Countermeasures to Reactor Manual Shutdown during Startup at Hamaoka No. 4. 2013. Accessed September 11, http://www.chuden.co.jp/english/corporate/press2007/pdf/pre1130_1_1.pdf.
Department of Environment.2010. Environmental Requirement : A Guide for Investors. http://www.doe.gov.my/portal/wp-content/uploads/2010/12/A-Guide-For-Investors1.pdf
DUTTA, B.K. 2007. Principles of Mass Transfer and Seperation Processes: PHI Learning.
Fogler, H.S. 2006. Elements of Chemical Reaction Engineering: Pearson Education Internat.
Himmelblau, D., and J. Riggs. 2012. Basic Principles and Calculations in Chemical Engineering: Pearson Education Land Clearing and Its Impacts.2013.Bush Land
Clearing and Its Impacts.2013.Bush Land Clearing and Its Impacts.2013.Bush Heritage Australia. http://www.bushheritage.org.au/natural_world/natural_world_land_clearing
Occidental Chemical Corporation. 2005. Ethylene Dichloride Finished Grade. Material Safety Data Sheet. http://www.nfc.umn.edu/assets/pdf/msds/ethylene_dichloride_finished_grade.p
Reactor Problem. 2013. Monitor and Control the Reaction Process. Accessed September 2, http://toolboxes.flexiblelearning.net.au/demosites/series2/204v2/PROC302/PROC302-020200- Technology Transfer Network Air Toxics Web Site.2007. Ethylene Dichloride (1,2-Dichloroethane). http://www.epa.gov/ttnatw01/hlthef/di-ethan.html
Tham, M.T. 2009. Factors Affecting Distillation Column Operation. Distillation an Introduction. Accessed September 3, http://lorien.ncl.ac.uk/ming/distil/distilop.htm.
The ecoCate Project.2013.Petronas Chemicals Olefin Sdn Bhd.. http://www.optimal.com.my/ecoCare.aspx
ThyssenKrup. 2013. Vinyl chloride and polyvinyl chloride.Accessed August 15, http://www.thyssenkruppuhde.de/fileadmin/documents/brochures/uhde_brochures_pdf_en_8.pdf
Perry, Robert H., and D.W. Green. 2008. Perry's Chemical Engineers' Handbook, Eighth Edition: McGraw-Hill.
Smith, J.M., H.C. Van Ness, and M.M. Abbott. 2005. Introduction to Chemical Engineering Thermodynamics: McGraw-Hill Book Company. Vinyl Chloride.2013.Accessed September 2. http://monographs.iarc.fr/ENG/Monographs/vol97/mono97-8A.pdf
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