CHAPTER 7: INSTRUMENTATION AND CONTROL

7.1 INTRODUCTION Control in process industries refers to the regulation of all aspects of the process. Precise control of level, temperature, pressure and flow is important in many process applications. Refining, combining, handling, and otherwise manipulating fluids to profitably produce end products can be a precise, demanding, and potentially hazardous process. Small changes in a process can have a large impact on the end result. Variations in proportions, temperature, flow, turbulence, and many other factors must be carefully and consistently controlled to produce the desired end product with a minimum of raw materials and energy. Process control technology is the tool that enables manufacturers to keep their operations running within specified limits and to set more precise limits to maximize profitability, ensure quality and safety. Process control refers to the methods that are used to control process variables when manufacturing a product. For example, factors such as the proportion of one ingredient to another, the temperature of the materials, how well the ingredients are mixed, and the pressure under which the materials are held can significantly impact the quality of an end product. Process control of the production process for three following objectives: i. Safety First Automatic control systems enable a process to be operated in a safe and profitable manner. They achieve this by continually measuring process operating parameters such as temperatures, pressures, levels, flows, and concentrations, and then making decisions to, for example, open valves, slow down pumps and turn up heaters so that selected process measurements are maintained at desired values.

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The overriding motivation for modern control systems is safety, which encompasses the safety of people, environment, and equipment. The safety of plant personal and people in the community is the highest priority in any plant operation. The design of a process and associated control systems must always make human safety the prime objective.

ii.

Profit When people, the environment and plant equipment are properly protected,

control objectives focus on the profit motive. Automatic control systems offer strong benefits in this intention. Plant wide control objectives motivated by profit include meeting final product specifications, minimizing waste production, minimizing environmental impact, minimizing energy use and maximizing overall production rate. Product specification sets by customers are an essential priority. Example product specifications range from maximum or minimum values for density, viscosity or component concentration, to specification on thickness or even color. iii. Production Rate and Quality Process control can reduce variability in the end product, which ensures a consistently high-quality product. Manufacturers can also save money by reducing variability. For example, in a gasoline blending process, as many as 12 or more different components may be blended to make a specific grade of gasoline. If the refinery does not have precise control over the flow of the separate components, the gasoline may get too much of the high-octane components. As a result, customers would receive a higher grade and more expensive gasoline than they paid for, and the refinery would lose money. The opposite situation would be customer receiving a lower grade at a higher price.

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In this chapter, there will be concise description of control strategies for two major equipments and three minor equipments which are: Reactor Distillation column Heat exchanger Pump Compressor

7.2 REACTOR CONTROL SYSTEM The main purpose of the reactor is to provide an area where ethylene and benzene could react to produce ethylbenzene via liquid phase reaction. Since the reactor is the main equipment that converts the feed into product, it is crucial that we perform a proper control around the reactor so that we produce consistent quality product. The first requirement for a successful control of a reactor is to establish proper stoichiometry in order to control flow of the reactants (composition control) in proportions required as to satisfy the reaction chemistry (Perrys, 1997). In this plug flow reactor, R-101, benzene to ethylene is fed in ratio of 4:1 to guarantee that product specifications are met. The control system objectives are defined as: 1. Production rate To maintain the product yield and quality of annual production rate of 500000 ton of ethylbenzene (EB) per annum, with a purity of 99.3% 2. Reactor temperature and pressure To maintain the reactor operation at optimum temperature and pressure

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3. Safety Provide the safeguards against the process runaway reaction and maintain the safe operation To maximize catalyst and prolong its life cycle

The fail-close valves are employed especially in the case of failure, that is when the reactors internal temperature is becoming too high, the coolant would still be flowing in the cooling coils via the fail-close valve and vice versa. This is vital to ensure that the coolant would be flowing to cool down the reactor rather than letting it overheated. A pressure safety valve, PSV is installed on the reactor to discharge excessive pressure whenever necessary.

Table 1: Summary of Control Strategy for Reactor Measured Variable Feeds flow rate at R-101 Manipulated Variable Benzene and ethylene flowrate Compositional changes in benzene and ethylene flowrate (B:E 4:1) Liquid level Feeds flowrate Reactors internal temperature Coolants flow rate into cooling coils Changes in feeds flowrate Feed Temperature Cascade control Feedback control Ratio control Disturbances Type of Controller

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Symbols: FT Flow Transmitter RC Ratio Controller FC Flow Controller LC Level Controller LT Level Transmitter TT Temperature Transmitter TC Temperature Controller CW Cooling Water

Title: Instrumentation and Control Strategy for Reactor Note: N/A Project : Ethylbenzene Plant Designer: GROUP 9 Date: 03-10-2010

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As the reaction scheme requires a stringent control to be exercised in terms of reactants compositions to attain optimal yield, therefore a ratio control is chosen to ensure that this requirement is fulfilled. This ratio control is a special type of feedforward control. Its objective is to maintain the ratio of (4:1). Therefore it measures the disturbance in which, is coming from both benzene and ethylene streams in this case. Secondly, as the reactions involved in the whole process are entirely in liquid phase, hence, the level of liquid resulted is among the main concern. Therefore, the simple feedback control scheme is proposed to provide better control of the liquid level. The liquid level from the reactor is measured and transmitted electronically to a level controller. The controller compares the measured value to the set point and takes the appropriate corrective action by sending signal to the control valve. Thirdly, as the reactor chosen is operating isothermally and that, the reactions carried out inside it are exothermic in nature, therefore temperature control is significant. For that reason, cascade control is ideally proposed and has the following features: 1. The output signal of the master controller serves as the set point for the slave controller. 2. The two feedback control loops are nested, with secondary control loop (slave controller) located inside the primary loop (master controller). The cooling water flows through the reactor jacket to regulate the reactor temperature. If dynamic lags occur in the jacket as well as in the reactor, the corrective action taken by the controller will be delayed. Therefore, a feedback controller as the secondary loop (slave) is added to provide cascade control as it measures the jacket temperature, compares it to a set point, and uses the resulting error signal as the input for the cooling water makeup.

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7.3 DISTILLATION COLUMN CONTROL STRATEGY This section will introduce the control strategy of distillation column. There are three distillation columns in Ethylbenzene Plant with different top and bottom products. The common operation of a distillation column is based on the production of a vapor phase by boiling the liquid mixture, and condenses the vapor allowing some liquid or reflux to return to the column. However, only the control system for C-102 is explained in detail in this report. The other two of distillation columns will be having similar control strategy. The control system for this column is designed with following control objectives: 1. Feedrate To maintain the federate to the distillation column at desired value. It is achieved by the feed flow is controlled. 2. Column pressure To control the pressure of top tray at desired value. It is achieved by manipulating the flowrate of cooling water. If the cooling water is increased, then more vapor is condensed at the pressure is reduced. 3. Column Temperature To control the temperature at the stripping section by manipulating the steam to the reboiler. 4. Top product composition The final product is most likely at the top product. It is important to control the top product composition. It is achieved by adjusting reflux rate. As the amount of reflux changed, the temperature profile in the column changes and hence the composition. 5. Liquid level in the distillation column Liquid level is controlled by manipulating the bottom product withdrawal. 92

Table 1: Summary of Control Strategy for Distillation Column Measured Variable Column pressure Column temperature Liquid level in distillation column Top product composition Feedrate Manipulated Variable Flowrate of cooling water Steam flow rate to reboiler Bottom product flowrate Reflux rate Disturbances Change of temperature cooling water Pressure of steam flow Distillate flowrate Type of Controller Feedback control

Cascade control Feedback and override cotrol Feedfforward and feedback feedback

Column temperature Pressure of feed flowrate

Feed flowrate

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Symbols: PT Pressure Transmitter PC Pressure Controller TT Temperature Transmitter TC Temperature Controller LT Level Transmitter LC Level Controller

Title: Instrumentation and Control Strategy for Distillation Column Note: N/A Project : Ethylbenzene plant Designer: GROUP 09 Date: 15-09-2010

In distillation column it is necessary to regulate the pressure in some way. Method that being used in this plant is the most common method for controlling the pressure, which is adjustment of the cooling water flow. In this case, the cooling water flow is increased so that more vapour is condensed and the pressure is reduced. The disturbance variable which is the cooling water temperature didnt give much effect. So it is simpler to use feedback control scheme here. To control the temperature of the distillation column, cascade control scheme is implemented. To control the temperature, the steam flowrate to the reboiler is 94

manipulated. But the disturbance is the pressure of the steam flowrate itself. Since the disturbance variable is associated with the manipulated variable, cascade control is the best way to overcome it. It consists of primary control loop of which control the column temperature and secondary control loop which control the steam pressure. If disturbance in a supply pressure occurs, the pressure controller will act very quickly to hold the steam pressure at it set point before it upsets the master set point. Liquid level of the distillation control is simply control by flow controlled. However, the problem exists here is that the safety concerns. Suppose the base level in a distillation column is normally held by bottoms product withdrawal. A temperature in the stripping section is held by steam to the reboiler. Situations can arise where the base level continues to drop even with the bottoms flow at zero (vapor boilup is greater than the liquid rate from tray 1). If no corrective action is taken, the reboiler may boil dry and the bottoms pump could lose suction. Thus, override control is taking place in this matter. When the level drops below the permitted level, then the temperature controller takes place in spite of the level controller. The feedrate to the distillation column is also simply feedback control. The other parameter most likely to be controlled is the composition of the tops product. the reason is that the final product come from the top of the column and it is important to know its composition. The method used is by adjusting the reflux rate. As the amount of reflux is changed, the temperature profile in the column also changes and affects the composition. It is improved by combining feedforward and feedback control in this strategy. We dont want the temperature of the column (disturbance variable) to upset the final product before we control it. Thus, we use feedforward control. On the other hand, it is also important to use feedback controller to measure its controlled variable.

7.4 HEAT EXCHANGER CONTROL SYSTEM

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The purpose of performing a control system for heat exchanger is to maintain the desired temperature of its outlet stream either by providing the heating or cooling utility. The outlet stream of the heat exchanger will be compared with the set point. If the temperature is not at the desired level, the controller will take action by manipulating the flow rate of the utility. In the plant, there are two heat exchangers and two coolers; the detail description is shown in Table X below. All the heat exchanger and cooler used same control system. The objective is to control the outlet temperature at the desired set point. The type of controller being use is cascade controller. 1. Temperature outlet stream Cascade control is implemented with the temperature control as the primary loop and flow control as the secondary loop.
Measured Variable Temperature of at liquid at outlet stream Manipulated Variable Flowrate of steam into heat exchanger Disturbances Changes in steam flowrate Type of Controller Cascade controller - (TIC) master loop

To maintain the temperature in the heat exchanger output process stream by manipulating the flow rate of the coolant or heating medium, cascade control strategy is being implemented. Due to the slow dynamic response of a heat exchanger system, a cascade control with primary loop of temperature controller and secondary loop of flow controller is implemented. The cascade control is placed to improve the dynamic response of the system and also to eliminate possible disturbances that may be caused by fluctuation of flow rate of utility. Since the dynamic response of the secondary loop is faster than the primary loop, the flow controller should be able to adjust the flow of utility to the heat exchanger based on the set point given by the temperature controller.

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Symbols: PT Pressure Transmitter PC Pressure Controller TT Temperature Transmitter TC Temperature Controller LT Level Transmitter LC Level Controller

Title: Instrumentation and Control Strategy for Heat Exchanger Note: N/A Project : Ethylbenzene plant Designer: GROUP 09 Date: 15-09-2010

7.5 PUMP CONTROL STRATEGY 97

Pumps are used to transfer liquids from one point to another and woked based on the principle of pressure difference. It should be noted that all the pumps that are used in our plant are of minor pumps, where they are working to hike the pressure of supply streams, and that their content and flow are abundant and will not dry out. Therefore, we will only allocate a pressure gauge on both of the inlet and outlet of the pump.

Table 5: Summary of Control Strategies for Pump Control Variable 1. Inlet flowrate 2. Inlet pressure Measured Variable Pressure difference across pump Flowrate of pump outlet Manipulated Variable Recycle line flowrate Pump speed Changes in the inlets flowrate Change in the inlet flowrate Close loop ration control Feedforward control Disturbances Type of Controller

Symbols: FT Flow Transmitter FC Flow Control

Title: Instrumentation and Control Strategy for Pumps Note: N/A Project : Ethylbenzene Plant Designer: GROUP 9 Date: 03-10-2010

The feedforward control system is proposed as it takes corrective action before disturbances upset the process. The changes in inlets flowrate is the disturbance in this case, is measured, and the final control element adjusts the inlet flowrate so as to balance the liquid demand. 98

7.6 COMPRESSOR CONTROL STRATEGY The main use of a compressor is to increases the pressure of a vapor stream. Compressor is a single phase unit as it cannot process mixed-phased stream that will destroy its blades. Table 6: Summary of Control Strategies for Compressor Control Variable 1. Inlet flowrate Measured Variable Pressure across compressor and pressure across restriction 2. Inlet pressure orifice Flowrate of compressor outlet Compressor speed Change in the inlet flowrate Close loop ration control Manipulated Variable Recycle line flowrate Changes in the inlets flowrate Feedforward control Disturbances Type of Controller

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Symbols: PG Pressure Gauge FT - Flow Transmitter FC Flow Controller

Title: Instrumentation and Control Strategy for Compressor Note: N/A Project : Ethylbenzene Plant Designer: GROUP 09 Date: 15-09-2010

CHAPTER 8: SAFETY AND LOSS PREVENTION

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8.1 8.1.1

Hazard and Operability Studies (HAZOP)

Description

A Hazard and Operability (HAZOP) study is a structured and systematic examination of a planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment, or prevent efficient operation. The HAZOP technique was initially developed to analyze chemical process systems, but has later been extended to other types of systems and also to complex operations and to software systems. A HAZOP is a qualitative technique based on guide-words and is carried out by a multi-disciplinary team (HAZOP team) during a set of meetings. The HAZOP study should preferably be carried out as early in the design phase as possible - to have influence on the design. On the other hand; to carry out a HAZOP we need a rather complete design. As a compromise, the HAZOP is usually carried out as a final check when the detailed design has been completed. A HAZOP study may also be conducted on an existing facility to identify modifications that should be implemented to reduce risk and operability problems.

8.1.2

Prerequisite

The HAZOP Analysis requires accurate Process flow diagrams, Piping and instrumentation diagrams (P&IDs), layout diagrams, material safety data sheets, provisional operating instructions, heat and material balances, equipment data sheets, and start-up and emergency shut-down procedures.

8.1.3

Advantages and Success Rates

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To ensure high success rates, we need to provide accuracy of drawings and data used as a basis for the study, utilize experience and skills of the HAZOP team leader, technical skills and insights of the team, ability of the team to use the HAZOP approach as an aid to identify deviations, causes, and consequences, ability of the team to maintain a sense of proportion, especially when assessing the severity of the potential consequences.

8.1.4

HAZOP Study Procedures

Figure 1: Schematic of HAZOP study procedures

The HAZOP study focuses on specific points of the process or operation called study nodes, process sections, or operating steps. In this HAZOP study, three study nodes has

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been done for three process lines, in which HAZOP assessments are performed on two major equipments and one minor equipment. The three equipments are: Node 1: Reactor (R-101) Node 2: Distillation Column (C-102) Node 3: Heat Exchanger (E-1)

Although the basic HAZOP Analysis approach is well established, the way that it is employed may vary from organization to organization. Table lists guide words that are commonly used in HAZOP Analysis.

8.1.5

Guidewords Table 8: List of basic HAZOP guidewords

GUIDEWORDS No (not, none) More (more of, higher) Less (less of, lower) As well as (more than) Part of Reverse Other than (other)

MEANING None of the design intent is achieved Quantitative increase in a parameter Quantitative decrease in a parameter An additional activity occurs Only some of the design intention is achieved Logical opposite of the design intention occurs Complete substitution another activity takes place

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Process Section: Reactor R-101 Intention: To transport raw materials into the reactor, R-101. Node 1: Stream S7 Process parameter: Flow Table 8: HAZOP Analysis for Node 1 - Flow Guide word No Deviation No flow Possible causes Use of fail closed typed control valve Fracture of pipe Less Less flow Leakage in piping Blockage in pumps Control valve failed partially opened/closed More More flow position Control valve fails open Possible consequences No feedstock supplied, no product produced as no reaction taken place Reactor shutdown Reduced rate of reaction Inconsistent production rate Reduced amount of process fluids to R101 Increased amount of process fluids to R-101 and over spillage Required actions Employ fail opened typed control valve Install emergency shutdown (ESD) valve or shutdown plant immediately Install flow indicator Install low flow or low level alarm to R-101 Install check valve to stream S-7 Install flow indicator Install high flow alarm and relief valve

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Reverse Reverse flow

Backflow due to backpressure in reactor

Reduced amount of feedstock, thus reduced yielded product

Install check valve or flow indicator and alarm to acknowledge the changes in flow Regular inspection and maintenance of valve

Process parameter: Pressure Table 10: HAZOP Analysis for Node 1 - Pressure Guide word Less Deviation Less pressure Possible causes Leakage in pipeline Possible consequences Reverse flow Loss of raw material, desired reaction cannot More More pressure Control valve fails open be achieved High pressure and could lead to overpressure (pressure build-ups) in R101 Runaway reaction Process parameter: Temperature Install relief valve Required actions Install pressure indicator Install low pressure alarm Install ESD valve Install pressure indicator and high pressure alarm Install ESD valve

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Table 9: HAZOP Analysis for Node 1 - Temperature Guide word Less Deviation Less temperatur e Possible causes Temperature indicator fails Heat exchanger failure/ inefficient More More temperatur e Temperature indicator fails External heating High pressure in reactor Uncontrolled and excessive heat release surrounding R-101 Possible consequences Optimal reaction scheme cannot be attained Reduced yield Required actions Inspect, maintain temperature indicator and replace it promptly if it fails Inspect and maintain heat exchanger periodically Install temperature indicator and high temperature alarm Instruct operator by procedures Install cooling water flow meter Check heat exchanger

Process Section: Distillation Column C-102 Intention: To transport process materials from separator C-101 to separator C-102.

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Node 2: Stream S11 Process parameter: Flow Table 11: HAZOP Analysis for Node 2 - Flow Guide word No Deviation No flow Possible causes Control valve fails closed. Column C-101 empty. Fracture pipe. Isolation valve Less Less flow closed. Pipe leaking. Control valve failed in partially open position. Blockage in pipe or More More flow pump. Control valve fails open Air pressure to drive Increased amount of process material to Install flow indicator C-102. Over spillage. Install high flow alarm Install relief valve at reactor 107 Less process material to separator. Ethylbenzene production rate decrease. Install flow indicator Install low flow or low level alarm to S-11. Possible consequences No process material to separator. No ethylbenzene produced. Plant shutdown. Release of hazardous material. Required actions Use control valve fails open. Install low flow alarm to alert operator Install hazardous substance detector and alarm.

valve fails Incorrect instrument Reverse Reverse flow reading. Backflow due to backpressure in reactor

Overpressure in separator.

Reduced amount of feedstock, thus reduced yielded product. Desired flow could not be achieved. Plant shutdown

Install check valve. Regular inspection and maintenance of valve.

Process parameter: Temperature Table 12: HAZOP Analysis for Node 2 - Temperature Guide word Deviation Possible causes Possible consequences Required actions

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Less

Less temperature

Heat exchanger failure. Temperature control error. Cooling water control valves fails closed.

Possible thermal runaway Decrease product yield

Install low temperature alarm. Adequate pipe installation.

More

More temperature

External heating Heat exchanger failure. Temperature control error. Cooling water control valves fails closed.

High pressure in distillation column. Uncontrolled and excessive heat release. Desired product cannot be separated

Install temperature indicator and high temperature alarm Install cooling water flow meter.

Process parameter: Pressure Table 13: HAZOP Analysis for Node 2 - Pressure Guide word Deviation Possible causes Possible consequences Required actions

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Less

Less pressure

Leakage/rupture in pipeline. Compressor malfunction.

Reverse flow Loss of raw material. Desired reaction cannot be achieved Runaway reaction

Install pressure indicator Install low pressure alarm

More

More pressure

Control valve fails close. Control valve fails open. Compressor malfunction. Build up pressure in C101.

Install pressure indicator and high pressure alarm Install ESD valve Install PSV.

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Process Section: Heat Exchanger E-1 Intention: To transport materials to transkylation reactor, R-102 Node 3: Stream S19 Table 14: HAZOP Analysis for Node 3 Parameter Flow Deviation No flow Possible causes Upstream flow disrupted Heater, its line and downstream line rupture Line blockage More flow Leakage in the heat exchanger tubes causing mixture of product of ethylbenzene stream with the feed of transkylation reactor Line fracture, leakage (flange/valve and heat exchanger shell) Failure of charge pump Mixture of ethylbenzene with transkylation feed stream affects the reaction and produce less product Decrease temperature of feed to R-102 Overflow of reactor and release of hazardous material Flow return to the mixer Low feed flow to the reactor Feed loss and release (e) Install bypass valve Covered by (a)Covered by (b) Possible consequences No feed to R-102, less yield Release of hazardous and flammable material Required Actions (a) Install control valve that fails open (b) Install low flow alarm at R-102 inlet (c) Install hazardous substance detector and alarm (d) Install high flow alarm at reactor inlet

Covered by (c)

Less Flow

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Reverse flow

Heat exchanger/Line rupture leading to low pressure and no flow

No/Low feed Potential flow back to mixer Feed loss and release of hazardous and flammable material Change of reactant phase

(f) Install check valve Covered by (a) Covered by (b)

Temperature Higher temperature

Heat exchanger failure Faulty transmitter

(g) Install high/low temperature indicator alarm at reactor inlet (h) Regular patrolling and inspection of the heat exchanger (i) Install two transmitter

Lower temperature

Heat exchanger failure Faulty transmitter Hot stream temperature at inlet heat exchanger is too low

Reactor conversion cannot be achieved Low reaction rate is achieve Covered (g), (h) and (i)

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Pressure

Lower pressure

Equipment/line rupture leading to less/no flow Clogging in pipe

Loss and spillage of feed Release of hazardous and flammable material Less feed to the reactor Bring damage to the equipment Overpressure will lead to line rupture Spurge flow into reactor Pressure build up in the reactor Loss and spillage of product Release of hazardous and flammable material No feed to reactor Reversible flow occur

(j) Install low/high pressure alarm at pump (water line) outlet (k) Install a pressure relief valve on pipeline Covered by (c)

Higher pressure

Blockage at reactor inlet

Covered (c) , (j) and (k)

No pressure

Equipment/line rupture leading to no flow

Covered (c) , (j) and (k)

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8.2 PLANT LAYOUT 8.2.1 Introduction

Plant layout and construction design must be considered early in the design work to ensure economical construction and efficient operation of the completed plant. This section of the report provides the basic information and safety justifications on the plant layout designed for the newly proposed ethyl benzene plant. In general, the layout shows the basic arrangement of main production site, supporting buildings and few important safety aspects. However, the plant layout adopted may affect the safe operation of the completed plant and if needed, any possible modification or extension must be accepted. Plant layout is often a compromise between a numbers of factors such as: The need to keep distances for transfer of materials between plant/storage units to a minimum to reduce costs and risks The geographical limitations of the site Interaction with existing or planned facilities on site such as existing roadways, drainage and utilities routings Interaction with other plants on site The need for plant operability and maintainability The need to locate hazardous materials facilities as far as possible from site boundaries and people living in the local neighborhood The need to provide access for emergency services The need to provide emergency escape routes for on-site personnel

However, the most important factors of plant layout as far as safety aspects are concerned are those to:

Prevent, limit and/or mitigate escalation of adjacent events (domino) Ensure safety within on-site occupied buildings Control access of unauthorized personnel 114

8.2.2

Plant Layout Consideration Factors

Based on the previous factors stated, the factor to design plant layout for the ethyl benzene has been narrowed down to several factors as followed. Thus, to ensure that the final design for plant layout is complied with all the factors that has been discussed earlier. a. Cost - Minimization of construction cost is done by adopting shortest run of connecting pipe between equipment. The cost is also reduced by having the least amount of structural steel work. The most important thing is to have an arrangement for best operation and maintenance.

b. Operation - Equipment such as valves, sample points and instruments are considered as frequently attended equipments. They are located not far away from control room, with convenient positions and heights, to ease the operators job. Also, sufficient working and headroom space are provided to allow easy access to equipments.

c. Maintenance - When laying out the plant, some considerations were made regarding maintenance work. For examples: Both reactors which use catalysts are located in open space for easiness of removing or replacing the catalysts Enough space is allocated for heat exchangers for withdrawing the bundles purposes All equipments are accessible to crane/lift truck Compressors and pumps are located under cover since they require dismantling for maintenance 115

d. Safety - Among the safety consideration that we have when laying out this plant are: Operators have 3 escape routes if anything occurs in the main process unit To minimize fire from spread, flammables handling process units are separated from each other Process vessels with substantial inventories of flammable liquids are located at grade Elevated areas will have at least one stairway Storage farm which stores the flammable materials are located at safe distance from the main process area Equipment subject to explosion hazard is set away from occupied buildings and areas.

8.2.3

Site Layout

Based on the earlier decision made, the plant location is situated in Pasir Gudang Industrial Area. The site layout can be divided into two parts: Non-Process area - area where there is no production activity and has low risk and hazards to workers. Process Area - consists of all processing units and equipments, where ethyl benzene is produced.

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8.2.3.1 Non-Process Area The non-process area usually occupies a smaller fraction of the overall plant site area. All the facilities in the non-process area should be located in a logical manner that considers site terrain, accessibility to roads, soil bearing capability and the climate including the wind direction and other unusual weather condition. This is important to avoid any undesired incident due to explosion or fire from the process zone that will be easily spread to the non-process area. Taking this into account, the entire process area where the reaction and separation occurs is surrounded with a buffer zone to ensure that surrounding buildings or sites are not affected in case of an emergency. Among the buildings or units in the non-process area are: a) Guard posts Guard posts are located at the entrance of the site in order to ensure that only authorized personnel gets access into the plant. There are three guard posts that are situated at the crucial entrances in the plant: Main entrance guard post (Gate 1) there is only one main entrance to check in and out the visitors, staffs and operators of the plant. Process area guard post (Gate 3) to control the flow in and out of personnel or vehicles between the process area and the non-process area. The personnel may be operators and engineers while the vehicles may be of contractors, fire truck and ambulance with whom have gain access to enter the process area to ensure security. Process entrance guard post (Gate 4) to only check in and out trucks. This is to avoid congestion and at the same time reduce the hazard of

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material spillage at the plant. With this, the public are less exposed to the danger of chemicals exposure or accidents with the trucks. b) Administration building The administration block is built near the parking area which acts as assembly area for staffs as well to ensure the staffs can arrive faster at the assembly point during an emergency. Based on the plant layout, the administration building is placed far from the process area in order to protect the staffs and visitors from any potential hazards. c) Canteen The canteen is located across the administration building for easy access to the employees and visitors, and far away from the process area to avoid contaminant in food and ensure safety of the public. The location is so strategic that in order to avoid the food supplier from being exposed to the process area allowing them to move in and out easily. There are other facilities that located in the non-process area including prayer hall, clinic and parking lot. Prayer hall is located near cafeteria for Muslims employees to perform their prayers during breaks. Clinic and parking lot is located side by side just next to Gate 4 for the staffs and visitors benefits. 8.2.3.2 Process Area Process zone is deemed as hazardous area where all processing equipment is allocated. Due to this, the safety precaution has to be applied at all time. The buildings or units situated in this process zone are:

a) Process area guard post (Gate 4) This facility is to ensure no unauthorized personnel will have access into the process area by using a security pass, to record the personnel activity, such as check-in and check-out between process area and non-process area. The purpose of this process 118

area guard post is to ensure that all the personnel will obey to the plant rule and regulations.

b) Control building All the control valves for the whole process area will be controlled and monitored from this central control building. The control building is designed with blast proof construction and has emergency backup power and is air conditioned in order to save and secure the vital documents of the process that it houses during emergency. c) Laboratory The quality of the purity of ethyl benzene is tested after the product is recovered to determine whether it meets the specifications or not. All the results will be sent to the control room and some adjustments in controlling will be made, if needed. The distance between laboratory and control room is not too far. Laboratory staffs will also perform analysis of the waste of the process before being channeled to wastewater treatment and flare system; or being released to atmosphere. d) Waste treatment plants The waste stream from the separation area will flow into the waste treatment plant to separate the contaminant from the water. The treatment plant is located far from separation units to prevent the waste release from contaminating the product and also away from the personnel in the process area. e) Reactor site This area places the major processing unit which is the reactor where the ethyl benzene is produced. Consideration from aspects including economy, operability and maintenance has been made to ensure the area is safe. Adequate spacing between equipment is also considered to minimize the spread of fire in case it happens. The reactor is located far from the storage to minimize domino effect that is going to affect hazardous materials and vital products. 119

f) Separation site The main objective of this treatment unit is to separate between the products, byproducts and unreacted reactants to be recycled back to the transalkylation reactor. Its location is at a distance away from the reactor site and next to laboratory. The units are arranged on the production line from high pressure to low pressure so as to ease the flow of product. The units are properly spaced among each other for maintenance and also for safety. g) Utilities site This unit will supply cooling water, high pressure steam and nitrogen to the main process unit. Its location is perfectly suitable to give the most economical run of pipe to and from the process unit. h) Storage Vessels and Drums This unit stores vessels and drums containing products that are going to be distributed locally, chemical substance, lubricants and catalyst used for the process. It also stores chemicals needed for the waste treatment plant. It is situated near the loading area just beside the laboratory. i) Warehouse and Maintenance shed Warehouse stores all the process equipments spare parts. Thus, it is placed near to the maintenance shed where maintenance job and hot work are conducted. It is also located beside to the control building where the engineers can easily monitor the contractors work in the maintenance shed and to ensure security for warehouse stores expensive equipments. j) Future site/Assembly area

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Ample area is allocated at the process area for future expansion in case the management decides to increase production rate or other crucial considerations. They occupy enough space for further expansion, whether for process reaction or producing the plants own utility such as cooling water and steam. k) Pump house and Compressor house Pump house and compressor house are located just beside the reactor site to house the pumps and compressor that are used in the production and distribution of the product, ethyl benzene to customers. l) Loading area Loading area is where the trucks deliver the chemicals used in running of the plant and also load the products that are going to be distributed locally. Thus, it is directly located to the storage. m) Flare area Flare is used to burn excess gas that is emitted from the process units as well as to burn some of the waste gas from waste treatment area. The flare is located in the same area for wastewater treatment plant and far from the process area and administration complex for this purpose.

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Separation Section

Warehouse Maintenance

Gate 3 Training Center/Seminar / Conference Room

Reactor System

Minor Equipments Housing

Fire station Control building

Future expansion site 1 / Assembly Area 1

Administration and Technical Services Future expansion site 2 / Assembly area 2 Guard House Gate 2 Gate 1

Laboratory Future expansion site 3 Wastewater treatment plant

Loading and unloading bay

Utility Sections

Parking

Clinic

Canteen

Flare Raw materials Chemical Storage Units Gate 4

Prayer Hall Main Power Supply

Figure 2: Plant Layout of Ethylbenzene Production Plan

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CHAPTER 9: WASTE WATER TREATMENT

9.1

Introduction Waste is unwanted or unusable materials. Waste is directly linked to human

development, both technologically and socially. The compositions of different wastes have varied over time and location, with industrial development and innovation being directly linked to waste materials. Wastewater is any water that has been adversely affected in quality by anthropogenic influence. It comprises liquid waste discharged by domestic residences, commercial properties, industry, and/or agriculture and can encompass a wide range of potential contaminants and concentrations. In a chemical plant, the wastewater is defined as a combination of the liquid or water that carries waste removed from commercial and industrial establishment. Wastewater, one of the major contributors to the increasingly heated environmental problem consists of toxic contaminants that may lead to direct fatal of all organisms including aquatic or land inhibited animals and even human beings. Non-biodegradable toxic waste is absorbed into the body system via food chain, which consequently leads to serious disease such as cancer, food poisoning and others. The major aim of wastewater treatment is to remove organic matter from the waste stream prior to discharge so that healthy oxygen levels could be maintained. Two waste streams discharge from a wastewater treatment plant: the liquid stream that we call effluent, and the semi-solid slurry that we call sludge. Before discharge, the wastewater passes through a variety of steps to separate, filter, disinfect and "digest" both organic and inorganic components in the waste stream. These steps are divided up into stages, with preliminary treatment providing only screening but no treatment, primary providing some and secondary and tertiary providing the most advanced level of treatment. In any chemical plant, waste treatment is a vital step because the waste created might pose potential harm or hazard to the environment as well as all living organisms if not treated properly. 123

Wastewater from Ethylbenzene production plant comprises of unused reactants and byproducts from the process side due to process divergence. The most appropriate wastewater treatment to be applied is the one that meets the recommended microbiological and chemical quality guidelines both at low cost and with minimal operational and maintenance requirements. 9.2 Laws and Regulations on Industrial Waste (Malaysia) Generally, all industries in Malaysia must comply with the law and regulations stated in the Environmental Quality Act 1974 (EQA 1974). Basically, this is an Act relating to the prevention, abatement, control of pollution and enhancement of the environment, and for purposes connected therewith. This act includes 34 regulations, which covers three (3) auxiliary regulations that are significant to the plant environmental issues:

i. ii. iii. iv.

Environmental Quality (Clean Air) Regulation 1978 Environmental Quality (Sewage and Industrial Effluent) Regulation 1979 Environmental Quality (Scheduled Waste) Regulation 1989. Other closely related regulations (a) Environmental Quality (Compounding of Offences) Rules 1978 (b) Environmental Quality (Licensing) Regulations 1977.

By referring to the mentioned act, the following paragraph will be discussing on the regulation limit of the solid, liquid and gaseous wastes according to Environmental Quality Act.

9.2.1

Solid Waste 124

According to Environmental Quality (Scheduled Wastes) Regulations 1989, solid wastes are categorized in 107 categories in the First Schedule wastes. It consists of two parts: i. ii. Part I: Scheduled Wastes from Non-Specific Sources Part II: Scheduled Wastes from Specific Sources

In the schedule, proper reference likes tagging with a specific number is required to make it easier for classification. It is important for plant management to classify the waste accordingly before proceed with the treatment. Each treatment differs for different kind of waste. Therefore, they must follow the guidelines stated in the regulations on waste collection, packaging, labeling, and transportation of the wastes for further treatment and disposal. Based on the regulation, schedule waste shall be treated at prescribed premises or at on-site treatment facilities only.

9.2.2

Liquid Waste

As for the effluent discharge from the industry, it needs to comply with the Environmental Quality (Sewage and Industrial Effluents) Regulations, (Regulation 8(1) Third Schedule, Standards A, EQ 1979). In this context, industrial effluent means liquid water or wastewater produced by reason of the production processes taking place at any industrial premises. The main consideration in wastewater treatment system is the COD, BOD value and also organic contents such as amine in the waste stream. Activities from the chemical industry must not discharge substance with high BOD or COD concentrations exceeding the specified limits of Standard A as in Table 15.

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Table 15: Plant Wastewater and Standard A Values of EQA Parameter Temperature BOD5 at 20C COD Suspended solids Unit C ppm ppm ppm Standard A 40 20 50 50 Plant wastewater 70.00 100-200 1000-1500 < 100

9.2.3

Gaseous Waste

The gaseous emission limits from the chemical industry must comply with the Environmental Quality (Clean Air) Regulations, 1977. The primary source of the gas emission of Ethylbenzene production plant is from the purge gas of benzene side product. The Clean Air Act that was enacted in 1970 includes the National Emission Standards for Hazardous Air Pollutants. This standard controls air emission levels of harmful toxins like benzene. It was reported that benzene exposure significantly increased one's risk of developing leukemia by adding benzene to the list of toxic air pollutants. Oil refineries and other industrial operations must comply with federal and state environmental law in regards to benzene emissions.

9.3

Wastewater Treatment Strategy

Wastewater treatment is a process, wherein the contaminants are removed from wastewater as well as household sewage, to produce waste stream or solid waste suitable for discharge or reuse. Wastewater treatment methods are categorized into three subdivisions which are physical, chemical and biological. General terms used to describe different degrees of treatment for increasing treatment level are preliminary, primary, secondary, and tertiary and/or advanced wastewater treatment. A generalized wastewater treatment process is summarized in Table 16. Table 16: General Treatment Description

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Treatment Stage Preliminary Primary Secondary

Description Removal of any constituents from wastewater which can clog or damage pumps, or interfere with subsequent treatment processes. Removal of organic and inorganic solids by the physical processes of sedimentation and flotation. Removal of colloidal and dissolved organic and inorganic solids of effluent from primary treatment. The secondary treatment process consists of the biological treatment of wastewater by utilizing many different types of microorganisms in a controlled environment.

Tertiary and/or Advanced

Removal of dissolved organic matter that cannot be removed by secondary treatment.

9.3.1

Physical Methods

Physical methods include processes where no gross chemical or biological changes are carried out and strictly physical phenomena are used to improve or treat the wastewater. Physical treatment is usually the first step in a larger wastewater treatment process. In general, the mechanisms involved in physical treatment do not result in changes in chemical structure of the target substances. Physical methods of wastewater treatment include sedimentation, aeration, and filtration as well as screening using bar racks, screens, deep bed filters, and membranes. A prominent physical water treatment method is sedimentation, wherein coarse screening of waste water is done to remove contaminating objects after allowing them to settle at the base by gravity. Usually this consists of simply holding a wastewater for a short period of time in a tank under quiescent conditions, allowing the heavier solids to settle, and removing the "clarified" effluent. This kind of treatment is a very common process operation and is usually employed at the beginning and end of wastewater treatment operations. Another physical water treatment method used is aeration. In aeration process, air is added to the wastewater physically to provide oxygen to it. Filtration can also be used as treatment 127

process. In filtration process, sewage is passed through filters to separate the contaminating solids from the water. Sand filter is a common filter used in this process. 9.3.2 Chemical Methods

In chemical water treatment, chemicals are used to treat wastewater in order to improve water quality. The most common method to treat water using chemicals is chlorination, wherein chlorine, a strong oxidizing chemical is used to kill the bacteria and slow down the rate of decomposition of the wastewater. Bacterial kill is achieved when vital biological processes are affected by the chlorine. Ozone, an oxidizing disinfectant, is another oxidizing agent used to treat polluted water. These oxidizing agents affect the biological growth process of bacteria, thus making the water usable. Neutralization is another chemical process used in many industrial wastewater treatment operations. Neutralization consists of acid and basis to adjust the pH levels back to neutrality. Lime is one of example of base used in the neutralization of acid wastes. Coagulation consists of the addition of a chemical. There are small particulates in wastewater where suspended in water forming a colloid. These particles carry the same charges, and repulsion prevents them from combining into larger particulates to settle. Thus, by adding a chemical, reaction will occur and forms an insoluble end product that serves to remove substances from the wastewater. Polyvalent metals, metals having more than one valence, are very often used as coagulating chemicals in sewage treatment. Lime, iron containing compounds like ferric sulfate, aluminum sulfate are some commonly used coagulants. There are a few water treatment processes which can be categorized as physical as well as chemical. The best example is the use of carbon, which adsorbs contaminants to clean the water.

9.3.3

Biological Methods

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In the biological water treatment process, microorganisms, mostly bacteria are used to biochemical decomposition of wastewaters to stable end products. More microorganisms, or sludges, are formed and a portion of the waste is converted to carbon dioxide, water and other end products. There are two sub-divisions of biological waste treatment which are aerobic and anaerobic, based on availability of dissolved oxygen. In the aerobic process, bacteria consumes the organic matter and helps convert it to carbon dioxide in the presence of oxygen, while in the anaerobic process, sludge is fermented at a particular temperature in the absence of oxygen. Another aerobic process is composting, where sludge is mixed with carbon sources such as sawdust to treat wastewater.

Table 17: Summary of Treatment Methods Properties Types of process Physical Sedimentation, aeration and filtration Chemical Chlorination, neutralization, coagulation, and carbon Advantage Simple and inexpensive process to separate solid and liquid waste and remove coarse debris in a short time Disadvantage Unable to remove bacteria Need wide space adsorption Capable to improve water quality using chemical reaction and it is efficient for specific process including both organic and inorganic contaminants Produce undesired and hazardous product Chemicals are costly 9.4 Wastewater Treatment of Ethylbenzene Production Plant Consume the contaminants in wastewater using microorganisms and accelerate natural decay process. High maintenance cost Need wide spaces Biological Aerobic Anaerobic

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There are three levels of wastewater treatment applied in the Ethylbenzene production plant which are preliminary, primary, secondary and tertiary (or advanced). In the preliminary treatment, any constituents which can clog or damage pumps, or interfere with subsequent treatment processes are removed from the wastewater. Then it proceed with the primary treatment which involve sedimentation, and is the process by which about 30 to 50 percent of the suspended solid materials in raw wastewater are removed. The purpose of preliminary treatment is to protect the operation of the wastewater treatment plant. This is achieved by removing from the wastewater any constituents which can clog or damage pumps, or interfere with subsequent treatment processes. The organic matter remaining after primary treatment is extracted by biological secondary treatment processes to meet effluent standards. Secondary treatment commonly is carried out using activated-sludge processes, trickling filters, or rotating biological contactors. Tertiary wastewater treatment is additional treatment that follows primary and secondary treatment processes. It is employed when primary and secondary treatment cannot accomplish 9.4.1 all that is required.

Preliminary Treatment

The objective of preliminary treatment is the removal of coarse solids and other large materials often found in raw wastewater. Removal of these materials is necessary to enhance the operation and maintenance of subsequent treatment units. Preliminary treatment operations typically include coarse screening, grit removal and, in some cases, communition of large objects. This treatment operation are designed to remove or to reduce in size the large, entrained, suspended or floating solids. These solids consist of pieces of wood, cloth, paper, plastics, garbage, etc. together with some fecal matter. It can also remove heavy inorganic solids such as sand and gravel as well as metal or glass and excessive amounts of oils or greases. Flow measurement devices, often standingwave flumes, are always included at the preliminary treatment stage. Equalization of wastewater flow and concentration is important, as periodic charges tend to overload 130

treatment units. Flow equalization and mechanical mixing in the collection sump will level out the hydraulics load on treatment units.

9.4.2

Primary Treatment

Primary treatment is designed to remove organic and inorganic solids by the physical processes of sedimentation and flotation. Approximately 25 to 50% of the incoming biochemical oxygen demand (BOD5), 50 to 70% of the total suspended solids (SS), and 65% of the oil and grease are removed during primary treatment. Some organic nitrogen, organic phosphorus, and heavy metals associated with solids are also removed during primary sedimentation but colloidal and dissolved constituents are not affected. Primary treatment devices reduce the velocity and disperse the flow of wastewater. In primary treatment the velocity of flow is reduced to 1 to 2 feet per minute to maintain a quiescent condition so that the material denser than water will settle out and material less dense than water will float to the surface. The solids that remain in suspension as well as dissolved solids will usually be biochemically treated in subsequent processes for physical separation and removal in the final (secondary) settling tanks. Further, the settling rate of a particle depends on the strength and freshness of the wastewater being treated, the weight of the solid compared to the specific gravity of water, the size and shape of the solid and the temperature of the water. Water is denser at lower temperatures, therefore, the required settling time increases. As the temperatures of the water increases, the required settling time decreases. Equal distribution of flow throughout the tank is critical. The greater the velocity of one area, the lesser actual detention time is. Solids not having sufficient time to settle out will be discharged in the effluent. 9.4.3 Secondary Treatment

The objective of secondary treatment is the further treatment of the effluent from primary treatment to remove the residual organics and suspended solids. The secondary treatment 131

process consists of the biological treatment of wastewater by utilizing many different types of microorganisms in a controlled environment. In most cases, secondary treatment uses aerobic biological treatment processes to remove biodegradable dissolved and colloidal organic matter. Aerobic biological treatment is performed in the presence of oxygen by aerobic microorganisms (principally bacteria) that metabolize the organic matter in the wastewater, thereby producing more microorganisms and inorganic endproducts (principally CO2, NH3, and H2O). Several aerobic biological processes are used for secondary treatment differing primarily in the manner in which oxygen is supplied to the microorganisms and in the rate at which organisms metabolize the organic matter. The microorganisms must be separated from the treated wastewater by sedimentation to produce clarified secondary effluent. The sedimentation tanks used in secondary treatment, often referred to as secondary clarifiers, operate in the same basic manner as the primary clarifiers described previously. The biological solids removed during secondary sedimentation, called secondary or biological sludge, are normally combined with primary sludge for sludge processing. 9.4.4 Tertiary and/or Advance Treatment

Advanced Wastewater Treatment may be broken into three major categories 1. Tertiary Treatment 2. Physical-Chemical Treatment 3. Combined Biological-Physical Treatment

Tertiary and/or advanced wastewater treatment is employed when specific wastewater constituents which cannot be removed by secondary treatment must be removed. Individual treatment processes are necessary to remove nitrogen, phosphorus, additional suspended solids, refractory organics, heavy metals and dissolved solids. Advanced treatment processes are sometimes combined with primary or secondary treatment 132

(e.g.chemical addition to primary clarifiers or aeration basins to remove phosphorus) or used in place of secondary treatment (e.g., overland flow treatment of primary effluent).

9.5

Solid Waste

Some examples of possible solid waste obtained from this plant are residue, spent catalyst and suspended solids. Residues are materials remaining from burning or heat reaction of coke and combustible or volatile waste. Suspended particles from source of steam (water) and particulates from equipments and piping lines also contribute to the solid waste.. According to Environmental Pollution Act, the waste can be classified as hazardous as the waste exhibits the following characteristics: ignitability, corrosivity, reactivity, and toxicity. Solid waste consist mainly the sludge removed from the liquid waste after biological treatment and little amount of spent catalyst. Suspended solids can be removed by settling and sedimentation using clarifiers. The characteristics of solids and sludge produced during wastewater treatment are summarized in Table 18

Table 18: Characteristic of Sludge Produced in Wastewater Treatment Solids or sludge Grit high velocities Description Made of heavier inorganic solids that settle with

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Scum/grease Primary sludge Activated sludge Digested sludge

Floatable material from primary and secondary settling tanks Usually grey and slimy with foul odour. Generally has a brownish, flocculants appearance Brown and has a flocculants appearance but usually no offensive odour.

Environmental Quality (Scheduled Wastes) Regulations 1989 requires that scheduled wastes be treated and disposed of at facilities approved by Department of Environment (DOE). Presently most local authorities in Malaysia dispose solid wastes in landfills. Incineration has always been viewed as a risk in terms of costs and effectiveness. The existing Town and Planning Act do not allow the use of incinerators in urban areas. Landfills cover 60 to 90 percent of the served areas, and are projected to cover up to 70 to 95 percent in the near future. 80 percent of the waste disposal sites had less than 2 years of operating life remaining in 1990, emphasizing the urgency for municipalities to secure new landfills before the existing ones is exhausted.

One of the disposal areas of scheduled wastes for Peninsular Malaysia is provided by Kualiti Alam Sdn Bhd. The company owns and operates the Integrated Scheduled Waste Management Centre (WMC) at Bukit Nanas, Negeri Sembilan. The waste treatment facilities provided are incineration, physical/chemical treatment, solidification and waste disposal in a secured landfill. Sludge is usually being turned to a suitable sludge cake for ease of loading into plastic lined drums before being transported to Kualiti Alam Sdn. Bhd. for further treatment or disposal to landfill.

9.6 Liquid Waste From the iCON data, the major liquid waste has been identified in the plant and following table shows the estimated amount of the liquid waste. Table 19: Liquid Waste in Vinyl Acetate Plant 134

Stream (S) S27

Component Ethyl Benzene Diethyl Benzene Ethyl Toluene Triethyl Benzene Diphenyl Ethane

Composition 0.02 0.05 0.01 0.31 0.62

Amount (kg/hr) 22.57 56.43 11.29 349.86 699.73

The estimated amount of wastewater that will be entering the wastewater treatment system is 1128.59 kg/hr. After completing the wastewater treatment, then only the treated water will be drained back into South China Sea.

Table 20: Plant Wastewater and Standard B Values of EQA Parameter Temperature PH value BOD5 at 20C COD Suspended solids Others Unit Standard B Plant wastewater C 40 39 5.5-9.0 6.0-8.0 ppm 50 100-200 ppm 100 150-250 ppm 100 < 100 None

9.7 Gaseous Waste

From the iCON data, the major gas waste has been identified in the plant and following table shows the estimated amount of the waste. Table 21: Gaseous Waste in Vinyl Acetate Plant Stream (S) S27 Component Benzene Ethyl Benzene Ethane Concentration 0.94 0.01 0.05 Amount (kg/hr) 6052.31 64.39 321.93

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Therefore, total estimated gaseous waste in the plant is 6438.63 kg/hr. National emission standard or limits have been established pertaining to particular source of gas emissions with respect to the country regulation itself. Therefore, an efficient and sophisticated degree of control must be implemented for industrial emission. These gases must be vented to avoid dangerously high pressure in the operating equipment, from plant start up and from emergency shutdown. The system for safely venting process equipment during these situations is called emergency relief systems. Such system usually has many safety valves tied into one collection system. They are designed with large pipes to ensure large volume can be handled at low pressure. The lines lead to a water seal drum and to a flare stack, where the gaseous such as benzene are flared at a safe height above the process area. Flare tips use steam to create a turbulent mixing between air and the stack gas at the top. It also provides some cooling of the flare tip and stack. The flammable gas is ignited at the top by a continuous pilot. The main control that needs to be maintained along the flaring process is the control of proper steam flow. This is because with proper steam flow, smokeless operation can be maintained at all conditions of gas flow, which provide an almost complete combustion of gaseous. The flaring process may results in some smoke emissions to the atmosphere. In order to ensure that the little amount of smoke emission is complying with Malaysian Environmental Quality (Clean Air) Regulations 1978, a filter could be installed on top of the stack gas tip before the gaseous is released to the air. Gas quality monitoring system need to be installed to ensure the quality of gas that being released into the environment is within the acceptable range of Clean Air Regulation 1978.

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Equalization Untreated Waste Water

Figure 3: Process Flow Diagram of Wastewater Treatment System for Ethyl Benzene Plant

Treated Water

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