Oleh:

Rochim B. Cahyono, Ph.D

Imam Prasetyo, Ph.D
 Personal Introduction

Rochim Bakti Cahyono

Email: rochimbakti@ugm.ac.id
Lab affiliation: Laboratorium Proses Pemisahan, TEKNIK KIMIA UGM
Education:
S.T. Teknik Kimia UGM (2002-2006)
M.Sc. Chem. Eng., Chalmers University of Technology, SWEDEN (2007-2009)
Ph.D. Chem. Eng., Hokkaido University, JAPAN (2011-2015)
Research interest:
Risk Management and Safety, Steel production, energy and environmental
Google Schlor ID :
https://scholar.google.co.id/citations?user=hcVwhRQAAAAJ&hl=id
INDUSTRY GOALS

SAFETY & Enviromental

PROCESS
(Terdiri dari banyak PRODUCTIVITY
jenis, step dll)

QUALITY

= PROFITS
 FLIXBOROUGH Explosion
• Produced caprolactam, a precursor chemical used in the
manufacture of nylon. The process involved oxidation of
cyclohexane with air in a series of six reactors to produce a
mixture of cyclohexanol and cyclohexanone.
• Two months prior to the explosion, a crack was discovered in
the number 5 reactor.
• It was decided to install a temporary 50 cm (20 inch) diameter
pipe to bypass the leaking reactor to allow continued operation
of the plant while repairs were made.
• At 16:53 on Saturday 1 June 1974, the temporary bypass pipe
(containing cyclohexane at 150°C and 1 MPa) ruptured,
possibly as a result of a fire on a nearby 8 inch (20 cm) pipe
which had been burning for nearly an hour.
• It killed 28 people and seriously injured 26

Bypass
 Ammonium Nitrate Explosion
Toulouse, France – September, 21 2001
Accident occurred exactly 80 years after the Oppau, Germany disaster!

A huge explosion ripped through AZF (Azote de France) fertilizer factory in an industrial zone on the outskirts of Toulouse,
southwest of France, at 10:15 am, Friday September 21, 2001. Immediately after the accident, 30 people were reported dead
The total number of injuries was said to be 2,442. More than 350 people were in the plant at the time (266 AZF employees and
100 subcontractors).
The explosion had occurred in a warehouse in which granular ammonium nitrate was stored flat, separated by partitions. The
amount is said to be between 200 to 300 metric tons of ammonium nitrate, which is used to make fertilizers. A spokesman for
the Interior Ministry in Paris ruled out a criminal attack, saying the explosion had been caused by an accident following an
"incident in the handling of products". The exact cause remains unknown.

Source: United Nations Environment Programme

 BP TEXAS CITY explosion

 BP took over the Texas City Refinery from Amoco in 1999. Produced 11 million gallons
of gasoline a day
 On March 23rd, 2005 a blast occurred during the startup of the isomerization unit
which produces materials to boost the octane rating of gasoline
 The explosion killed 15 workers and injured 180 others
 Shattered windows of homes and businesses up to three quarters of a mile away from
the 1,200 acre refinery

Movie
Methyl Isocyanate Tank Rupture and Release
Bhopal, India – Dec. 2-3, 1984

Source: United Nations Photo Source: Indian state

Environment Programme government of Madhya Pradesh

Bhopal, India (1984) - Pabrik Pestisida, kebocoran zat kimia ke lingkungan,

2500 orang meninggal, 200.000 orang terluka dan kerugian sekitar
$250,000,000
IAOH - 2013 8

Bhopal Gas Disaster

 The Union Carbide Pesticide Plant in Bhopal, released 40 tons of Methyl
Isocyanate (MIC) gas, killing between 2,500 to 5,000 people in the early hours of
the morning.
 The World’s worst Industrial Disaster
IAOH - 2013 9

 The gas being heavier than air, started entering into the homes of the unwary
population. Many who panicked and ran out also got crushed in stampedes.
 Around 500,000 were estimated to be exposed to the gas & around 20,000 have
died as a result. Over 120,000 continue to suffer from the from the effects of the
disaster.
Dalam Negeri
• Ledakan dan kebakaran pabrik PT. Petro Widada Gresik (Pabrik Bahan
Kimia Pelemas Plastik) - - Tanggal 20 Januari 2004
Lokasi : Kompleks PT. Petro Widada
Jl. Prof. Dr. Muh. Yamin Gresik

Gambaran kejadian :
Tingginya temperatur pada vessel menyebabkan terjadinya ledakan pada
tangki Phtalic Anhydride
Korban :
- 3 orang meninggal dunia
- 79 orang luka (berat + ringan)
Kerugian :
10 unit mobil sedan, 4 truk tangki, 134 kendaraan roda 2, Bangunan pabrik
dan kantor kecuali unit 3
Pemukiman penduduk sekitar pabrik
 How to manage the Chemical
Industries?

Control

Assess

Recovery

Identify
Accident Sequences
People
Barrier Barrier Barrier

Asset
Barrier Barrier Barrier Damage
Hazard Top Event
(Accident)
Environment
Barrier Barrier Barrier

• Pressure / safety relief valves Reputation

???? • High temperature cut-off switches
• Correct / valid operating procedures

Hazard : A condition or action that has the potential for an unplanned release
of, or unwanted contact with, an energy source that may result in harm or
injury to people, property or the environment.
Accident Sequences

Hazard
Identification
(HAZID)

RISK
HAZARD IDENTIFICATION (HAZID) Approach

• What can go wrong?

• What incidents or scenarios could
arise as a result of things going
wrong?
• What could cause or could
contribute to these incidents?
Accident Causes
Identifikasi bahaya
(Hazard Identification)
Material Safety Data Sheets
(MSDS)
• Primary communication tools for
the user of chemical
• Material Safety Data Sheets
(MSDS) menyediakan informasi
keselamatan dan kesehatan,
peringatan pada saat penanganan
bahan berbahaya (hazardous),
termasuk keadaan darurat dan
prosedur pertolongan pertama.
• MSDS must always be available for
flammable, toxic and caustic used in
the facility
• Available at worksite location and
accessible to all
 COURSE CONTENTS: COMPELETE PHA PROCEDURE

System Description

Hazard Identification

Scenario Identification

Accident Probability Accident Consequences

Risk Determination
Modify:
Risk and/or NO • Process or plant
hazard • Process operation
acceptance • Emergency response
• Other
YES
Build and/or
operate Hazards Controlling
system