PRODUCTION

OF
METHANOL
H81FED - COURSEWORK II

Group 30

Name Student ID
Saw Meng Kiat UNIMKL- 023927
Isabelle Tay Sui Kim UNIMKL- 023322
Vera Tanzil UNIMKL- 023932
Rachel Hu Jia Yun UNIMKL- 014842

Date of submission: 10 December 2015

Academic supervisor: Dr. Show Pau Loke

1
 Table of content

Section I
Brief literature search on equipment Pages
1.1 Auto-thermal Reformer (Isabelle Tay) 3-7
1.2 Fire Heater (Saw Meng Kiat) 8-12
1.3 Let-down Vessel (Vera Tanzil) 13-17
1.4 Distillation Column (Rachel Hu) 18

Section II
Engineering AutoCAD Drawing
2.1 Autothermal Reformer (Isabelle Tay) 19-20
2.2 Fire Heater (Saw Meng Kiat) 21-23
2.3 Let Down Vessel (Vera Tanzil) 24
2.4 Distillation Column (Rachel Hu) 25

Section III
Environmental protection and process safety
3.1 Bow Tie Diagram 26
3.2 Bow Tie Diagram Description 27-30

Section IV
Extended Summary
4.1 Extended Summary by Saw Meng Kiat 31
4.2 Extended Summary by Isabelle Tay 32
4.3 Extended Summary by Vera Tanzil 33
4.4 Extended Summary by Rachel Hu 34

Section V
References
5.1 Combined references 35-38

Section VI
Appendix
6.1 Material Safety Data Sheet (Methane) 39-43
6.2 Emergency Response Plan 44-45
6.3 Emergency Evacuation Plan 46
6.4 Plant Operation Accident Investigation 47-48
Form

2
1.1 Brief Literature Review on Autothermal Reformer

[Isabelle Tay Sui Kim-023322]

Introduction:

The primary step in any gas-to-liquids scheme is to produce synthesis gas

(syngas) from its feedstock. Syngas is a mixture containing hydrogen and
carbon monoxide with varying ratios depending on the desired end product. It is
almost always made by the reformation of natural gas. Nickel-based catalyst is
favored for this reformation as it promotes the reaction. The steam-methane
reformation (Reaction 2) is highly endothermic, whereas the water-gas shift
(Reaction 3) is only slightly exothermic. This causes the overall reaction to be
endothermic. To achieve near equilibrium yields in the industry, certain design
considerations are taken into account, such as the composition of natural gas,
the steam to carbon ratio in the feed, system pressure, method of supplying
heat of reaction, and the amount of carbon dioxide being recycled. The recycling
of the carbon dioxide can be used to lower the H 2/CO ratio in the syngas, as it
causes a shift in the forward direction for the water gas shift (Reaction 3).

Location Reaction Equation ΔH298K/kJ

mol-1
Combustion Partial CH4+ 3/2 O2 ⇌ CO + 2 -35.9824
zone oxidation H 2O
(Reaction 1)
Thermal and Steam- CH4 + H2O ⇌ CO + 3H2 +205.4344
catalytic methane (Reaction 2)
zones reforming CO + H2O ⇌ CO2 + H2 -41.0032
(Reaction 3)

Autothermal Reforming (ATR):

This process is a combination of non-partial oxidation and steam reforming. This

reforming process produces syngas from the reformation of natural gas in the
presence of steam, oxygen and a catalyst. (Sciencedirect.com, 2015) An ATR
reactor is designed with a burner and a combustion zone at the top and a
catalyst bed at the bottom. A mixture of feedstock with a sub-stoichiometric
amount of oxidant (oxygen) and steam will be burnt in the combustion zone,
facilitated by a turbulent diffusion flame. Partial combustion reactions take place
in the combustion zone. Hot gases continue to react in the intermediate conical
recirculation section, which is followed by methane steam reforming reaction as
well as shift conversion to equilibrium as the gases are passed over the catalyst
bed at the bottom section. (Steven F. Rice and David P. Mann, 2007) The overall
reaction for production of syngas is exothermic, with outlet temperature being
between 850°C and 1110°C, and its pressure reaching up to 100 bar.
(Topsoefuelcell.com, 2015)

3
Cross-Section of ATR and Table of Comparison for Reformers (Sandia National
Laboratories, 2007)

ATR is chosen as the reformer compared to the others due to:

 Favorable H2/CO ratio (1.6 – 2.6)
 Reduction of emissions (internal heat supply)
 High methane conversion
 Possibility to adjust the syngas composition (by changing the operating
temperatures)
 Lower capital costs (25 % less compared to SMR)

An ATR reactor system comprises of the following elements:

Vessel  Very stable multi-layer refractory lining is used. This is

and to protect the pressure vessel from the hot gases that
Refractory react in the reformer.
Burner  Hydrocarbon and oxygen feedstock is mixed in the
burner. The design of the burner nozzle helps ensure a
flow pattern that has efficient mixing yet protects the
burner and the reformer from the hot flame core.

Catalysts  Catalysts chosen have high thermal stability as it helps

ensure long and stable operations of the ATR. The
catalysts will allow operations to be run at severe
conditions and it provides extended catalyst lifetimes.

4
Schematic cross section of an ATR reactor vessel (Steven F. Rice and David P.
Mann, 2007)

Specification and Justification Sheet:

Pressure Shell
Outer Diameter (Top Length of Top Section: Width:
Section): 3.96m 6.12m 0.27m
Outer Diameter Length of Bottom Section: Material Used:
(Bottom Section): 6.71m Steel
4.87m
Justification:
Steel was chosen as the material for the pressure shell as it has high
thermal conductivity. The width used is 0.27m, it is not too thick as there
will be multi refractory layers within the shell.

Refractory Lining
1 Layer: Foil-backed
st
2nd Layer: Calcium 3rd Layer: Heat
Bubble Pack Silicate Brick Insulating Brick
Justification:
The foil-backed bubble pack was chosen, as its reflective surface will
prevent heat loss transferring from the syngas in the outlet stream to the
surrounding surfaces. It is also flexible, so it can easily encase the pipe
carrying syngas. (Ecofoil.com, 2015) Calcium silicate brick was chosen as
it has high thermal resistance and stability. It is non-combustible and
non-corrosive, so it can be placed near the burner and combustion
chamber. It is also re-usable and has long life, so maintenance costs can
be reduced. (Jrrefractory.com, 2015) Light-weight heat insulating bricks
are chosen as the final layer for the refractory lining. The purpose of this
layer is to prevent heat transferring to the pressure shell. The composition
of this brick is Alumina:Silica:Ferric Oxide = 37:61:2. It is soft and light,
and can be easily cut to fit the shape of the pressure shell and to
compliment the shapes of the previous two layer. Air is the best insulation
for the refractory, and this particular insulating contains many tiny air
spaces shaped like a honeycomb. (Traditionaloven.com, 2015) (Refractory
Engineering - Materials - Design - Construction, 2005)

5
 Burner & Combustion Chamber
Burner: CTS Burner Shape of Combustion Chamber:
Conical
Justification:
CTS Burner was chosen because of its burning characteristics, such as its
centered flame and efficient mixing at the burner nozzles. These
characteristics allow a soot free combustion, which reduces soot deposit
onto the catalyst, prolonging the lifetime of the catalyst. The efficient
mixing also allows homogenous temperature and gas distribution from the
combustion chamber at the top to the bottom of the catalyst bed. (Dahl et
al., 2015) The combustion chamber (recirculation chamber) is conically
shaped. This is in order to protect both the refractory and the burner from
the hot flame core and gas at the combustion section. (Steynburg and
Dry, 2004)

Catalyst
1st Type: Topsoe 2nd Type: Topsoe Shape of Catalyst Pellet:
RKS-2-7H RKS-2P-7H with seven axial holes
Justification:
Both catalysts are nickel based catalyst which are favourable for the
synthesis of methanol. The 2P-7H catalyst has lower nickel content, it has
lower reforming activity and will retard deposition of foreign matter onto
the catalyst. The 2P-7H will be loaded onto the 2-7H catalyst (as shown in
equipment design). Both these catalyst have magnesium alumina spinel
carrier, which has high thermal ability, as the spinel has higher melting
point and a generally higher thermal strength and stability than alumina
based catalyst. This is necessary as the catalyst bed will be under very
high temperature (850 °C) The shape of the catalyst pellet is shaped
optimized with seven axial holes. This is to increase it surface area to
provide a higher catalyst activity as well to induce low catalyst pressure
drop. (Haldor Topsoe A/S, 2015)

Operating Conditions
Pressure: 100 bar Temperature in the Minimal Volume
Combustion Chamber: Required:
850 °C 2.715 m3
Calculations:
Pressure = 100 bar = 98.6923 atm
Total no. of moles/hour = 2909.51163 moles/hour
Gas Constant, R= 0.082 atm*L/mole*K
Temperature = 1123 K

PV=nRT:
V=nRT/P = (2909.51163 moles/hour) (0.082 atm*L/mole*K) (1123 K)
/ (98.6923 atm)
= 2715 L
= 2.715m3

6
 Other Features (Manholes)
Diameter of the manholes: 2.16m Number of manholes: 2
Justification:
The manholes are designed wide enough so that technicians can enter the
reformer during maintenance. This also makes it easier for the catalyst
beds to be changed. In case of emergencies while technicians are in the
reformer, the multiple manholes allow them to evacuate more efficiently.

Precautions and safety measures before installation of the Autothermal

Reformer:

Proper verification of the installation site has to be done in order to ensure that
the site is able to withstand the weight of the equipment. Before anyone
operates or performs maintenance on the ATR, they should understand the basic
functions of every component of the system, as every component has their
distinct function; some are for basic operations and control, whereas others are
safety devices that shut the system down automatically in order to prevent
damage and personal injury. The ATR has layers of safety checks that are
designed to protect both the operators and the equipment itself from harm. If a
particular safety device is not functioning, other safety checks will still be in
place to back them up. A major safety measure is the flame monitor. If the
flame at the burner is not present, the valves will prevent incoming flow of the
feedstock.
(Industrial Heating, 2015)

7
1.2 Brief Literature Review on Fire Heaters

[SAW MENG KIAT-023927]

A fire heater is a direct-fired heat exchanger which uses the combustion of fuels
to increase the process fluid temperature. These process fluid flow through the
coils and tubes which are aligned or mounted throughout the heater. Once the
desired temperature is achieved, the fluids will then proceed to the next reaction
stage such as auto thermal reforming. By using this type of heater, the
operation can be made continuous and the foam formation can also be reduced.
All types of fire heaters have some features in common. For example, they are
built with two different heating zones or sections, which are radiant zones and
convection zones. Shield or stack zone is another zone which serves as a
separator between radiant and convection zones. (Corporation, 2015)

The function served by fire heaters in a chemical plant can be as simple as

providing enough heat to raise the temperature of the process fluid. Fire heaters
may also be used in reforming or cracking reactions where large amount of heat
is required.

There are basically two types of fire heaters which are:

 Box type heater

 Vertical cylindrical heater

In the vertical cylindrical fire heater, the radiation section has a cylinder shape
with a vertical axis, which means the radiant tubes are arranged vertically in a
circle. Besides, burners are usually positioned at the bottom floor of the heater.
The heat exchange area covers the vertical walls and therefore shows circular
symmetry with respect to the heating assembly. However, the shield and
convection tubes are normally horizontal. (Fired process heaters, n.d.)

Cylindrical heaters are generally more favoured by the chemical industry

compare to box type heaters, mainly due to higher thermal efficiency as well as
higher uniform heating rate. It is also the most common type of fire heater
being used in chemical industries. Besides, there are few more factors which
contribute to this idea. For example: (Amec Foster Wheeler, 2015)

 Better process control and design (Cylindrical type heater can reduce
the residence time towards the process outlet and it is very beneficial to
critical services.
 Cost saving design
Cylindrical type heater can be a dependable and cost effective design by
minimizing the plot surface and material cost. Vertical tube designs with
top-mounted convection typically requires smaller construction area
 Minimum number of burners used
With combustion-air pre heat, these cylindrical design can be tailored to
reduce the number of burners used.

8
Design Justification of Fire Heater

 4 main sections of fire heaters (AMETEK, Inc., 2015)

Radiant Section

1. The vertical radiant tubes are situated along the cylindrical walls in the
radiant part of the heater and they get radiant heat straight from the
burners.
2. Most of the heat released in the heater (50-65%) are delivered to the
process fluid primarily by direct radiation from the hot flame gas.
3. The refractory lining in the radiant section is the most expensive
component of the heater and normally 85% of the radiant heat must be
obtained from here.
4. Very important for thermal analysis and design of fire heater.
5. The bridge wall temperature has a range of 800-1000 °C.
6. The radiant tubes are installed with minimum spacing from refractory.

Convection section

1. Instead of hitting the radiant section directly, the process fluid will
normally enter the coil inlet in the convection section where it is pre
heated before moving into the radiant tubes for further heating. The
convection section eradicate heat from the flue gas to preheat the
contents of the convection tubes and notably reduce the temperature of
the flue gas leaving the stack.
2. The process fluid receive about 25-35% of the total heat released in this
section and some are lost due to flue gas exiting the stack.
3. Inside the radiant and convection section, tube temperature is measured
and monitored regularly.

Shield Section

1. Shield section is located at the bottom of convection section. It consists of

rows of shielding tubes which protect the convection tubes from direct
radiant heat.
2. Furthermore, the bridge wall temperature is the flue gas temperature
after the radiant heat is eliminated by the heater radiant tubes and before
it reaches the convection section.
3. Draft measurement, which is very critical is also carried out at this section
of the heater as this will decide how good the heater is being established.
This is because either negative pressure draft or positive pressure draft
can cause severe glitches inside the fire heater.

Breeching Section and Stack

1. When flue gas flows from the convection section and before reaching the
stack, it will pass by one section which is the breeching section. Most of
the heat should be recuperated and the temperature should be reduced
when the flue gas reaches the stack.

9
 2. A stack has a cylindrical structure which brings flue gas to the surrounding
atmosphere and deliver necessary draft.
3. Draft is the pressure of flue gas which is always negative when measured
at any point in the heater. This literature review focuses more on natural
draft heater, which means no fan or air blower is required to move the
combustion air into the heater. All the actions are carried out by the stack
alone including the removal of flue gas from the heater.
4. The flue gas temperature as it leaves the convection section is known as
stack temperature.

 Other components design (KLM Technology Group, 2015)

Component Function

Damper Introduce variable resistance to control the flow rate of gas

or air and to control the draft in the heater. This can be
done through the stack.
Header/ Return A 180°cast fitting which is used to connect the straight
Bend tubes in the heater.
Coil (Vertical/ A series of straight tubes connected by 180 degree return
horizontal) bends, forming a continuous path for the flowing of process
fluid as it gets heated.
Burners Introduce air and fuel at set velocities, concentration and
turbulence into the heater to form and maintain proper
combustion. Two burners are needed due to high volume
and high flow rate of process fluid. To ensure uniform
heating.
Refractory Lining Being used throughout the inside of heater to shield the
heater casing from excess temperatures and to reduce the
outside temperature of the metal casing to 180°F. Example
can be ceramic fibre.

Material of Construction (Corporation, 2015)

Heater casing Carbon steel with fibre insulation lining

and stainless steel inner lining
Heater tubes Stainless steel 18 Cr-8 Ni, Type AISI
304
Coil supports Type 304 stainless steel
Inlet and Outlet Connections ANSI B16.1 flanges, SA-105
Combustion Air Piping A106-B
Fuel Gas Piping A106-B, steel flanged construction
Structural Steel A-36
Exhaust stack A-53. The stack is also externally
insulated with jacketed ceramic fibre
for personnel protection
Inlet and Outlet Connections ANSI B 16.1 flanges

10
Operating Conditions

For ideal operation, excess oxygen in the flue gas entering the convection
section is reduced and there is a slight negative pressure at the convection
section inlet.
However, for most of the heater design, thermal efficiency is the most significant
operating factor. This is especially true in view of existing trend of rising fuel
price and environmental issues.

 Combustion and Thermal Efficiency

Secondary
Air register Refractory CO 2
Gas
Premix Water Vapour
Chamber
Oxygen

NOx
Primary
Air register
PPM Combustibles
Burner
Tip
Nitrogen

The function of the burner is to pre-mix the fuel with the primary air that is
aspirated into the burner through the flowing of flue gas. Without removing the
flame off the burner, the air should be flowing at its maximum rate. Besides, due
to the fact that low gas pressure is able to reduce the optimum performance of
fire heater, the pressure of the fuel gas supplied to the burner must be properly
maintained. Most of the air (primary air) is transferred to the burner together
with the fuel gas. On top of that, secondary air is also introduced into the burner
and adjusted with the registers. Excess or too little secondary air can contribute
to poor combustion. (AMETEK, Inc., 2015)

There are 2 main supplies of heat input to the radiant section which are the
combustion heat of fuel, Qcofuel and the sensible heat of air combustion, Qair and
fuel combustion, Qfuel. Radiant tubes, QR and shield tubes, Qshield captivate some
of the heat input in the radiant section. The residual heat is then carried by the
flue gas which is leaving the radiant section, Qfluegases or lost due to radiation on
the heater walls, Qlosses. The heat loss is dependent on the size of the heater and
therefore, the smaller the heater, the greater the heat losses. Below is the given
equation for heat balance. (Fired process heaters, n.d.)
Qcofuel + Qair + Qfuel = QR + Qshield + Qfluegases + Qlosses

The overall thermal efficiency of the fire heater is reliant on the efficiency of the
heat recovery from the flue gases, which in turn depends on the dimension of
the heat exchange surface area in fire heater. In order to expand the heat
transfer area and therefore further boost the overall efficiency of the heater,
studded or finned tubes are usually used in the convection section.

11
Fire Heater Design Considerations

- The minimum radiation loss is 2.6% of the total heat supplied.

- 20% of excess air is needed since fuel gas is the primary fuel in this
natural draft type fire heater.
- The film temperature cannot be too high to avoid fluid cracking and also
coke deposition.
- This coke deposit reduces the heat transfer since it has become an
insulator. This results in overheating of tube as well as restricting the flow
of process fluid.
- Baffles are employed to minimize flue gas bypass.

Equipment specification (Fire Heater) (Corporation, 2015)

Unit Process Conditions

Process Fluid Syngas, Inlet pressure (atm) 1.00
H2O, CH4
Fluid flow rate (kg/h) 6674.8 Outlet pressure (atm) 0.9544
Inlet temperature (°C) 374 Efficiency (%) 78.00
Outlet temperature (°C) 805 Radiation losses (%) 3.5

Fuel and Air Characteristics

Type of fuel Natural gas Molecular weight 19.99
(kg/kmol)
Net calorific value 925447 Fuel flow rate (kmol/h) 80.2
(kJ/kmol)
Molar heat (kJ/kmol.K) 20.5 Percentage of excess air 26
Fuel Temperature (°C) 24.9 Air flow rate (kmol/h) 950
Composition CH4 - 80.5 C3H8 - 4.65 Air temperature (°C) 24.8
(% mol) C2H6 - 9.1 CO2 - 3.55
H2S - 0.08 N2 - 1.74

Characteristics of Fire Heater

Ext. height of heater (m) 20.5 Weight - heater (kg) 278000
Total number of tubes 90 - refractory lining (kg) 246000

Characteristics of Radiant Section

Number of radiant tubes 54 External diameter of tube (mm) 205
Total tube length (m) 18.55 Tube wall thickness (mm) 7.8
Tube spacing (mm) 385

Characteristics of Convection Section

Number of convection 29 External diameter of tube (mm) 150
tubes
Number of shield tubes 7 Tube wall thickness (mm) 7.8
Total tube length 18.55 Tube spacing (mm) 235

12
1.3 Brief Literature Review on Let down Vessel

[Vera Tanzil-023932]

For industrial purposes now and then there is a need to separate a vapour-liquid
mixture. This is where let-down vessel, which is also commonly known as knock-
out drum (vessel) or vapour-liquid separator, is brought to play. This equipment
is used to decelerate gases, allowing liquid to “fall out” of the gas stream with
the help of gravity (Alliedflare.com, n.d.). At the bottom of the vessel is where
the liquid will accumulate and withdrawn. Entrainment of any liquid droplets in
the vapour is diminished by the vapour travelling at a designed velocity (See,
n.d.).

Installation of let-down vessel can be either in a vertical or horizontal

arrangement. For both arrangements, the presence of liquid level gauge or
indicator is a must as drainage must be maintained to ensure no liquid surplus.

(Source : http://www.jmcampbell.com/tip-of-the-month/2014/12/troubleshooting-gas-liquid-
separators-removal-of-liquids-from-the-gas/)

Vertical arrangement is chosen to be discussed in this academic literature. The

first reason is because due to this arrangement, also contributed by the height of
the vessel, therefore providing a better separation between the liquid and
vapour (gas). Secondly, the contact surface area of the mesh pad (i.e. shown as
mist extractor in figure 1.1) in the vertical arrangement is larger compared to
the latter. Thirdly, the horizontal arrangement take up more space compared to
the vertical arrangement. Moreover, the effectiveness of liquid extraction is
standardized or does not vary according to the level of the liquid as the vacant
area for the vapour flow in the vessel remains constant.

In addition to the discussion of choice above, an inlet diffuser is added as one of

the components. Justification of the choice made is discussed in the following
page.

13
Below here are the summary of the components found in the equipment.
Components
Primary separation section (inlet)
Inlet diffuser
(Source: https://www.sulzer.com/en/Products-
and-Services/Separation-Technology/Feed-Inlet-
Devices/Shell-Schoepentoeter-and-
Schoepentoeter-Plus)
Secondary separation section
(Gas gravity separation setion)
Liquid separation section
(Liquid gravity separation section)
Wire mesh/ eliminator
Explanation
The main function is to separate
liquid from gas. Rapid elimination of
bulky liquid and liquid slugs from the
gas stream, vice versa, is desired.
 Mixed phase inlet stream is
divided into a series of lateral
flowing streams
 Kinetic energy is being
dissipated by the vanes as
providing a smooth entry into
the vessel. Separation of the
liquid from the vapour is also
supported as the vanes also
provides centrifugal
acceleration needed for the
separation.
 Thus, this offers the coarse
separation of liquid from the
vapour and the distribution of
the vapour in the vessel
(Digitalrefining.com, 2015)
In this section, gravity settling helps
in the removal of smaller liquid in this
section of the equipment. Reducing
gas turmoil and decreased gas
velocity play an important role.
This is where the liquid accumulates
and is also where gas bubbles which
are trapped within the liquid are
being removed.
 Also known as mist extractor or
demister pad
 This mist collecting system is
made up of knitted materials
with irregular loops of metals
or plastic interconnecting each
other
 This is where the entrapped
drops of liquid in the gas,
which was not removed in the
secondary separation section,
is being eliminated
14
  Provides efficient removal (up
to 99% removal of droplets 3
micron and larger) and low
pressure drop due to a great
number of hurdles diverting
entrapped droplets in a flowing
vapour.

(Demisterpads.com, 2015)
Vortex breaker Averts troubleshooting of potential
pump suction especially when there is
a need to remove the accumulated
liquid.

Specifications

The equipment chosen to be discussed consists of some highlighted components

such as inlet diffuser and wire mesh pad. Below are the specifications of each
component and the equipment itself.

Equipment Let-down vessel

Material Stainless steel
Volume 2.67m3
Diameter 1.50m
Height 4.20m
Temperature 321K
Pressure 1 bar
Wall thickness 0.02m
Residence time 15 minutes
The chosen material to build this vessel is stainless steel because even though it
is comparatively more expensive than other material such as carbon steel, it is
worth the price as it reduces the problem of corrosion greatly.

In order to decide on the diameter of the vessel, calculation on the minimum

vessel diameter is required. For this value to be obtained, the settling velocity
should first be calculated since in this case a wire mesh pad is involved (Sinnot,
2005).

Settling velocity:

U1 = 0.07[(ρL-ρv)/ ρv]1/2

where U1 = settling velocity, m/s,

ρL = liquid density, kg/m3

ρv = vapour density, kg/m3 (Sinnot, 2005)

15
The calculated U1 based on mass balance from coursework 1 is 0.364 m/s

Minimum vessel diameter:

Dv = √(4Vv/ πUs)

where Dv = minimum vessel diameter, m

Vv = gas, or vapour volumetric flow-rate, m3/s

Us = U1 when involving wire mesh pad (Sinnot, 2005)

The final calculated Dv based on the related mass balance from previous
assignment is ≈ 0.9 m. The finalized height of the vessel is 1.5m by taking
safety and also possible increase in future production into considerations.

Volume of the vessel is determined by using the ideal gas law formula:

PV = nRT

where P = absolute pressure, Pa

V = volume, L

n = number of moles, mol

R = universal gas constant, 8.3145 J/mol K

T = absolute temperature, K

Calculation:

Given, P = 1 bar = 100000 Pa R = 8.3145 J/mol K

n = 100 moles T = 321 K

PV = nRT

Therefore, V = nRT/P

V = (100)(8.3145)(321)/100000

V = 2.67 m3

16
Specifications of the inlet diffuser

Component Inlet diffuser

Material Stainless steels
Alloys 25, 825
Dynamic pressure <8000 Pa
(Gas/Liquid Separation Technology, n.d.)

The inlet feed in this system is a mixture of liquid and gas, thus prone to corrosion
complications, therefore stainless steel inlet diffuser is preferred. Moreover, inlet
diffuser is able work well at higher pressure, despite that it is generally designed
at dynamic pressures of <8000 Pa.

Specifications of the wire mesh pad

Component Wire mesh pad

Material Stainless steels
Alloy C22, C276, 400, 625,
825 and 20,
Copper
PP, FEP, ETFE, PTFE,
Glass fibers
Separation efficiency To droplet sizes of 2 to 3µm
(Gas/Liquid Separation Technology, n.d.)

As the wire mesh pad will also come in contact with liquid (also containing water),
stainless steel is one of the main materials in order to prevent hassles due to
corrosion (i.e. frequent replacement of the wire mesh pad).

17
1.4 Brief Literature Review on Distillation Column

[Rachel Hu Jia Yun-014842]

Process of Distillation Column

Distillation is a process of separating 2 or more mixture of liquid by using their

difference in boiling point. Heat is added to the liquid until the more violate
component in the mixture evaporated.

In the methanol-water distillation column, some molecules of water is

vaporised with the methanol when it is heated. The methanol-water vapour is
repetitively condensed and vaporised again to give a higher mole fraction of
water in liquid state and a higher mole fraction of methanol in the vapour state
until the water rich liquid is collected as bottom product and the methanol rich
vapour is condensed and then collected as a top product. [a]

Key Features

 Sieve trays
Sieve tray is chosen because it is cheaper than other type of trays and
need low maintenance. Sieve tray is a punctured plate with holes of 0.5
inches diameter on it. Multi orifices effect will occur as the vapour comes
out from the holes and the vapour flowed through the tray to make
contact with the liquid is controlled by the number of holes on the tray.
The liquid is transported down the distillation column by the down-comers
which is an overflow device and dam on the side of the plate.

 Condenser
A stainless steel shell and tube heat exchanger is used to condense the
vapour from the top of the distillation column. The coolant used in the
heat exchanger is water.

 Reboiler
Reboiler is used to produce boil-up vapour in the distillation column. It is
covered with insulator and the main heating element will be stainless
steel.

 The main material used to build the distillation column will be stainless
steel due to the slight corrosive nature of methanol. [b]
Equipment Specification

The height of the distillation column will be 120 feet tall with the diameter of 12
feet. The distillation column has 69 sieve trays with about 1.5 feet distance
between each plate. The distance from the first tray to the top of the column is
about 8 feet high. [c] [d] [e]

18
2.1 Autothermal Reformer (Isabelle Tay Sui Kim)

19
20
2.2 Fire Heater (Saw Meng Kiat)

21
22
23
2.3 Let-down Vessel (Vera Tanzil)

24
2.4 Distillation Column (Rachel Hu Jia Yun)

25
3.1 Bow-tie Diagram

26
3.2 Bowtie Diagram Description

Incident: Explosion in Fired Heater

Introduction:
As many hazards are involved in methanol synthesis, a bow tie diagram was
done to access potential hazards and damages and to come up with ways of
controlling the danger and mitigating losses. The “explosion/fire in the fired
heater” incident was chosen as the fired heater plays a huge role in methanol
production by producing the desired temperature of the process fluids. As the
heater operates under high temperature (805°C), there are a lot of potential
hazards that can be related to this particular equipment.

HAZARDS

Hazard 1: Rupture of radiant tube:

As the radiant tubes are located close to the burner, should rupture in the
radiant tube occur, the flammable process fluid would then be in direct contact
with the flame, thus causing an explosion.

Preventative Measures:
 With the mounting of sight doors on the casing, operators can have visual
access to the interior of the firebox. This allows operators to monitor any
abnormal behavior of burner flames.
 Under positive firebox pressure, any hot gases that escape through the
sight door may injure unprotected observing operators. With the usage of
proper protective gear, operators can protect themselves from burns and
other injuries.

Hazard 2: Overheating/unbalanced heating of fired heater:

Even distribution of heat throughout the fired heater is crucial, as it will affect
the temperature of the outlet stream. Uncontrollable heating will cause the
pressure to build inside the heater, which may lead to explosion.

Preventative Measures:
 Temperature sensors at both ends of the heater help to ensure the
temperature is within the desired range.
 Should there be any abnormal deviation in the temperature, the alarm
system will be triggered and emergency response plan will be executed.

Hazard 3: Incomplete pre-ignition purging (Born Heaters Canada Ltd., 2015):

Proper pre-ignition purging of the fired heater is mandatory and crucial for its
safe operation. This is to prevent the accumulation of combustible gas in the
heater that may accidentally combust, and set off an explosion.

Preventative Measures:
 Normally, the heater would be allowed to purge naturally for a period of
20-30 minutes on a cold light off, at the operator’s discretion.

27
  There has to be four volume changes in the heater prior to light off, which
is impossible to measure via natural purge. This is why options such as
the Purge Blower and Fan are introduced.

Hazard 4: Accumulation of explosive mixture in the heater (Born Heaters Canada

Ltd., 2015):

The gas mixture in the heater is extremely flammable. If left to accumulate

without proper monitoring, it could reach dangerous levels. This will cause an
explosion if ignited.

Preventative Measures:
 The safety shut off valve will prevent the inlet flow of the process fluids
into the heater once it reaches a certain level.
 Certified shut off valves are of better quality and will not easily
malfunction.

Hazard 5: Burner malfunction (Wildy, 2015):

The operation parameters for the burner are specific in order for the heater to
function safely and efficiently to produce the desired outlet stream. Any
malfunction, should be detected immediately to prevent accidents at the
equipment.

Preventative Measures:
 The analyzer should be placed in the convection section for easier access.
It should not be placed near the burner, as the temperature is not
favorable.
 Certified technicians should perform frequent inspection of the burner and
logbooks should always be properly updated.

Hazard 6: Inlet/Valve Leakage:

As the inlet and valve transport explosive process fluids, should there be leakage
to the surroundings, and accidentally ignited, it will cause a fire or even an
explosion at the equipment.

Preventative Measures:
 Pressure gauge or piezoelectric sensor should be installed in order to
detect even the slightest leakage in the inlet pipe and valve before
accidents occur.
 Constant monitoring by qualified personnel will ensure preventive
measures (ie. replacing the pipe or valve) are taken.

Hazard 7: Inexperienced operators during start up procedure after light-off:

Light off is done once every few years for fired heaters. Operators that are not
accustomed to the proper procedures may make mistakes that are costly and
dangerous.
Preventative Measures:

28
  Concrete training regarding the function of every single component of the
heater as well as standard operating procedures after light-off will prepare
them for the event.
 A supervisor who is present will be able to ensure that they conduct the
procedures properly and safely.

Hazard 8: Other sources of ignition nearby:

Other sources of ignition apart from the heater itself might trigger an
explosion should there be any unwanted gas leakage.

Preventative Measures:
 Suspension or in repeated cases, termination will be acted upon any
employees who smoke in the plant as a way of deterring them from
contributing to unwanted accidents.
 Any maintenance that causes sparks or naked flame, should be planned in
advance so that proper precautions can be taken beforehand.

CONSEQUENCES

Consequence 1: Casualties/Major Injuries:

Preparedness Control:
 Special Emergency Response Team (SERT) should be notified and they
can carry out emergency response plan.
 Employees will be evacuated to the assigned assembly point with at least
a distance of 10m to prevent further injuries.

Consequence 2: Damage to whole plant:

Preparedness Control:
 Isolation of the unit to prevent further spreading of combustible natural
gas to other parts of the plant.
 If the fire or explosion is very serious, production at other places should
be stop if possible. As methane gas is easily ignited, if it spreads to other
equipment which might act as heat source, the damage to the plant could
be devastating.

Consequence 3: Damage to fired heater:

Preparedness Control:
 Emergency alarm system will trigger to indicate problem at the unit and to
warn workers
 Preplanned emergency response plan will be carried out to mitigate
damage and impact to the equipment and workers’ safety.

Consequence 4: Minor Injury:

Preparedness Control:
 Workers who wear proper personal protective equipment can lessen the
risk of injuries.

29
  Employees will be evacuated to the assigned assembly point to prevent
further injuries.

Consequence 5: Financial Loss:

Preparedness Control:
 Proper documentation of the whole event including details of how the fire
or explosion started and steps carried out in response will be useful in
terms of legal claims
 Previously bought insurance policies can be claim to lessen financial
losses, if all the details of the accidents are in order (no insurance fraud).

Consequence 6: Pollution:

Preparedness Control:
 Containment of the smoke particles from the incident will prevent
pollution as well as damage the health of employees.
 Proper waste management will help minimize the impact of the ash and
smoke particles on the environment.

Consequence 7: Production Halt:

Preparedness Control:
 Technicians will be on-call to provide immediate response to malfunction
of equipment components.
 Alternative heaters will be use as a short-term response while waiting for
replacement or repairing of the heater

Consequence 8: Damage to company’s reputation:

Preparedness Control:
 Public relations consultant can provide the necessary information and
expertise in dealing with such crisis
 An official press statement to the public to provide explanations and
official apology to those who are affected can help save the company’s
name.

Conclusion:

Great care must be taken with the installation, implementation and maintenance
of a fired heater. However, even though the hazards can be foreseen, and the
proper preventative measures can be put in place; there are still chances of
unwanted accidents. Thus, certain controls have to be preplanned to lessen the
consequences. Proper documentation should also be done not only for legal or
insurance purposes, but also other people are aware as to how to handle the
incident if it were to happen again in the future.

30
4.1 Extended Summary

(Isabelle Tay Sui Kim – 023322)

The equipment that I have chosen is the Autothermal Reformer (ATR). The
particular features of the reformer are the burner, combustion chamber and the
catalyst bed. These three main features are important because they are part of
the pathway for the natural gas to be converted to syngas. They are specifically
chosen to complement each other. The burner will allow soot-free combustion,
which prevents carbon deposit on the catalyst, thus prolonging its life. The
conical combustion chamber protects the burner from the hot flame core and gas
while in recirculation. The locations of the three inlets are separate to allow a
more efficient and productive process flow. The natural gas and steam come in
from separate inlets and will meet and mix partially on the way to the burner,
where there will be equal mixing by the burner nozzle. The oxygen inlet is
introduced at the burner itself to ensure a constant oxygen flow there, in order
to maintain constant combustion. After passing through the catalyst bed, the
syngas flow through several small openings to the collection chamber, it will
then come out to the syngas outlet.

The ATR is normally a cheaper option compared to the steam-methane reformer

(SMR) as its initial capital cost is estimated to be $228,000 , rather than
$253,000 (SMR). Normally, the upkeep and production of the ATR causes it to
be a costlier investment in the long term, due to the high cost of the oxygen and
hydrogen gas. However, due to the earlier investment of a second hand
oxygenator and hydrogenator, we can overcome this particular short fall.

A few assumptions made were the dimensions and operating conditions of the
ATR. As there were contradicting operating conditions based on multiple
literature and sources, it was difficult to determine suitable conditions. The
dimensions were hard to determine, as the volume of the space from the
combustion chamber to the catalyst bed to the collection chamber depended on
how much natural gas would be entering the vessel. Since this volume is the
center of the reformer, other dimensions have to be able to support this basis.
Other minor assumptions were the composition of materials used and the price
of the equipment.

An improvement towards the design is to include the heat source for the
reformer such as copper coils or flue gas for inductive heating and combustion.
Another improvement is to include room in the reformer after the manhole, so
that there is space between the manhole and the refractory. This is to properly
depict the space for which technicians can perform maintenance or change the
catalyst beds.

In my opinion, the ATR is one of the most important equipment in the synthesis
of methanol via natural gas. Of course the earlier mentioned improvements
towards the design of the reformer will help to make it better commercially and
other adjustments can make this equipment better in terms of environmental
and safety.

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4.2 Extended Summary

(Saw Meng Kiat – 023927)

The equipment which I have chosen to do the literature review in this

coursework is fire heater, due to its importance in our methanol synthesis
process. Before the process fluid flows into the auto-thermal reformer where a
large temperature is required, it will be heated up inside the fire heater to
achieve its desired temperature. The main features in my heater design are the
cylindrical typed fire heater with vertical tubes and burners. By using vertical
tubes, the total design is more cost-effective due to smaller area of construction.
Since our production capacity is not so huge, low power cylindrical heater is
more preferred and therefore the cost to run the equipment is also much
cheaper. Two burners are used in my plant so that the heating process inside
the heater can be made quicker and also to provide more uniform heat
distribution to the process fluid.

Based on the result of process economic analysis, few fire heaters are required
in order to meet the production capacity of methanol. This will eventually result
in greater cost of running and maintaining. In the market, each 20m height
carbon steel fire heater is sold at around USD 480,000. After considering the
high flow rate of our process fluid, which is 6674.846 kg/h and the need to
produce 50,000 tonnes of methanol per year, 3 fire heaters are being used. For
each fire heater, there is 30 days of down time in a year, which means the
machine will be operating only 335 days in a year. Besides, there will be 5
technicians being allocated to monitor the operation of fire heater and at least
one engineer/supervisor.

There are some areas of uncertainty in my heater design such as the way to
ensure uniform heating on the heater tubes. We do not take into consideration
about thermal expansion as well. Besides, in the heater design, there is no
special component which can accurately measure the amount of air being
aspirated into the burner.

The equipment design can be improved by making sure there is extra space in
the convection section tube layout for future installation of soot blowers.
Besides, the heater arrangements can be varied to allow for replacement of
individual tubes without disturbing the adjacent tubes. Some component can be
added in as well to ensure the film temperature wouldn’t reach that high which
can cause coke deposition.

In conclusion, I believe that the equipment that I chose is relevant to the

process of methanol synthesis. In order to make sure my equipment is in high
quality and can last for a long time, the methods of improvement mentioned
above should be taken into account. Besides, regular checking and maintenance
should be carried out. It is by far one of the best equipment to heat up the
process fluid to a very high temperature in a short time. Last but not least, I
personally think that this coursework is a good platform for me to learn about
one specific equipment in detail.

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4.3 Extended Summary

(Vera Tanzil – 023932)

The chosen equipment to be discussed is the let-down vessel or more commonly

known as knock out drum (vessel). This particular equipment plays a huge role
in the separation of gas and liquid. The two distinctive features of this equipment
are the wire mesh pad and the inlet diffuser. Both facilitate the separation but
the separation by the inlet diffusor acts as a coarse separator, while the fine
separation is executed by the mesh pad.

Grounded by the research on the process economic analysis of the chosen

equipment, let-down vessel, it is shown that they are extensively used among
other industries, not only in the production of methanol, such as oil refineries.
They are also applicable in systems such as refrigerant, air conditioning and
compressor systems. In each of the application, let-down vessel generally plays
a vital role such as preventing pump damage especially in refrigerant systems
and compressor systems.

Leakage in the pipes, either inlet or outlet, is one of the issues regarding safety
and environmental. Safety wise, both inlet and outlet contain flammable gas(es)
which may severely cause explosion if is not taken care of. On the environmental
side, both inlet and outlet also contain greenhouse gases. Water pollution may
also occur due to the cleaning process of the vessel itself. Furthermore,
equipment including first aid kits and fire extinguisher should be available
nearby as an emergency response.

The major uncertainty in the chosen equipment is the interior design of the inlet
diffuser including the size and the angle of the vanes fitted in the inlet diffuser.
Another one includes the minimum and maximum distance between the inlet
diffuser and the liquid level.

There are several changes that could be done to this equipment design in order
to improve it. Firstly, a liquid level sensor or a peeping hole can be installed to
keep an eye on the rise and fall of the liquid level. Secondly, a valve can be
included after the liquid outlet to be in control of the flow of the liquid. Thirdly, a
temperature and pressure sensor can be installed to make sure that the fluid
coming in and out of the vessel are within the desired temperature range. Lastly,
a manhole can be added to the design as this will ease the cleaning and
maintaining processes of the equipment.

Overall, regarding the equipment I chose, which is the let-down vessel has a
significant role in the process of methanol synthesis as the separation of the
fluid to two different states in order to collect the desired product which in this
case is methanol in liquid state. Without it, separation of particular gases from
the liquid is going to be challenging.

33
4.1 Extended Summary

(Rachel Hu Jia Yun – 014842)

The equipment selected is distillation column. The key features of the

distillation column is sieve tray, reboiler and condenser. The main material used
to build the distillation column is stainless steel. The ratio to height of the
distillation column is 10.

The rough estimated cost of the distillation column is USD 119600.

The area of uncertainty of the distillation column is that the thickness of

the wall of the distillation column is unsure and the thickness and the number of
holes of the sieve tray is also unsure. The height, diameter and the number of
trays of the distillation column are all estimated according to the data obtainable
in the internet. The rest of the details of the distillation column are all estimated
according to the guidelines obtained in the internet. The cost of the distillation
column is also a rough estimation. In the nutshell, more knowledge and research
of the distillation column to reduce the uncertainty of the design.

In my opinion, I have learned a lot of new information regarding the

design of distillation column. But it is not enough to design a distillation column
that can be put to use as there are still too many uncertainties in the design.

34
5.1 References

1. Born Heaters Canada Ltd., (2015). Safety Controls and Burner

Management Systems (BMS) on Direct-Fired Multiple Burner Heaters.
[online] Available at:
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[Accessed 1 Dec. 2015].

2. Dahl, P., Christensen, T., Winter-Madsen, S. and King, S. (2015). Proven

Autothermal Reforming Technology for Modern Large-Scale Methanol
Plants. 1st ed. [ebook] Available at:
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dern_large_scale_methanol_plants_nitrogen_syngas_conference_feb_201
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Available at: http://www.delavaninc.com/pdf/total_look.pdf [Accessed 30
Nov. 2015].

4. Ecofoil.com, (2015). Double Bubble Insulation - Ecofoil Reflective Bubble

Insulation. [online] Available at: http://www.ecofoil.com/All-
Products/Double-Bubble-Insulation [Accessed 1 Dec. 2015].

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Available at: http://www.ecn.nl/docs/library/report/2000/c00122.pdf
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6. Haldor Topsoe A/S, (2015). Topsoe Secondary Reforming Catalyst RKS 2-

7H. [online] Available at:
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~/media/PDF%20files/Methanol/Topsoe_sec_ref_cat_RKS%202.ashx
[Accessed 1 Dec. 2015].

7. Industrial Heating, (2015). Types of Burners and Combustion Systems.

8. Jrrefractory.com, (2015). Calcium Silicate Bricks. [online] Available at:

http://www.jrrefractory.com/silicatecalciumbricks.htm [Accessed 1 Dec.
2015].

9. Pipeline Leak Detection Techniques. (2015). [online] Available at:

http://arxiv.org/pdf/0903.4283.pdf [Accessed 8 Dec. 2015].

10.Refractory Engineering - Materials - Design - Construction. (2005). 2nd

ed. [ebook] Available at: https://books.google.com.my/books?id=cKj-
X_QWrbwC&pg=PA151&lpg=PA151&dq=three+layers+of+refractory+linin
g&source=bl&ots=Bs8Nsk2Vt8&sig=7Hem3Wz5_Z7ihxnV9c92ul544-
I&hl=en&sa=X&redir_esc=y#v=onepage&q&f=false [Accessed 2 Dec.
2015].

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11.Sciencedirect.com, (2015). Autothermal reforming of methane to
synthesis gas: Modeling and simulation. [online] Available at:
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[Accessed 29 Nov. 2015].

12.Steven F. Rice, and David P. Mann, (2007). Autothermal Reforming of

Natural Gas to Synthesis Gas. [online] Available at:
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13.Steynburg, A. and Dry, M. (2004). Fischer-Tropsch Technology. 1st ed.

[ebook] Available at:
https://books.google.com.my/books?id=gJfVfbd1Bd0C&pg=PA335&lpg=P
A335&dq=pressure+shell+material+for+atr&source=bl&ots=eUZiGQL5nK
&sig=wDjlVyAHHKUPhpIKAd7wB0x5s9E&hl=en&sa=X&redir_esc=y#v=on
epage&q&f=false [Accessed 2 Dec. 2015].

14.Topsoefuelcell.com, (2015). Haldor Topsoe - Autothermal reforming.

[online] Available at:
http://www.topsoefuelcell.com/business_areas/synthesis_gas/Processes/A
utothermalReforming.aspx [Accessed 18 Dec. 2015].

15.Traditionaloven.com, (2015). Insulating fire bricks. [online] Available at:

http://www.traditionaloven.com/articles/81/insulating-fire-bricks
[Accessed 1 Dec. 2015].

16. Vitcas.com, (2015). STANDARD DENSE CASTABLE | VITCAS Refractories,

Fire Bricks, Fire Cement. [online] Available at:
http://www.vitcas.com/refractory-castable-standard-dense [Accessed 28
Nov. 2015].

17.Wildy, F. (2015). Fired Heater Optimization. [online] Available at:

http://www.etaassociates.com/Fired%20Heater%20Optimization%20ISA
%20AD.pdf [Accessed 1 Dec. 2015].

18.Amec Foster Wheeler, (2015). Fired heaters. [online] Available at:

https://www.amecfw.com/documents/downloads/about-us-
documents/brochures/fired-heaters.pdf [Accessed 19 Nov. 2015].

19.AMETEK, Inc., (2015). Process Heaters, Furnaces and Fired Heaters.

[online] Available at:
http://file:///C:/Users/h%20p/Desktop/FINAL%20PRODUCT/Process-
Heaters-Furnaces-and-Fired-Heaters.pdf [Accessed 25 Nov. 2015].

20.Corporation, E. (2015). Offshore Heater Specification - Fired Heater Stack

Requirements | Exotherm Corporation. [online] Exotherm.com. Available
at: http://www.exotherm.com/offshore-heater-specification.html
[Accessed 9 Dec. 2015].

36
21.Fired process heaters. (n.d.). 1st ed. [ebook] Available at:
http://cdn.intechopen.com/pdfs-wm/11623.pdf [Accessed 12 Nov. 2015].

22.KLM Technology Group, (2015). FURNACE (ENGINEERING DESIGN

GUIDELINE). [online] Available at:
http://kolmetz.com/pdf/EDG/ENGINEERING%20DESIGN%20GUIDELINE-
%20Furnace%20Rev02%20web.pdf [Accessed 15 Nov. 2015].

23.N. Jethva, M. (2013). Fired Heater Design and Simulation. 1st ed. [ebook]
Available at: http://www.ijettjournal.org/volume-4/issue-2/IJETT-
V4I2P215.pdf [Accessed 14 Nov. 2015].

24.Sigma Thermal, (2015). Direct Fired Heaters and Gas Fired Heaters -
Sigma Thermal. [online] Available at:
http://www.sigmathermal.com/direct-fired-heaters/ [Accessed 9 Dec.
2015].

25.Tulsa Heaters Midstream (THM), (2015). Beginners Guide to Fire Heaters.

[online] Available at:
http://tulsaheatersmidstream.com/media/files/Beginners%20Guide%20to
%20Fired%20Heaters%20(rev00).pdf [Accessed 18 Nov. 2015].

26.Alliedflare.com, (n.d.). Knock Out Drums. [online] Available at:

http://www.alliedflare.com/products/sealsdrums/57-knock-out-
drums.html [Accessed 29 Nov. 2015].

27.Demisterpads.com, (2015). Demister Pad and How to Work, Why to Use

Wire Mesh Demister. [online] Available at:
http://www.demisterpads.com/technology/demister-pad-1.html [Accessed
4 Dec. 2015].

28.Digitalrefining.com, (n.d.). New design features enhance separation

performance. [online] Available at:
http://www.digitalrefining.com/literature/1000298,New_design_features_
enhance_separation_performance.html#.Vmhhk9zyHIU [Accessed 2 Dec.
2015].

29.See, J. (n.d.). Heating Application: KO Drums. [online] Exheat.com.

Available at: http://www.exheat.com/application/case-study/ko-drums
[Accessed 29 Nov. 2015].

30.Sinnot, R. (2005). Chemical engineering design. Oxford: Elsevier

Butterworth-Heinemann, pp.461,462.

37
31.Gas/Liquid Separation Technology. (n.d.). 1st ed. [eBook] Available at:
http://www.nt.ntnu.no/users/skoge/prost/proceedings/distillation10/DA20
10%20Sponsor%20Information/Sulzer/Gas_Liquid_Separation_Technolog
y_20090819.pdf [Accessed 8 Dec. 2015].

32.[a] Srsengineering.com, (2015). Distillation Columns, Functioning

Columns. [online] Available at: http://www.srsengineering.com/our-
products/distillation-columns/ [Accessed 1 Dec. 2015].

33.[b] Methanol Recovery Optimization via Distillation. (2012). [online]

Available at:
http://webservices.itcs.umich.edu/mediawiki/algaebiofuel/sites/algaebiofu
el/uploads/b/bd/Distillation_Report_-_Rotation_1.pdf [Accessed 1 Dec.
2015].

34.[c] Distillation Senior Design CHE 396. (2015). [online] Available at:
http://www.che.utah.edu/~ring/Design%20I/Articles/distillation%20desig
n.pdf [Accessed 1 Dec. 2015].

35.[d] Used 2009 JETT WELD DISTILLATION COLUMN. CARBON STEEL

CONSTRUCTION, #. (2015). Used 2009 JETT WELD DISTILLATION
COLUMN. CARBON STEEL CON.... [online] Machinio.com. Available at:
http://www.machinio.com/listings/5040583-used-2009-jett-weld-
distillation-column-carbon-steel-construction-v780-379-in-western-usa
[Accessed 1 Dec. 2015].

36.[e] www.alibaba.com, (2015). Methanol Recovery Tower - Buy Methanol

Recovery Tower, Methanol Extraction Column, Methanol Recovery Column
Product on Alibaba.com. [online] Available at:
http://www.alibaba.com/product-detail/methanol-recovery-
tower_60266545060.html?spm=a2700.7724857.29.46.cb78to [Accessed
1 Dec. 2015].

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6.1 Material Safety Data Sheet (Methane)

39
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6.2 Emergency Response Plan

First Action Plan: Fire and Explosion

In the event where the fire is minor in a contained area, the following steps
must be taken to avoid any accident to happen.

 Immediately alert nearby personnel and neighbouring facility/

departments.
 Attend to the victims and provide first aid if possible.
 Locate the nearest fire extinguishers and sound the fire alarm.
 Identify the origin of fire to understand the risk. If there is a risk of
explosion, follow the fire and explosion evacuation plan.
 If fire is caught on any equipment in the plant, shut down the equipment
immediately if possible.
 All plant personnel should know how to use a fire extinguisher. If one is
not enough to put out the fire, evacuate the facility.
 If the fire starts spreading, contact the fire department and proceed with
the fire evacuation plan.
 In the event where the fire is successfully put off, immediately report to
the supervisor and plant safety department.
 A detailed report with possible causes of fire and losses should be
prepared by the plant safety department.

However, if the fire starts spreading or there is an explosion, the following steps
must be taken to minimize the causality.

 Immediately sound the fire alarm with evacuation siren and proceed with
the fire safety evacuation plan.
 Attend to victims and help them to come out from the plant.
 Keep low if there is smoke coming out.
 Contact the fire department, police and ambulance.
 Shut down all plant processes from the control room. This can be done
through the team leader who can power down the mains at their
respective facilities.
 All personnel are to be evacuated by following the emergency response
plan to the nearby assembly point.
 At the assembly point, team leaders have to perform headcounts for their
respective departments. Report any missing personnel.
 Do not use the elevators.
 Do not return to the fire/explosion place unless there is missing
headcount.
 After the incident, a detailed report with possible causes of fire/ explosion
is to be submitted by the plant safety department.

44
Second Action Plan: Spilling of chemicals

There are many chemicals (gases/ liquids) which can be found inside the
methanol plant. Some of it are:

Chemical Nature of Chemical

Methane (CH4) Flammable, Explosive

Carbon Monoxide (CO) Flammable, Toxic, Irritant

Hydrogen Sulphide (H2S) Flammable, Hazardous, Toxic, Irritant

Ethanol (CH3CH2OH) Flammable, Corrosive, Irritant

Methanol (CH3OH) Flammable, Toxic

In order to prevent accident from happening,

 All workers must wear personnel protective equipment (PPE) while

working inside the plant.
 In the case of chemical spill, all workers should be evacuated from that
part of the plant at least 30 feet away to avoid inhaling toxic fumes from
the spill.
 Mask must be worn by all workers.
 The emergency safety coordinator is responsible to use a rope to form a
circle of 30m radius.
 Workers must ensure that the windows and doors are closed to prevent
any toxic gas from releasing into the environment.
 Workers who have skin contact with the chemicals must take immediate
action to rinse with water for at least 5 minutes to ensure no chemicals
staying on the skin which can cause harmful effect.
 Any collapsed equipment should be returned upright to prevent further
spilling.
 Some kind of chemical absorbent such as soil or sawdust should be used
to spread all over the spill area to prevent chemical from leaching into the
soil.
 Inform the authorities if any chemicals have leaked into the water system
so that they can shut down the water access to residents.
 Medical staff should be standby to give medical treatment to any injured
or affected workers.

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6.3 Emergency Evacuation Plan

46
6.4 Plant Operation Accident Investigation Form[f]

Employee Name: __________________________________________________

Employee I.D.:____________________________________________________

Employee Contacts: _______________________________________________

Employee Job Classification/Position/Title: ______________________________

Department: _____________________________________________________

Foreman/Supervisor Name: _________________________________________

Foreman/Supervisor Contacts: _______________________________________

Date and Time of Accident: __________________________________________

Location of Accident: ______________________________________________

________________________________________________________________

Descriptions of the Accident:

________________________________________________________________

________________________________________________________________

Conditions and Factors that Leads to the Accident: (e.g. poor maintenance,
weather, visibility, etc.)

________________________________________________________________

________________________________________________________________

Is the employee trained for the activity?

________________________________________________________________

Was there any special permits/authorization needed for the activity? If yes,
please describe.

________________________________________________________________

________________________________________________________________

Were proper procedure/controls being used? (e.g. ventilation, air monitoring,

machine guards, etc.)

________________________________________________________________

________________________________________________________________

Is Personal Protective Equipment used during the activity? If yes, please list the
PPE down.

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________________________________________________________________

________________________________________________________________

Is there any equipment/utilities damaged due to the accident? If yes, please list
them down.

________________________________________________________________

________________________________________________________________

Please state Nature of Illness/Injuries due to the accident: (e.g. sprain, bruise,
burn, exposure to contaminant, etc.)

________________________________________________________________

________________________________________________________________

Please state the body part(s) that is injured:

________________________________________________________________

________________________________________________________________

Please state the type of the accident and describe it: (e.g. fall, exposure to
chemical, struck by an object, etc.)

________________________________________________________________

________________________________________________________________

Please state the action taken/medical treatment given to the employee:

________________________________________________________________

________________________________________________________________

Please state the final determination of the cause of the accident:

________________________________________________________________

________________________________________________________________

Please state the new/additional preventive measures to be implemented:

________________________________________________________________

________________________________________________________________

________________________________________________________________

Investigator Name:

Investigator Signature:

Date:

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