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DESIGN PROJECT
MARCH 2019-JULY 2019
PRODUCTION OF 100 000 MTPA OF CUMENE VIA ALKYLATION
OF PROPYLENE AND BENZENE WITH EFFICIENT WASTE TREATMENT
PROCESS
SUPERVISOR
DR. SITI AMINAH MD ALI
FACULTY OF CHEMICAL ENGINEERING
UNIVERSITI TEKNOLOGI MARA
CAWANGAN PULAU PINANG
AUTHOR’S DECLARATION
“Thereby declare that this report is the result of my own work except for
quotation and summaries which have been duly acknowledge”
i
SUPERVISOR’S CERTIFICATION
“Thereby declare that I have read this thesis and in my opinion this
project report is sufficient in terms of scope and quality for the award
Signature : ………………………………………
Date : ………………………………………
ii
TABLE OF CONTENT
AUTHOR’S DECLARATION i
SUPERVISOR’S CERTIFICATION ii
LIST OF TABLES iv
LIST OF FIGURES v
EXECUTIVE SUMMARY vi
4.6 CONCLUSION 24
REFERENCES: 25
iii
LIST OF TABLES
iv
LIST OF FIGURES
v
EXECUTIVE SUMMARY
The proposed design to produce 100,000 ton of cumene per annum is via
alkylation of propylene and benzene. Cumene usually produce as a raw material to the
production of acetone and phenol. In alkylation of propylene and benzene, both raw
materials are introduced into a tubular packed bed reactor at a high temperature to
produce cumene. In this process, two flash energy integrated technology was used for
an economically friendly process.
vi
CHAPTER 4
Factory and Machinery Act (FMA) 1967 is referred to as the act that
provides the control of factories with respect to matters that are related to
safety, health and welfare of person therein, the registration and inspection of
machineries and other related matters[8]. The objectives of FMA 1967 are to
control factory operations with respect to safety, health and welfare of persons
and to conduct registration and inspection of machineries. The relevant
regulations for the production plant of cumene are as follows:
3
1. Factories and Machinery (Noise Exposure) Regulations 1989
Occupational Safety and Health Act (OSHA) 1994 is defined as the act
that furthers the provisions and welfare of persons at work, protects others
against risks to safety and health related to the activities performed by the
persons at work and to establish the National Council for Occupational Safety
and Health. The concepts of OSHA 1994 include accident prevention as an
essential part of a good management and workmanship, management and
workers must cooperate, and top management must take the lead of
occupational safety and health at the workplace. The list of regulations under
OSHA 1994 is as follow:
4
ii. If the chemical to be classified is not listed as a classified chemical in
Part 1 of the Industry Code of Practice, the classification of the chemical
as a hazardous chemical shall be in accordance with the physical,
health and environmental hazard of the chemical as specified in Part 2
of the Industry Code of Practice.
2. Occupational Safety and Health (Notification of Accident, Dangerous
Occurrence, Occupational Poisoning and Occupational Disease) Regulations
2004
i. Subject to subsection 1(2) of the Act, these Regulations shall apply to
all places of work.
ii. Nothing in these Regulations shall prejudice any requirement imposed
by or under any other written law relating to reporting of accident,
dangerous occurrence, occupational poisoning or occupational disease
ii. The register shall be maintained in good order and condition and be
updated from time to time and shall contain the following information:
(b) the current Chemical Safety Data Sheet for each of the
chemicals hazardous to health except for pesticides which shall
have information as specified in Schedule III
(c) the average quantity used, produced or stored per month or per
year whichever is applicable for each of the chemicals
hazardous to health;
(d) the process and work area where the chemicals hazardous to
health are used; and
(e) the name and address of the supplier of each of the chemicals
hazardous to health.
5
iii. The register shall be accessible to all employees at the place of work
who may be exposed or are likely to be exposed to chemicals
hazardous to health.
iii. The requirements in sub regulations (i) and (ii) shall not apply if the
employer has complied with the requirements of regulation 9 and sub
regulation 11(1) of the Environmental Quality (Scheduled Wastes)
Regulations 1989 [P. U. (A) 139/89]
4. Occupational safety and Health (Safety and Health Officer) Regulations 1997
Appointment of officers.
Application.
6
6. Occupational Safety and Health (Control of Industrial Major Accident Hazards)
Regulations 1996
Environmental Quality Act (EQA) 1974 is an act established to prevent, abate, control
pollution and enhance the environment, and for any related purposes[10]. EQA 1974
restricts the wastes discharge into the environment according to the acceptable
conditions[11]. The relevant regulations of EQA 1974 for the chemical plant of the
production of ethylene are as follows[11]:
Industry
Transportation
(1) Every waste generator shall, within 30 days from the date of generation of
scheduled wastes, notify the Director General of the new categories and quantities of
scheduled wastes which are generated.
(2) The notification given under sub regulation (1) shall include the information
provided in the Second Schedule.
8
(1)Recovery of material or product from scheduled wastes shall be done at prescribed
premises or at on-site recovery facilities.
(2) Residuals from recovery of material or product from scheduled wastes shall be
treated or disposed of at prescribed premises.
(1) A waste generator may apply to the Director General in writing to have the
scheduled wastes generated from their particular facility or process excluded from
being treated, disposed of or recovered in premises or facilities other than at the
prescribed premises or on-site treatment or recovery facilities.
(2) An application under sub regulation (1) shall be submitted to the Director General
in accordance with the guidelines for special management of scheduled wastes as
prescribed by the Director General and shall be accompanied by fee of three hundred
ringgit and shall not be refunded.
(3) If the Director General is satisfied with the application made under sub
regulation(1), the Director General may grant a written approval either with or without
conditions.
(1) Every waste generator shall ensure that scheduled wastes generated by him are
properly stored, treated on-site, recovered on-site for material or product from such
scheduled wastes or delivered to and received at prescribed premises for treatment,
disposal or recovery of material or product from scheduled wastes.
(2) Every waste generator shall ensure that scheduled wastes that are subjected to
movement or transfer be packaged, labelled and transported in accordance with the
guidelines prescribed by the Director General.
(1) Scheduled wastes shall be stored in containers which are compatible with the
scheduled wastes to be stored, durable and which are able to prevent spillage or
leakage of the scheduled wastes into the environment.
(2) Incompatible scheduled wastes shall be stored in separate containers, and such
containers shall be placed in separate secondary containment areas.
9
(3) Containers containing scheduled wastes shall always be closed during storage
except when it is necessary to add or remove the scheduled wastes.
(4) Areas for the storage of the containers shall be designed, constructed and
maintained adequately in accordance with the guidelines prescribed by the Director
General to prevent spillage or leakage of scheduled wastes into the environment.
(5) Any person may store scheduled wastes generated by him for 180 days or less
after its generation provided that:
b) the Director General may at any time, direct the waste generator to send any
scheduled wastes for treatment, disposal or recovery of material or product from the
scheduled wastes up to such quantity as he deems necessary.
(6) A waste generator may apply to the Director General in writing to store more than
(7) If the Director General is satisfied with the application made under subregulation(6),
the Director General may grant a written approval either with or without conditions.
(1) The date when the scheduled wastes are first generated, name, address and
telephone number of the waste generator shall be clearly labelled on the containers
that are used to store the scheduled wastes.
(2) Containers of scheduled wastes shall be clearly labelled in accordance with the
types applicable to them as specified in the Third Schedule and marked with the
scheduled waste code as specified in the First Schedule for identification and warning
purposes.
11. Waste generator shall keep an inventory of scheduled wastes A waste generator
shall keep accurate and up-to-date inventory in accordance with the Fifth Schedule of
the categories and quantities of scheduled wastes being generated, treated and
disposed of and of materials or product recovered from such scheduled wastes for a
period up to three years from the date the scheduled wastes was generated.
(2) A waste generator shall complete Part I of the Sixth Schedule in six copies and
hand over the six copies of the Schedule to the contractor when the scheduled wastes
are delivered to him.
(1) Every waste generator shall provide information in accordance with the Seventh
Schedule in respect of each category of scheduled wastes to be delivered to the
contractor and shall give the Schedule to the contractor upon delivery of the waste to
him.
(2) The waste generator shall inform the contractor of the purpose and use of the
Seventh Schedule.
(3) The contractor shall carry with him the Seventh Schedule for each category of
scheduled wastes being transported and shall observe and comply with the
instructions contained therein
(1) In the event of any spill or accidental discharge of any scheduled wastes, the
contractor responsible for the waste shall immediately inform the Director General of
the occurrence.
(2) The contractor shall do everything that is practicable to contain, cleanse or abate
the spill or accidental discharge and to recover substances involved in the spill or
accidental discharge
15. Conduct of training Every waste generator shall ensure that all his employees
involved in the identification, handling, labelling, transportation, storage and spillage or
discharge response of scheduled wastes attend training programmes.
(1) Every offence which consists of any omission or neglect to comply with, or any act
done or attempted to be done contrary to these Regulations may be compounded
under section 45 of the Act.
11
(2) The compounding of offences referred to in sub regulation (1) shall be in
accordance with the procedure prescribed in the Environmental Quality (Compounding
of Offences) Rules 1978 [P.U. (A) 281/1978]
The regulations are under Third Schedule, Regulation 8(1), 8(2) & 8(3) in which the
limit for the parameter given in a table. There are two standard that have to be complied
which is Standard (A) and Standard (B). The regulations are applied to monitor and
control the quality of the waste water treatment facility to make sure that the waste
water that will be discharged to the environment is within the limit that will not harm the
environment. The list of the parameter and the limit that have to be followed are listed
showed in table 4.1.
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FIFTH SCHEDULE
[Paragraph 11(1)(a)]
ACCEPTABLE CONDITIONS FOR DISCHARGE OF INDUSTRIAL
EFFLUENT OR MIXED EFFLUENT OF STANDARDS A AND B
13
4.4 WASTEWATER TREATMENT
Wastewater
influent STORAGE TANK
EFFLUENT
CENTRIFUGAL THICKENING
With industrial development, there is increase in the amount of oil used, but
various technical and management developments lag behind other reasons that are
not perfect and make a lot of oil into the water, forming pollution. Treating oily
wastewater sources is very broad, as the oil in the oil industry, oil refining, oil storage,
transportation and petrochemical industries in the production process generate lot of
oily wastewater. The process of cumene production release a little amount of waste
that contain di-isopropyl benzene. Di-isopropyl benzene is a by-product of cumene
process only few of it produces. Its immiscible in water so the characteristic of this
waste is same as oil. The wastewater treatment plant involve coagulation, flocculation
sedimentation and sludge process.
Figure 4.1 shows the waste water treatment plant process in the cumene
production plant. All of this process is in physical and chemical treatment. The
wastewater treatment process started with the effluent came out of the plant. The
wastewater influent is store in a close tank due to low effluent. After that, the
wastewater undergoes coagulation process in the coagulation tank with adding the
coagulant agent. among other treatment to treat waste, coagulation is the most
effective and economically to treat di-isopropyl benzene. According to, Li Yu (2013) for
the treatment of oily wastewater oil industry has developed a composite coagulant
CAX, when the original oil in water concentration was 207 mg/L, COD concentration
was 600 mg/L, after coagulation treatment, oil and COD removal efficiency reached
98% and 80% respectively using aggregation zinc silicate (PISS) and anionic
14
polyacrylamide (A-PAM) composite flocculant oily wastewater treatment, improved oil
removal efficiency up to 99%, suspended solids concentration was less than 5 mg/L,
and met back water requirements[12]. For enhancing the floc, the flocculation process
in the flocculation tank is added. The suspended solid from the process is sedimented
by the clarifier and the suspended solid is settled down to the sludge dewatering
process. The sludge is been dispose in a suitable dispose area.
15
Figure 4. 2 Flowchart of HIRARC system
This value is based on the likelihood of an event occurring. You may ask the
question “How many times has this event happened in the past?” Assessing likelihood
is based worker experience, analysis or measurement. From the table 4.1 it indicates
the likelihood of an occurrence. Likelihood levels range from “most likely” to
“inconceivable.” The rate of the likelihood is from 1 to 5. For example, a small spill of
bleach from a container when filling a spray bottle is most likely to occur during every
shift. Alternatively, a leak of diesel fuel from a secure holding tank may be less
probable[14]. From the table 4.2 it shows that the rating of the likelihood is at 5.
16
Table 4. 2 Indicate Likelihood
Most likely The most likely result of the hazard / event being 5
realized
Severity can be divided into five categories. Severity are based upon an
increasing level of severity to an individual’s health, the environment, or to property[14].
Table 4.3 indicates severity by using the following table:
Table 4. 3 Severity
17
risk throughout a plant and area in a workplace. The results of risk assessment that
presented in a risk matrix are essential to make decision on risk control[13]. Risk is the
combination of the likelihood and severity of a specified hazardous event occurring. In
mathematical term, risk can be calculated by the equation:
From the equation, it shows that the likelihood is an event likely to occur within
the specific period or in specified circumstances and severity is outcome from an event
such as severity of injury or health of people, or damage to property, or insult to
environment, or any combination of those caused by the event[14]. The relative risk
value can be used to prioritize necessary actions to effectively manage work place
hazards. Table 4.4 determines priority based on the following ranges:
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4.5.5 HIRARC form
PIC due
Exciting Risk Likelih Severi Recommended control
No Chemical Hazard Cause/Effect Risk date
Control ood ty measure
status
Extremely Eye: Causes eye irritation. Spills/Leaks: Abs Engineering Controls: Use
flammable liquid Skin: Causes skin irritation. Harmful if absorbed through orb spill with inert stringent control measures
and vapor. Vapor the skin. Prolonged and/or repeated contact may cause material (e.g. such as process enclosure to
may cause flash defatting of the skin and dermatitis. vermiculite, sand prevent product release into
fire. Harmful if Ingestion: May cause central nervous system or earth), then the workplace. Use backup
swallowed, depression, characterized by excitement, followed by place in suitable controls (e.g. double
inhaled, or headache, dizziness, drowsiness, and nausea. Advanced container. mechanical pump seals) to
absorbed through stages may cause collapse, unconsciousness, coma and prevent the release of this
the skin. Causes possible death due to respiratory failure. May cause material due to equipment
eye, skin, and effects similar to those for inhalation exposure. Aspiration failure. Use non-sparking
1 benzene 5 3 15
respiratory tract of material into the lungs may cause chemical ventilation systems, approved
irritation. Contains pneumonitis, which may be fatal. explosion-proof equipment
benzene. Benzene Inhalation: Causes respiratory tract irritation. May cause and intrinsically safe electrical
can cause cancer. drowsiness, unconsciousness, and central nervous systems in areas where this
Aspiration hazard system depression. Exposure may lead to irreversible product is used and stored
if swallowed. Can bone marrow injury. Exposure may lead to aplastic
enter lungs and anaemia. Potential symptoms of overexposure by
cause damage. inhalation are dizziness, headache, vomiting, visual
May cause blood disturbances, staggering gait, hilarity, fatigue, and other
abnormalities. May symptoms of CNS depression.
19
cause central Chronic: May cause bone marrow abnormalities with
nervous system damage to blood forming tissues. May cause anaemia
effects. and other blood cell abnormalities. Chronic exposure to
benzene has been associated with an increased incidence
of leukaemia and multiple myeloma (tumour composed of
cells of the type normally found in the bone marrow).
Immunoexpressed effects have been reported. This
substance has caused adverse reproductive and fatal
effects in laboratory animals.
Extremely Spill or Leak
flammable gas Inhalation Risk: On loss of containment this gas can cause Eliminate all
Contains gas suffocation by lowering the oxygen content of the air in ignition sources
under pressure; confined areas. Vapor concentrations above recommended (no smoking,
may explode if exposure levels are irritating to the eyes and the respiratory flares, sparks or
heated tract, may cause headaches and dizziness, are anaesthetic flames in
Vapours may and may have other central nervous system effects. Causes immediate area). Engineering Controls
cause drowsiness suffocation (asphyxiant) if allowed to accumulate to All equipment The use of local exhaust
or dizziness concentrations that reduce oxygen below safe breathing used when ventilation is recommended to
levels. Effects of Short-Term Exposure: Rapid evaporation handling the control emissions near the
of the liquid may cause frostbite. The substance may cause product must be source. Laboratory samples
2 propylene 5 4 20
effects on the central nervous system. Exposure could grounded. Do not should be handled in a fume
cause lowering of consciousness. touch or walk hood. Provide mechanical
Eye Contact: Exposure to rapidly expanding gas or through spilled ventilation of confined spaces.
vaporizing liquids may cause frostbite (cold burns) or tissue material. Stop leak Use explosion-proof ventilation
damage. if you can do it equipment
Skin Contact: Exposure to rapidly expanding gas or without risk. If
vaporizing liquid may cause frostbite (cold burn). In case of possible, turn
frostbite, place affected area in warm water until circulation leaking containers
returns. so that gas
Ingestion: Not considered to be a hazard. escapes rather
than liquid.
20
Flammable liquid Inhalation May be harmful if inhaled. Causes respiratory Spill or leak Engineering controls: Use
and vapor tract irritation. Methods and engineering controls to
Harmful if Skin May be harmful if absorbed through skin. Causes skin materials for maintain airborne level below
swallowed irritation. containment and exposure limit requirements or
Causes skin Eyes Causes eye irritation. cleaning up guidelines. If there are no
irritation Ingestion May be harmful if swallowed. Aspiration hazard Contain spillage, applicable exposure limit
Causes eye if swallowed - can enter lungs and cause damage. and then collect requirements or guidelines,
irritation with an electrically use only with adequate
Suspected of protected vacuum ventilation. Local exhaust
causing cancer cleaner or by wet- ventilation may be necessary
May cause brushing and for some operations.
respiratory place in container Individual protection
irritation for disposal measures
according to local Eye/face protection: Use
Isopropyl regulations (see safety glasses (with side
3 benzene section 13). 2 3 6 shields). If exposure causes
(cumene) eye discomfort, use a full-face
respirator
Skin protection Hand
protection: Use gloves
chemically resistant to this
material when prolonged or
frequently repeated contact
could occur.
Respiratory protection:
Respiratory protection should
be worn when there is a
potential to exceed the
exposure limit requirements or
guidelines.
21
Combustible liquid Causes skin irritation Causes serious eye irritation May Contain spillage, Engineering Measures
Causes skin cause respiratory irritation soak up with non- Ensure that eyewash stations
irritation Causes combustible and safety showers are close
serious eye absorbent to the workstation location.
irritation May material, (e.g. Ensure adequate ventilation,
cause respiratory sand, earth, especially in confined areas.
irritation diatomaceous Use explosion-proof
earth, vermiculite) electrical/ventilating/lighting/e
De-
and transfer to a quipment.
isopropylb
4 container for 1 3 3
enzen
disposal according
(DIPB)
to local / national
regulations (see
section 13). After
cleaning, flush
away traces with
water. Eliminate all
ignition sources if
safe to do so.
Extremely Eyes Direct contact with liquid propane can result in eye Recovery and Engineering Measures Use
flammable gas. burns Neutralization Stop adequate ventilation to keep
Contains gas Skin Direct contact with liquid propane can result in skin the source of the gas and vapor concentrations
under pressure, burns (frostbite). release, if safe to of this product below
may explode if Ingestion Risk of ingestion is extremely low. However, if do so. Materials occupational exposure and
5 propane 3 2 6
heated. oral exposure occurs, seek immediate medical assistance and Methods for flammability limits, particularly
Inhalation This product is classified as a simple asphyxiant. Clean-Up in confined spaces. Use
High vapor concentrations may produce a reversible central Do not flush down explosion-proof equipment
nervous system depression (anesthesia) and asphyxiation. sewer or drainage and lighting in
systems. Do not classified/controlled areas.
22
touch spilled liquid
(frostbite/freeze
burn hazard!).
Consider the use
of water spray to
disperse vapors.
Isolate the area
until gas has
dispersed.
23
4.6 CONCLUSION
24
REFERENCES:
[2] F. Khan, S. Rathnayaka, S. Ahmed, Methods and models in process safety and
risk management: Past, present and future, Process Saf. Environ. Prot. 98
(2015) 116–147. doi:10.1016/j.psep.2015.07.005.
[3] J.A. Kent, T. Bommaraju, S.D. Barnicki, Handbook of Industrial Chemistry and
Biotechnology, (2017). doi:doi:10.1007/978-3-319-52287-6.
[5] cumene, Some Chem. Present Ind. Consum. Prod. Food Drink. (2012).
[9] M, Occupational Safety and Health (Classification, Labelling and Safety Data
Sheet of Hazardous Chemicals) Regulations 2013, (2012) 5.
[10] OSHA, Act 127- Environmental Quality Act 1947, Law Malaysia. (2006).
[11] V. Bhatara, D.L. Clark, L.E. Arnold, Behavioral and nystagmus response of a
hyperkinetic child to vestibular stimulation., Am. J. Occup. Ther. 32 (2010) 1–
78. doi:10.1016/j.cej.2013.06.055.
[12] L. Yu, M. Han, F. He, A review of treating oily wastewater, Arab. J. Chem. 10
(2017) S1913–S1922. doi:10.1016/j.arabjc.2013.07.020.
25
[13] A.C. Ahmad, I.N. Mohd Zin, M.K. Othman, N.H. Muhamad, Hazard
Identification, Risk Assessment and Risk Control (HIRARC) Accidents at Power
Plant, MATEC Web Conf. 66 (2016) 00105.
doi:10.1051/matecconf/20166600105.
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