GROUP 14

PRODUCTION OF 21,000
MTPA OF ETHYLENE

CONTENT
1

Comparison between Simulation and Manual (Mass &

Energy Balance)

Chapter 3: Heat Integration & Utilities

Chapter 4: Process Equipment Sizing & Piping

Chapter 5: Process Control & Safety Studies

Conclusion

COMPUTER SIMULATION
(MASS & ENERGY BALANCE)

MASS BALANCE
COMPARISON
Strea
m

Manual
(kg/hr)

Aspen
(kg/hr)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

23409.52
23409.52
23409.52
17868.51
5541.01
5541.01
5541.01
5541.01
3004.81
3004.81
3004.81
9382.81
9382.81
9386.008
9386.008
46613.16
46613.16
5006.267
50992.9
50992.9

23403.93
23403.93
23403.93
17865.94
5537.992
5537.992
5537.992
5537.992
3012.978
3012.978
3012.978
9800.959
9800.959
9800.792
9800.792
46613.16
46652.26
4976.763
51476.29
51476.29

% Error

Strea
m

Manual
(kg/hr)

Aspen
(kg/hr)

% Error

-0.02388
-0.02388
-0.02388
-0.01438
-0.0545
-0.0545
-0.0545
-0.0545
0.271121
0.271121
0.271121
4.266433
4.266433
4.232149
4.232149
1.56E-14
0.083821
-0.59285
0.93906
0.93906

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

50992.90
50992.90
3206.94
47782.86
47782.86
3206.94
3206.94
2700.116
506.8257
50852.16
50852.16
50852.16
1068.297
54791.88
54791.88
54791.88
200
4788.527
50203.36
1011.17

51476.29
51476.29
3282.549
48193.74
48193.74
3282.549
3282.549
2702.3
508.4
50861
50861
50861
1075.3
55230.76
55230.76
55230.76
200
4824.524
50203.36
1064.29

0.93906
0.93906
2.303311
0.852565
0.852565
2.303311
2.303311
0.080809
0.309664
0.017375
0.017375
0.017375
0.651275
0.794623
0.794623
0.794623
0
0.746116
7.19E-06
4.991267

Average 1
% error

ENERGY
BALANCE
COMPARISON

Equipment

Manual
(kJ/hr)

Aspen
(kJ/hr)

% Error

C-1
E-1
X1
C-2
E-2
C-3
E-3
C-4
M-1
E-4
R-1
E-5
T-1
E-6
P-2
T-2
P-4
T-3
E-7
T-4
P-6
T-5
C-5
E-8

3305576.16
2022726.59
245412.37
791398.75
579301.50
699301.65
1108598.11
5214956.42
0.00
1002041.07
-47867923.33
712802.12
2872800.00
2903069.47
7700.88
40399700.00
508.81
7064235.00
175472.10
648.00
3291.90
32374.84
21223.12
5127090.99

3693381
2385291
282733.1
942141.4
733293
803795
1347021
5667815
0
1110910
-6.3E+07
836229.6
3600000
3280304
8238
48325000
534.8
8950000
206389.2
800
3674
39753
24968.38
5803356

10.5
15.2
13.2
16
21
13
17.7
7.99
0
9.8
24.38
14.76
20.2
11.5
6.52
16.4
4.86
21.07
14.98
19
10.4
18.56
15
11.653

Average
14%
error

ASSUMPTIONS
The plant is on the basis of 21,000 metric tons per year operating for 8000
hours per year.
This process does not consider the third reaction, as it is suppressed
by vinyl chloride (can be ignored in mass balance as the amount is in
ppm).
All the components in the system behave in ideal conditions.

No losses in pipes and vessels in the system.

Input = Output for compressor, pump, mixer and heat exchangers.

Chapter 3
Heat Integration & Utilities

PINCH ANALYSIS
Equipment

Temperature
of source
(C)

Temperature
of target (C)

Heat
Duty
(kW)

Cp
(kW/C)

Type of
stream

T (C)

E-3

-13.23

35

374.1666

7.757965

Cold

48.23

E-1

178.675077

80

662.5

6.713955

Hot

98.67508

E-2

256.657137

120

203.6925

1.490537

Hot

136.6571

E-4

137.28034

230

337.2519

3.637329

Cold

92.71966

E-7

25

70

1611.111

35.80247

Cold

45

E-6

67.251316

50

1029.20

59.65929

Hot

17.25132

E-5

230

170

232.2860

3.871433

Hot

60

E-8

46.6747243

10

170.8693

4.65905

Hot

36.67472

PINCH
POINT =
-8.23c

THot pinch = Pinch Temperature + 1/2T min = -8.34

+ 10/2 = -3.34 C
TCold pinch = Pinch Temperature -1/2Tmin = -8.34

E-3

E-7

E-4

INTEGRATION
OF THE HEAT
EXCHANGER

E-1

E-2

NETWORK
(HEN)

E-5

E-6

E-8

PROCESS FLOW DIAGRAM

E-2
E-5
E-3
E-8
E-7
E-6
E-4
E-2
E-4
E-5

COMPARISON OF UTILITIES NEEDED

BEFORE & AFTER THE INTEGRATION
PROCESS
Before
Utility

After

integrati integrati

%
Saving

Utilities Costing for electricity

Peak hours

: RM0. 337

on (kW)

on (kW)

QHOT

2299

605

73.5%

Off peak : RM 0.202

QCOLD

2323

765

67.1%

Electricity (peak hours)

Total for energy saving for hot

stream,
QHOT
= 2299 609 100%
2299

74%

Total energy saving for cold

stream,
QCOLD = 2323-765 100%
67%
2323

: 0800 2200 (4667

hr/yr)
Electricity (off peak hours): 2200 0800 (3333
hr/yr)

Energy
consumption

kW

Electricity
cost
(RM/yr)

Whole plant

3621.615

8.1 mil

Tariff, E1 Medium Voltage General Industrial Tariff,

TNB (2014)

Chapter 4
Process Equipment Sizing

Reactor (R-1)
to
to Ethylene
Ethylene Oxide
Oxide

Equipment Specification Sheet

Identification
: Packed Bed Reactor
Item no
: R-101
Function
:: To
Function
To convert
convert Ethylene
Ethylene

Number
Number of
of Reactor
Reactor :: 1
1 reactor
reactor
Material of construction
Stainless steel
Material of construction
Stainless steel
18.37
Volume of reactor ()
18.37
Length
11.15
Length of
of reactor
reactor (m)
(m)
11.15
Diameter of reactor (m)
3.36
Diameter of reactor (m)
3.36
Residence time (s)
20
Residence time (s)
20
5.601
Average heat transfer U (W/)
5.601
230
Operation temperature, ()
230
Operation pressure (atm)
21.7
Estimated
1.4
Estimated cost
cost (RM)
(RM)
1.4 mil
mil
Dimension
Dimension of
of tube
tube
Outside
60.325
Outside diameter
diameter (mm)
(mm)
60.325
Wall thickness (mm)
3.9116
Wall thickness (mm)
3.9116
Length of tube (m)
10.74
Length of tube (m)
10.74
0.0022
Area of tube ()
0.0022
Number
1500
Number of
of tube
tube
1500

Vessel Specification
Vessel weight (kN)
1020.63
Type of insulation
Fibre glass
Vessel thickness (mm)
12.7
Vessel Support
Type of Support
Standard steel saddle
Bolt root diameter (mm)
27.00
Pressure design stress, (N/mm2)
14.21
Flow condition (Shadiya & Olamide, 2005)
Type of flow in the reactor
Highly turbulent

DISTILLATION COLUMN
Equipment
Distillation Column 1

Function
To separate water from Ethylene Oxide

Distillation Column 2

To further purify the Ethylene Oxide by

removing
more
water
and
other
components present
Absence of liquid dispersion difficulties
High residence time

Why tray
column?

Lower maintenance cost

Man holes are provided for cleaning

Sieve Plate
structure

Design information is more readily

available and reliable

Column

T-2

T-3

Column

T-2

T-3

Temperature
Feed temperature at
saturated liquid
condition(C)
Dew point (C)
Bubble point (C)
Column
of
Material
construction
Column diameter, Dc
(m)
Column cross-sectional
area, Ac (m2)
Column height, ht
(m)
Trays
Tray spacing (m)
Minimum number of
trays
Efficiency (%)
number
of
Actual
trays
location
Feed-plate
(trays from top)
Type
Reflux
Minimum reflux ratio
Actual reflux ratio
Provisional Plate Design
Plate thickness, tp (mm)
Plate area

206
169
210

125
110
197.5

1.28
50.000

47.0281
37.0757

0.7487
50.000

19.4807
12.2721

Stainless
Steel
1.6

Stainless
Steel
1.0

2.01088
7.71

0.7855
7.50

Weir Design
Weir length, lw (m)
Weir height, hw (m)
Weir liquid Crest
i.
Maximum, how (mm
liquid)
ii. Minimum, how (mm
liquid)
Weep Point
Minimum, Uh (m/s)
Actual, Ua (m/s)
Turn down

5.5478
13.2969
70% max rate

0.6000
4.9~5
37.8856
9
2.3590

0.6000
5.6~6
44.8764
12
9.7643

Hole Design
Hole diameter, dh (m)
Area (m2)
Number of holes
Hole pitch (mm)
Plate Pressure Drop
Total pressure drop (mm
liquid)

4.0242
3.7086
70% max
rate

5.0000
1.96 *10-5
7169
13.25

118.4921

Sieve

Sieve

6.6272
9.9407

5.0000

0.2223
0.3334

5.0000

Down comer Design

Apron height (mm)

Area under apron (m2)

Downcomer head loss (mm)

Height of liquid backup (m)]

Residence time, tr (s)

40.0000
0.0512
25.5786
0.2311
3.4690

40
0.0299
1.8181
0.2896
8.7218

Plate Layout
Angle, c
Mean length (m)
Unperforated, AU (m2)

93o
2.5159
0.1258
0.1095

100o
1.6581
0.0829
0.0697

5.0000
1.96 *10-5
1520
18

149.0508

Storage Tanks
Equipment

Function

Storage Tank of Ethylene, K-1

To store the raw material, Ethylene

Storage Tank of Water, K-2

To store Water used to absorb Ethylene Oxide in

Ethylene Oxide absorber

Storage Tank of Potassium Carbonate To store the Potassium Carbonate solution used
solution, K-6

to absorb Carbon Dioxide in Carbon Dioxide

Storage Tank of Ethylene Oxide, K-5

absorber
To store the product, Ethylene Oxide

Tank

K-2

Component to be
stored
Pressure (bar)
Shape of tank
Material of
construction

N/A : for tanks in

which recycled
species will enter

K-1

Ethylene
Oxide

Ethylene

3.5
2

30
2

Cylindrical

Cylindrical

Spherical

Carbon Steel

Carbon
Steel

Stainless
Steel

Fixed Cone
Closed
0.806

Fixed Cone
Closed
0.806

N/A

N/A
300
9.14
4.57

2 week
300
9.14
4.57

10 days
200

3.95

4.38

4.38

N/A

120.00

150.00

474.00

1575.07

4.76

4.76

4.76

4.76

8.94

10.97

10.97

11.23

Saddle

Saddle

Saddle

Bracket

0.88 mil

0.91 mil

1.09 mil

3.48 mil

1
1
Cylindrica
l
Carbon
Steel

Fixed
Cone
Closed
0.657
N/A
200
7.45
3.72

Number of tanks

STORAGE
TANKS

K-5

Water

Roof
Type
Open/closed
Height (m)
Period of inventory
Volume (m3)
Tank Diameter (m)
Liquid Height (m)
Tank Height (m)

Design Stress (N/mm )

Minimum Wall
Thickness (mm)
Total Wall Thickness
(mm)
Type of vessel support
Estimated Cost
(RM/tank)
2

K-6
20% Potassium
Carbonate
solution
1
2

8.31

N/A

Absorbers and Stripper

Equipment

Function

Ethylene Oxide Absorber (T-1)

To separate Ethylene Oxide from other

Carbon Dioxide Absorber (T-4)

components
To separate Carbon Dioxide from other

Carbon Dioxide Stripper (T-5)

components
To separate Carbon Dioxide from Potassium
Carbonate

Column

Weir Design
Weir length, lw (m)
Weir height, hw (m)
Weir liquid Crest
i.
Maximum, how
(mm liquid)
ii. Minimum, how
(mm liquid)
Column
of
Material
construction
Column diameter,
Dc (m)
cross Column
sectional area, Ac
(m2)
Column height, ht
(m)
Trays
Tray spacing (m)
Efficiency (%)
Actual number of
trays
Type
Provisional Plate Design
Plate thickness, tp

T-1

T-4

T-5

Ethylene

Carbon

Carbon

Oxide

Dioxide

Dioxide

Absorber

10.7143
50.000

63.4857
50.0504

Absorber

12.2807
50.000

61.0290
48.1137

Stripper

10.7143
50.000

52.3790
41.2842

Stainless
Steel
0.8

Stainless
Steel
0.6

Stainless
Steel
1.0

0.4852
9.05

0.3283
12.07

0.9042
4.78

0.60
90
9
Sieve

0.60
57.96
14
Sieve

0.25
60
6
Sieve

5.0000

5.0000

5.0000

Column
Weep Point
Minimum, Uh (m/s)
Actual, Ua (m/s)
Turn down

T-1

2.9814
1.3268
70%
max
rate
Hole Design

5.0000
Hole diameter, dh (m)
1.96
Area (m2)
*10-5
Number of holes
1942
Plate Pressure Drop

pressure
drop 1.1832
Total
(kPa)
Down comer Design

40
Apron height (mm)
Area under apron (m2) 0.0230
Downcomer head loss 62.926
(mm)
3
Height of liquid backup 0.625
(m)]
1.0851
Residence time, tr (s)
Plate Layout

98o
Angle, c
1.0734
Mean length (m)
0.0537
Unperforated, AU (m2)
0.0476
Calming area, A (m2)

T-4

3.7881
0.7739
70%
max
rate

5.0000
1.96
*10-5
1262

1.1377

T-5

6.4123
1.9510
70%
max
rate

5.0000
1.96
*10-5
3618

1.0715

40
40
0.0173 0.0296
55.900 35.340
2
8
0.625 0.275
1.1292 1.7387

98o
98o
0.7871 1.3596
0.0394 0.0680
0.0332 0.0640

Heat Exchangers

Type of Exchangers

Item No.
Function
Material Of
Construction
Coolant Fluid
Temperature Inlet (C)
Temperature Outlet (C)
No. of Tube
Area (m2)
Type of vessel support
Estimated Cost (RM)

Equipment

Function

Heat Exchanger 2 (E-1, E-2, E-5, E-6,

Cool down the stream

E-8)
Heat Exchanger 3 (E-3, E-4, E-7)

Heat up the stream

Shell and Tube

Heat Exchanger
2 Shell Pass,
6 Tube Pass

Shell and Tube

Heat Exchanger
2 Shell Pass,
6 Tube Pass

Shell and Tube

Heat Exchanger
1 Shell Pass,
2 Tube Pass
E-5
Cooling
Carbon Steel

Shell and Tube

Heat
Exchanger
1 Shell Pass,
2 Tube Pass
E-6
Cooling
Carbon Steel

Shell and Tube

Heat
Exchanger
1 Shell Pass,
2 Tube Pass
E-7
Cooling
Carbon Steel

E-1
Cooling
Carbon Steel

E-2
Cooling
Carbon Steel

Cold Water
179

Ethylene glycol
257

Cold Water
230

Cold Water
67

Cold Water
47

80
172
19.02
Saddle
43.5 k

120
148
17.20
Saddle
40 k

170
60
13.80
Saddle
38.7 k

52
774
68
Saddle
66 k

10
7
9
Saddle
18 k

Type of Exchangers

Shell and Tube Shell and Tube

Heat
Heat
Exchanger
Exchanger
1 Shell Pass,
1 Shell Pass,
4 Tube Pass
2 Tube Pass

Shell and
Tube Heat
Exchanger
1 Shell Pass,
2 Tube Pass

E-3
Heating
Stainless Steel

E-4
Heating
Carbon Steel

E-8
Heating
Carbon Steel

Hot Water

Fuel Oil

-13.25

138

Steam

25

Temperature Outlet (C)

35

230

70

No. of Tube
Area (m2)
Type of vessel support
Estimated Cost (RM)

118
18.5
Saddle
38.9 k

153
34
Saddle
46 k

437
76
Saddle
68 k

Item No.
Function
Material Of
Construction
Heating Fluid
Temperature Inlet (C)

Compressors/Expander

Identification
Item No
Function
Type
Material of
Construction
Flowrate (kg/hr)
Pressure Inlet (bar)
Pressure Outlet (bar)
Temperature In ()
Temperature Out ()
Actual work (kW)
Type of vessel
Actual
support work (kW)
Type
of vessel
Estimated
Cost
support
(RM)
Estimated Cost
(RM)

Equipment

Function

Compressor 1, C-1

Increases the stream pressure

Compressor 2, C-2

Increases the stream pressure

Compressor 3, C-3

Increases the stream pressure

Expander 4, C-4

Decreases the stream pressure

Compressor 5, C-5

Increases the stream pressure

Compressor
C-1
Compress
pressure
Centrifugal
Carbon Steel

Compressor
C-2
Compress
pressure
Centrifugal
Carbon Steel

Compressor
C-3
Compress
pressure
Centrifugal
Carbon Steel

Expander
C-4
Expand pressure
Centrifugal
Carbon Steel

Compressor
C-5
Compress
pressure
Centrifugal
Carbon Steel

23400
1
3
25
180
180
1387
Saddle
1387
Saddle
1.5
mil

5538
3
9
25
170
170
298
Saddle
298
Saddle
600 k

5538
8.7
22
45
164
164
258
Saddle
258
Saddle
540 k

3000
30
22
35
11
11
285
Saddle
285
Saddle
570 k

1250
18
22
71
89
89
13
Saddle
13
Saddle
30 k

1.5 mil

600 k

540 k

570 k

30 k

The
estimated
cost is
obtained
from
Offshore-CPI
Supply SDN

MIXER (M-1)
Mixer (M-1)
Function

To ensured the ethylene stream, air

stream and recycle stream be in one
stream before entering the reactor (R1)

Design

Horizontal cylindrical vessel

Material of construction

Stainless steel

Type of vessel support

Saddle
Operating conditions

Operating
temperature ()

145

Molar flowrate
(kmol/s)

323.7

Operating pressure
(bar)

Vessel diameter
(m)
Vessel length (m)
Vessel
volume ()
Estimated cost
(RM)
Estimated
(RM)
20 cost
k
20 k

21
0.8
4.0
2.0

MEMBRANE SEPARATOR (X-1)

Function

To separate oxygen and nitrogen gas

Type of membrane

Dimethylsilicone rubber

Type of membrane separator

Hollow membrane

Type of shell

Carbon steel

Membrane surface area, ()

396

Number of modules
184
Number of modules
184
Type of vessel support
Saddle
Type of vessel support
Saddle
Operating
Operating conditions
conditions
Operating
80
Operating Pressure
80
Operating Pressure
temperature ()
(bar)
(bar)
Inlet
Inlet
Outlet
Outlet
Hollow
Shell
Hollow membrane
membrane
Shell
Diameter
(m)
0.015
Diameter
Diameter (m)
0.015
Diameter (m)
(m)
Length
(m)
2.9
Length
(m)
Length (m)
2.9
Length (m)
Estimated cost (RM)
Estimated cost (RM)
177
177 k
k

3
3
2
2
0.2
0.2
3
3

Equipments

SUMMARY OF
MAJOR
EQUIPMENT
COSTS

~The methods of the

calculation for equipment
sizing and costs are taken
from Turtons (2009) and
Sinnots (2005) writings~

Cost (RM)

Reactor (R-1)

1.4 mil

Distillation column 1 (T-2)

2.8 mil

Distillation column 2 (T-3)

2.2 mil

Ethylene oxide storage tank 1

3.48 mil

Ethylene oxide storage tank 2

3.48 mil

Ethylene storage tank (K-1)

1.09 mil

Ethylene storage tank (K-1)

1.09 mil

Water storage tank

0.88 mil

Potassium carbonate storage tank

0.91 mil

An empty cylindrical, carbon steel vessel

0.91 mil

Ethylene oxide absorber (T-1)

2.0 mil

Carbon dioxide absorber (T-4)

2.3 mil

Carbon dioxide stripper (T-5)

1.2 mil

Heaters (E-3, E-4, E-8)

153 k

Coolers (E-1, E-2, E-5, E-6, E-7)

206 k

Compressors and Expander (C-1, C-2, C-3, C-4, C5)

Mixer (M-1)

3.24 mil
20 k

Membrane Separator (X-1)

TOTAL ESTIMATED COST

177 k
27.54 mil

Chapter 5
Process Control & Safety
Studies

ASSUMPTIONS
One failure at a time.
The system is operated and maintained
in line with design intent.
Modes of operation: Normal operation
Guideword: No, More, Less, High, Low,
Reverse
Node: Major Equipment

HAZOP on Reactor (RDeviation

Paramet Guidewor
er
d
No flow to
the
reactor
More flow
Flow to
to the
the
reactor
reactor
Less flow
to the
reactor
Pressure
in reactor

Less
pressure
More
pressure

Possible causes

1)

Consequences

Valve V-8 fail

close.

No reaction occurs

Valve V-8 fail

open.

Runaway reaction
Runaway reaction

Piping leakage

Explosion if excess of
gaseous released

Gas breakthrough
(inadequate
Runaway reaction
venting)
Valve V-11 fail
close

Low
Valve V-9 fail
Temperatu
temperatu
open
re in
re
reactor
High
Valve V-9 fail

temperatu
close
re

Explosion
Runaway reaction
Explosion

Recommendations
Install flow mass alarm at inlet stream.
Check regularly the instrument air at
valve.
Install flow mass alarm at inlet stream.
To check regularly the instrument air at
valve.
Install flow mass alarm at inlet stream.
To check regularly the instrument air at
valve.
To check regularly the process safety
relief valve.
Install flow mass alarm at outlet stream.
To check regularly the instrument air at
valve.
Install flow mass alarm at jacketed
cooling water inlet. To check regularly
the instrument air at valve.

P & ID for Reactor (R1)

HAZOP on Distillation
Columns

Deviations
Paramet Guide Word
ers
No flow to the
distillation
column

Possible Causes

Control valve closed No operation

Line fracture

Flow on
Distillatio
n Column

Consequences

Temperature and pressure

increased in the pipe.
Level decreased in the
column.

Production loss.
Blockage
Pressure build-up in pipe
could lead explosion.
Less flow to the Control valve fails to Level decreased in the
distillation
respond
column.
column
Fewer products.

More flow to the Control valve

distillation
malfunction
column
Reverse product Higher pressure in
flow
the column
Other
Equipment failure
(Maintenance)

Recommendations
Install back-up controller.

Install high temperature / pressure

alarm.
Install high temperature
emergency shutdown.
Install low-level alarm at the base
of column.

Install high temperature / pressure

alarm.

Low separation

Install control valve to control the

flow/ level.
Check control valve.

Flooding in the column

Install flow indicator.

Change in the product

composition
No separation occurs
Loss of product
Reaction stops

Install high-pressure alarm to alert

operator
Pipes and fittings are constructed
to the proper materials which
could withstand the stress loaded

Deviations
Parameter
Guide Word
s
Less pressure
of the flow
Pressure on
Distillation
Column

Temperatur
e on
Distillation
Column

Possible Causes
Control valve fails to
respond

Consequences
No separation occurs

Recommendations
Install pressure alarm to alert operator

Changes in flow,
Install pressure emergency shutdown.
temperature and level
More pressure Control valve malfunction Lines subject to full delivery Install a pressure gauge upstream of the
of the flow
pressure.
delivery pump.
Thermal expansion in the Line fracture.
Provide thermal expansion relief valve
valve section.
Less steam flow in heat
Changes in product quality
Particular attention to heat input and
exchanger
output control of the heat exchanger
Less column
Phase effect
temperature
Ineffective separation
process
Cooling water leak into
Pressure changes
Install low pressure alarm to alert
pressure condenser
operator
breakdown
Condenser failure
Column flooding
Particular attention to heat input and
output control
More column
Phase effect

temperature
Reboiler control failure
Failed boiling in column
Particular attention to heat input and
and reboiler (equipment
output control
failure)

Phase effect
Heating medium leak into Pressure changes.
process
Changes in product quality

Install high-pressure alarm

Parameters

Deviations
Guide word
No top product flow to
distillate distillation column

Possible Causes
Inlet flow block

Consequences
Loss in product
No separation in column
Overflow of accumulator

Flow on
Distillate
Distillation
Column

Pump at the condenser breaks

down.
Less top product flow to
distillate distillation column
More top product flow to
distillate distillation column

Column failure
Same as No

Same as inlet flow block

Same as No

Feed to column
increased
Failure in reflux control

Product loss/ product quality

decreases
Less reflux. Liquid level in
accumulator decrease

No bottom product flow to

bottom distillation column

Inlet flow stop

Low separation
Less separation in column
Accumulation increase in bottom
product level
Changes in product quality

Column Failure
Tube leakage/ blocking
Flow on Bottom
Less bottom product flow to
Distillation
bottom distillation column
Column
More bottom product flow to
bottom distillation column

Same as inlet flow stop

Pressure build-up in pumps and

could lead explosion.

Leaking flange / leaking Fewer vapour recycled back to the
valve stub
column.
Increased flow in
Product loss / product quality
column feed
decrease
Less reflux
Accumulation decrease.

Recommendations
Install low-level alarm at the base
column
Install high temperature alarm to alert
operator
Install high-pressure alarm to alert
operators.
Same as inlet flow block
Same as `No`
Install composition indicator
Install high-level indicator for condenser

Install low-level alarm on LIC at the base

of column
Install composition indicator
Install high-pressure alarm to alert
operator
Same as inlet flow stop
Emergency plant shutdown
Same as `No`
Install low level alarm

Deviations
Parameters
Guide Word
Temperature of
More temperature
Distillate
at distillate
Distillation Column distillation column

Possible Causes
Temperature builds up
in column

Temperature builds up
in column
Reboiler control failure
High feed temperature

Less column level

Outflow greater than

inflow
Control level
measurement failure

Level of distillation More column level

column

Pressure changes (lead to

high pressure)
Flooding

Reboiler/ condenser
failure

Temperature of
More temperature
Bottom Distillation at bottom
Column
distillation column

Consequences

Outlet isolated or
blocked

Inflow greater than

outflow

Changes in product quality

Same as temperature builds
up in column

Changes in product quality

Reboiler fails to boil

Changes in product quality

Recommendations
Install high-pressure alarm
Install pressure relief valve
Install high-level indicator for
condenser
Install temperature control for
reboiler`
Perform maintenance
operations on the
reboiler/condenser
Install high temperature alarm
in the column
Install high temperature alarm
in the column

Incomplete separation

Install high temperature alarm

in the column
Install level controller

Quality change in product.

Incomplete separation

Install level alarm

Quality change in product.

Line leakage in the column
Flooding in column
Incomplete separation
Higher impurities
Same as outlet isolated or
blocked

Schedule frequent cleanness

Install flow indicator in outflow
Automatic cut off on supply
inlet
Install level controller
Same as outlet isolated or
blocked

P & ID for Distillation columns

HAZOP on Storage Tanks

Deviations
Parameters
Guide Word
Flow (Ethylene
oxide storage
tank)

No flow to the
storage tank of
product
Less flow to the
storage tank

Possible Causes
Line blockage.

Level control system

malfunction
Line fracture

Valve failure

Consequences

Over flooding on liquid reflux Install flow meter

at the bottom of the
distillation column.
Reduction in product
Install low flow alarm

Discharge of chemicals into

the surroundings

More flow to the

Tank overload
storage tank

Pressure (Ethylene More pressure of High

pressure
from Explosion hazard
oxide storage
the flow to the bottom product of the
tank)
storage tank of distillation column
product
Level (Ethylene,
potassium
carbonate and
water tanks)

Low
level Tank leakage
indicated in the
storage tank of
the raw material

Recommendations

Insufficient

raw

Proper maintenance
Install high-level alarm.
Consider standby tank.
Routine maintenance
Use a pressure regulator to
lower pressure of piping

material Routine maintenance

source for the process to Install

take place

monitor
material

a level indicator to
the

level

of

the

P & ID for Storage Tanks

Ethylene oxide
storage

Ethylene, Potassium
carbonate and Water
tanks

HAZOP on Absorbers
and Stripper
Deviations
Parameters
Guide Word
Less absorbers/
stripper level

Possible causes
Outflow greater than
inflow
Control level
measurement failure

Level of absorbers More absorbers/

stripper level
and stripper

Outlet isolated or
blocked

Inflow greater than

outflow
Control failure
(mechanical
breakdown)

Consequences

Recommendations

Incomplete separation

Install level controller

Quality change in product.

Incomplete separation

Install level alarm

Quality change in product.

Line leakage in the column
Flooding in column
Incomplete separation
Higher impurities
Same as outlet isolated or
blocked
Same as outlet isolated or
blocked

Schedule frequent cleanness

Install flow indicator in outflow
Automatic cut off on supply
inlet
Install level controller
Same as outlet isolated or
blocked
Same as outlet isolated or
blocked

Deviations
Paramete
rs

HAZOP
of FLOW
Absorbers & Stripper
Possible
Causes onConsequences
Recommendations

Guide Word

No
flow
to
the Control valve
absorber and stripper. close.
Blockage
Less flow to the
absorber and stripper
Flow to the
absorbers More flow to the
and
absorber and stripper
stripper
Reverse product flow
Other (Maintenance)

fail No operation

Pressure build-up in the

pipe could lead to
explosion.
Control valve fails to Level decreased in the
respond.
column.
.
Failure of control Change in the product
valve.
composition.
Failure of product No separation occurs.
sources
resulting
backward flow
Failure
of Loss of product.
equipment.
Reaction stops.
Control valve fails No separation occurs.
to respond.
Changes
in
flow,
temperature and level.

Install back-up controller.

Install high temperature/ pressure alarm.
Install low-level alarm at the base of column.
Install high temperature / pressure alarm.
Install control valve to control flow, and level.
Install flow indicator.
Install backup valve.
Install check valve in product line.
Consider non-return valve.

Pipes and fittings are constructed to the right

materials and stress relieved.
Less pressure of the
Install back-up control valves or manual
Pressure of flow
bypass valve.
the flow
Install pressure alarm to alert operator
Install pressure emergency shutdown.
More pressure of the Control
valve Line subject to full Install a pressure gauge upstream of the
flow
malfunction.
delivery of pressure.
delivery pump.
Temperatur Less absorber and
Low steam pressure Phase effect
Particular attention to heat input and output
e in
stripper temperature. and temperature
Ineffective separation control of the heat exchanger.
absorbers
process.
and
Pressure changes
stripper
More absorber and
High steam
Pressure changes.
Install high-pressure/ temperature alarm.
stripper
pressure and
Particular attention to heat input and
Phase effect.
temperature
temperature
output control.

P & ID for Absorbers and Stripper

HAZOP on Heat Exchangers

Deviations
Parameter
Guide
s
Word
Temperatur High
e (Cooler) temperatur
e in heat
exchanger
Temperatur Low
e (Heater) temperatur
e in heat
exchanger

Possible
Causes

Consequences

Recommendations

The flow
The desired
rate of the
temperature was
cooling fluid not achieved
is too high

Install a high temperature indicator and alarm

system at the end of the heat exchanger
Install a control valve at the cooling fluid stream

The flow
rate of the
heating
fluid is too
high

Install a low temperature indicator and alarm system

at the end of the heat exchanger
Install a control valve at the heating fluid stream

The desired
temperature was
not achieved

P & ID for Heat Exchangers

Cooler

Heater

HAZOP On Compressor
and Expander
Deviations
Paramete
rs

Possible Causes
Guide
Word
More
Compressor/Expan
pressure der malfunction

Pressure in
compresso
Less
Compressor/Expan
r and
pressure der malfunction
expander

Consequences

Recommendations

Increased pressure
risk the fracture of
the pipe system or
pressure build-up at
the next equipment

Install high pressure

indicator and alarm at the
outlet of the
compressor/expander

The pressure would

not be sufficient
when the flows
meets at the mixer,
which might cause
backflow

Install low pressure

indicator and alarm at the
outlet of the
compressor/expander

P & ID for Compressor

and Expander

HAZOP on Mixer (M-1)

Deviations
Parameter
s

Flow to the
mixer

Pressure in
the mixer

Guide Word

Possible Causes

Consequences

Recommendations

No flow to the
mixer
Less flow to the
mixer

Control valve closed No operation

Install manual bypass valve

Control valve failure

Product composition
deviated

Install a flow indicator

More flow to the

mixer
Reverse inlet
product flow

Control valve failure

Product composition
deviated
No operation

Install back-up controller.

Less pressure in
the mixer

Control valve fails to Changes in the

respond
component volumes

Install a pressure alarm

More pressure in
the mixer

Same as Less

Same as Less

Higher pressure in
mixer

Same as Less

Install high pressure alarm

P & ID for Mixer (M-1)

HAZOP on membrane
separator (X-1)
Deviations
Parameters
Guide Word
No/ Less flow to
the membrane
separator
Flow to the
membrane
separator

Pressure in
membrane
separator

Possible Causes
Feed line/ valves
blocked

Particulate or
condensate film on the
membrane
Aging of the membrane

Consequences

Recommendations

No separation

Inefficient separation

Inefficient separation

No separation

Maintenance of lines/
valves

Install check valve in

product line, consider nonreturn valve, install highpressure alarm
Check the compressor, the
mass flow controller and
the valve

More flow to the

membrane
separator
Reverse flow to
the membrane
separator

Membrane failure
High pressure in
membrane separator

No separation occurs

Less pressure in
membrane
separator

The valve fails

Lower oxygen recovery

More pressure in
membrane
separator

The valve fails

Lower membrane
selectivity, damage to the
membrane

Check the filtration

system, clean membrane
Membrane substitution
Membrane substitution

Check the valve

P & ID for Membrane

Separator

CONCLUSION/RECOMMENDATION
FOR THE PROCESS SAFETY
Safety studies of all the nodes in the PFD are
successfully covered by the HAZOP analysis.
Safety Interlock Systems can be installed in case of any
possible severe conditions in the plant.
Other safety studies such as the Failure Mode and Effect
Analysis (FMEA) and Fault Tree Analysis (FTA) could also
be done in order to help overcoming the little
drawbacks of HAZOP.

ECONOMIC POTENTIAL AT
LEVEL 5
Economic Potential 5
50
Economic Potential 5, EP5 (107RM/yr)

40

At the optimum
conversion of 90%, the
EP5 is obtained as

30
20

RM389 million.

10
0
0.2

0.3

0.4

0.5

0.6

0.7

-10
Conversion, X

0.8

0.9

1.0

1.1

CONCLUSION
Mass and energy balance error
are lesser than 5 % and 30 %
respectively.
74 % of hot utilities and 67 %
of cold utilities can be saved
by integrated HEN.
The total estimated cost for
the major equipment is RM27.9
million.
P&ID is successfully developed
from the HAZOP studies.