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Web Lecture 25
Class Lecture 21 4/2/2013
CSI
Ammonium Nitrate Explosion
Monsanto Explosion
T2 Laboratories Explosion
dT Q g Q r
dt
N A C PA
Qg (rAV )(H Rx )
Qr FA0 C PA (T T0 ) B ( H B H B 0 ) UA(T Ta )
5
dT
dt
g
Q r
H Rx rA V FA 0 i C Pi T T0 UA T Ta
N i C Pi
Adiabatic
dt
N iC Pi
t (min)
showed up!
Why did they come?
What did they want?
Nitroanline Synthesis
Reaction
NO2
NO2
Cl
+
ONCB
NH2
2NH3
Ammonia
+
Nitroaniline
NH4Cl
+ Ammonium
Chloride
Nitroanline Synthesis
Reaction
NH3 in H2O
ONCB
Autoclave
175 oC
~550 psi
O-Nitroaniline
Product Stream
NH3
Separation
Filter
Press
To Crystallizing Tanks
fast Orange
Old
10
3 kmol ONCB
43 kmol Ammonia
100 kmol Water
V = 3.25 m3
NO2
Cl
+
ONCB
Chloride
NH2
2NH3
Ammonia
+
Nitroanaline +
NH4Cl
Ammonium
MBA-Style:
Nitroanline Synthesis Reactor
New
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9 kmol ONCB
33 kmol Ammonia
100 kmol Water
V = 5 m3
Qr
(r V)( H rx ) UA (T T0 )
dT
A
dt
N A 0 C pA N B0 C pB N W C pW
NC P N A 0 C pA N B0 C pB N W C pW
dT Q g Q r
dt
NC p
13
dt
NC p
The rate of heat removed is
UA
c C Pc Ta1 T 1 exp
Qr m
m
c C Pc
14
Q g (rA V )H Rx rA V H Rx
rA k 1C A C B
Q g k 1C A C B H Rx
dT Qr Qg
dt
NCPS
UA
c C Pc Ta1 T 1 exp
m
m
c C Pc
Vary
15
0.0001167 C 2A 0 1 X
Everything is OK
0.2C / min
dt
NC p
Temperature-Time trajectory
Temperature oC
dT Qq Qr
0.2 C / min
dt
N Cp
400
200
175
18
9:55
t=0
Isothermal
Operation
Qr = 0
Cooling Restored
fuse
10:40 10:50
midnight 12:18
Disk Rupture
The pressure relief disk should have ruptured when the temperature
reached 265C (ca. 700 psi) but it did not.
If the disk had ruptured, the maximum mass flow rate out of the
reactor would have been 830 kg/min (2-in orifice to 1 atm).
vap H vap UA T Ta
Qr m
kcal
Q r 449,000
min
kcal
Q g 27,460
min
Q r Q g
No explosion
20
x3!
!!
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Step1b. At the end of Step 1a, MnCl2 is added to the reactor. It reacts with
sodium methylcyclopentadiene to produce manganese
dimethylcyclopentadiene and sodium chloride:
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WhatHappened
T2 Laboratories Explosion
On December 19, 2007, when the reactor reached a
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SimplifiedModel
Let A = methycylcopentadiene, B = sodium, S = Solvent (diglyme), and D = H2.
r2S k 2sCS
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What Happened
T2 Laboratories Explosion (contd.)
This reaction produced even more hydrogen, causing the pressure to rise
even faster, eventually causing the ruptured disk to break, which was set
at 28.2 atm absolute(400 psig), in the 4-inch diameter relief Line of H2.
Even with the relief line open, the rate of production of H2 was now for
greater than the rate of venting, causing the pressure to continue to
increase to the point that it ruptured the reactor vessel initiating a horrific
explosion.
The T2 plant was completely leveled and four personnel lives were lost.
Surrounding businesses were heavily damaged and additional injuries
were sustained.
Before continuing with this example it might be helpful to view the 9
minute Chemical Safety Board (CSB) video, which you can access
directly from the Chapter 13 Summary Notes on the Web site, or you can
read the supporting reports
[http://www.chemsafety.gov/videoroom/detail.aspx?VlD=32]. You can also
search the Web for "T2 explosion video."
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28
Net Rates:
29
1.26 10 7 J K
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