Parameter of Hazard Effect and Frequency

Effect Parameter Frequency Parameter

Parameter Severe Major Minor Parameter Most Likely Unlikely

Human Non-fatal More than
Fatal accident No accident Hazard 1-10 times in Once in 10
Resources accident 10 times in
Frequency 10 years years
Losses more Losses between Losses less 10 years
Asset than US$ US$ 100,000 – than US$
1,000,000 1,000,000 100.000
Environment Major damage Minor damage No damage
Background
HAZID Analysis
HAZID Analysis
HAZID Analysis
HAZID Analysis
HAZID Analysis
HAZID Analysis
HAZID Analysis
HAZID Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
HAZOP Analysis
 No. Waste Name Plant Classification Main Composition
Hydrolysis top
1 Pretreatment Liquid Waste Water, Furfural
product
Electricity
2 Ash boiler product Solid Waste Ash
Generation
Electricity
3 Boiler flue gas Gas Emission N2, CO2
Generation
Ethanol
Waste 4 T501 liquid bottom
Production
Liquid Waste Water, Xylose

Identification 5 T503 top product

Ethanol
Production
Liquid Waste Water, EG

O2 & CO2
Condensate
6 deaerator top Gas Emission CO2, O2
Treatment
product
Neutralization gas Ethanol
7 Gas Emission CO2
product Fermentation
Clarifier bottom Ethanol Water, Xylose,
8 Solid Waste
product Fermentation CaCO3
 No. Waste Name Plant Classification Main Composition
Centrifuge bottom Ethanol Water,
9 Liquid Waste
product Fermentation Saccharomyces
Seed fermenter gas Ethanol
10 Gas Emission Ammonia, CO2
product Fermentation
Waste 11
Main fermenter gas
product
Ethanol
Fermentation
Gas Emission Ammonia, CO2
Identification 12
Cartridge filter
Water Utility Liquid Waste Water, Minerals
retentate
13 RO retentate Water Utility Liquid Waste Water, Minerals
CIP chemical ion
14 Water Utility Liquid Waste Water, Caustic, Acid
exchange
15 Cooling water Water Utility Liquid Waste Water
Waste Management Concept

Solid Waste
• Collecting Pit
• Treated and Sold into Another Industry

Liquid Waste
• Waste Water Treatment
• Neutralizing Pit
Waste Water Treatment
 Operational Details
• Commissioning
• Utilities Commissioning
Start-Up
• Operational Testing
Procedure
• Start-Up Procedure Operational
Testing
Utilities
Commissioning

Commissioning
 Commissioning

• Piping and Instrument

• Equipment Checking for Safety Aspect
• Pressure Leak Testing
• Cleaning and Flushing
 Utilities Commissioning

• All utilities (water and air) should be commissioned.

• Typically, we have to make sure that all the valves
and compressor are properly installed
• Ensure water and air needed for cooling system and
fermentation is enough in process.
 Operational Testing
• At the operational testing, we try to operate closer to the actual operating
conditions.
• This stage lasts for 2-3 weeks after all the equipment have been
independently checked or tested.
• Air and water tests should be set up in a closed loop with fluid
continuously recycled, with loops as large as possible. The loop should
ideally be the same loop that will be subject to solvent testing.
• Tests should continue for several days in order to give all shifts a chance
to conduct the same tests. All shifts should be given the opportunity to
start up and shutdown each closed loop test.
 Startup & Shutdown
Procedure
Startup Procedure
• Make sure all the raw material is enough for the operation
• Check the electricity supply.
• All parameters in instrument which need controls must be
set, such as pressure and temperature.
• Turn on the combustion for reactor and other section
• Prepare the reactor for the process. This step is to maintain
the temperature and pressure in reactor to avoid the shock
in reactor.
• Open all inlet valves to flow the inlet stream.
• Open utility valve for cooling water, air, and fuel
• Turn on all rotating equipment such as pump, and
compressor.
• The preconditioning is 1 – 2 hours to see if the reaction
occurs or not.
• If the reaction does not occur, the startup procedure should
be repeated
Led by commissioning first
Shutdown Procedure
• Close all the inlet raw material valve
• Shut down heating and cooling sources
• Flooded with water or a solvent to remove deposit on the
reactor
• Purge with steam or gas to remove
• Eliminating undesirable materials (cleaning process)
• After an hour, stabilize the temperature of reactor (prevent
thermal shock)
• Pressure trapped between two closed valves or closed
process equipment loops should be released immediately
• Bring the vessel to atmospheric pressure (if any reactors that
operate above atmospheric pressure)
• Shut down the electricity
Other types of shutdown:
 Process Shutdown (PSD)
 Emergency Shutdown (ESD)
 Start-Up Procedure

Only for main equipment as follow:

• Fermenter
• Distillation
Start-Up of Fermenter

Source: Henry C. Vogel, Celeste C. Haber-Fermentation and Biochemical Engineering Handbook-William Andrew (2007)
Start-Up of Distillation

Source: Severa, 1973

Area Classification
• Raw Material Storage Area
• Hydrolysis (Pre-treatment) Area
• Neutralization Area
• Fermentation Area
• Enzyme Recovery Area
• Distillation Area
• Cooling Production Area
• Utility Area
• Product Storage Area
• Photovoltaic Area
Safe Range between Equipment
Safe Range between Equipment
Equipment Distance (ft) Unit
Reactor to Cooler 25
Reactor to Filter 50
Pre-Treatment
Filter to HE 10
Filter to Fired Heater 50

Fired Heater to Turbine 30

Turbine to Turbine 30
Turbine to Cooler 30
Electricity
Cooler to Cooler 5
Pump to Cooler 10
Heater to Separator 10
Reactor to Clarifier 50
Clarifier to Reactor 50
Ethanol Production
Reactor to Reactor 25
Reactor to Centrifuge 25
Centrifuge to HE 10
HE to Column 10
Column to Column 15 Ethanol Purification
Column to Pump 10
Plant Layout
NOTES:
1.RAW MATERIAL STORAGE
2. PRETREATMENT
3. NEUTRALIZATION AREA
OCEAN 4. SEED FERMENTATION
5. MAIN FERMENTATION
6. ENZYM RECOVERY
7. ETHANOL DEHYDRATION
8. ELECTRICITY GENERATION
To Hospital
9. COOLING AREA
10. UTILITY AREA
11. ETHANOL STORAGE
8 30" 9 12. PHOTOVOLTAIC AREA
5"
30"

ASSEMBLY POINT

FIRE
STATION
25"

4
25"
6

25"
15"
1
25"
50" 15" 10" 10"
10
2 5
50"
10"
3 11
25" 50" 7
12
UNLOADING
AREA

MAINTENANCE ASSEMBLY POINT HSE

LOBBY CLINIC
DEPARTMENT OFFICE CANTEEN
TOILET
DCS PARKING AREA
CENTRE MAIN
1:1000
QC OFFICE ASSEMBLY
LABORATORY MOSQUE POINT

SECURITY
CHECK
MAIN GATE POINT
Piping Perspective
NOTES:
1.RAW MATERIAL STORAGE
2. PRETREATMENT
3. NEUTRALIZATION AREA
OCEAN 4. SEED FERMENTATION
5. MAIN FERMENTATION
6. ENZYM RECOVERY
7. ETHANOL DEHYDRATION
8. ELECTRICITY GENERATION
To Hospital
9. COOLING AREA
10. UTILITY AREA
11. ETHANOL STORAGE
8 30" 9 12. PHOTOVOLTAIC AREA
5"
30"

ASSEMBLY POINT

FIRE
STATION
25"

4
25"
6

25"
15"
1
25"
50" 15" 10" 10"
10
2 5
50"
10"
3 11
25" 50" 7
12
UNLOADING
AREA

MAINTENANCE ASSEMBLY POINT HSE

LOBBY CLINIC
DEPARTMENT OFFICE CANTEEN
TOILET
DCS PARKING AREA
CENTRE MAIN
1:1000
QC OFFICE ASSEMBLY
LABORATORY MOSQUE POINT

SECURITY
CHECK
MAIN GATE POINT
SuperPro Simulation for Treatment
UniSim Simulation for Electricity Production

39
SuperPro Simulation for Ethanol Fermentation
UniSim Simulation for Ethanol Purification