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0 INTRODUCTION
Heptane is a higher olefin, or alkene with the chemical formula of C7H14. The
commercial product is a liquid that is a mixture of isomers. Heptane is typically used as
an additive in lubricants, it also acts as catalyst and as a surfactant.
The purpose of this project was to simulate the separation process that occurs
during the production of 1-heptene and other unsaturated products from an initial
mixture of C3 and C4 hydrocarbons. 1-heptene is the main product desired from this
process since it has several applications including usage as a high-octane blending
agent for gasoline and it aids in the production of plasticizers.
Two liquid feed streams containing propylene and butene and a stream of catalyst
slurred with 1-hexene are mixed at a pressure of approximately 8 bars prior to being
sent to the reactor. The reactor consists of five essentially well-mixed sections, with
similar concentrations in each section. Heat removal is achieved by using pump-around
from each stage through external heat exchangers. The reactor effluent is partially
vaporized before being fed to the first of three distillation columns. The first column
(T-1201) removes the unreacted C3 and C4 components, which are used subsequently
as fuel (Stream 7) or sent to LPG storage (Stream 6). The next column (T-1202)
separates the 1-hexene product overhead (Stream 10) and sends the bottoms stream to
the final column (T-1203). In T-1203, the main 1-heptene product (Stream 13) is taken
overhead, and the C8 and heavier compounds are taken as the bottoms product (Stream
14). The bottoms product is processed off-site to remove the heavy material and to
recover spent catalyst. [Turton et all, 2013]
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Figure 1: Process Flow Diagram of Production of Heptene from Propylene and Butene (Unit 1200).
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Figure 2: Stream table for Unit 1200
Source: (Turton et all, 2013)
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2.0 Process Hazard Analysis
Process Hazard Analysis (PHA) studies are the foundation for process safety and risk
management programs. They help companies identify hazard scenarios for a process
that could adversely affect people, property, or the environment. PHA techniques such
as Hazard and Operability Studies (HAZOP), What-If Studies, Failure Modes and
Effects Analysis (FMEA) and Major Hazard Analysis (MHA) are used.
For this assignment, we are required to provide 3 techniques of PHA which are: -
1) HAZOP
2) Fault Tree Analysis (FTA)
3) Event Tree Analysis (ETA)
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3.0 HAZOP FOR SELECTED EQUIPMENT
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Lower 1. Heat exchanger 1.Temperature in 1. Proper
failure the reflux drum Maintenance by
decrease. company.
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3.2 HAZOP FOR REBOILER: E-1203
Item Study Note Process Deviation Possible Causes Possible Action Required
Parameter (Guidewords) Consequences
E-1203 Reboiler Flow Less Pipe blockage Temperature of Install high temperature
process fluid remain alarm
constant
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Corrosion Corrosion of Accumulation of Reduce heat transfer Continuous on-line
tube acidic inert operation have to be
maintained
The reboiler is
frequently spared to
facilitate cleaning
while the column is in
operation.
Remove by venting
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3.3 HAZOP FOR TOWER: T-1204
Item Study Process Deviation (guide word) Possible causes Possible consequences Action required
node parameter
T-1201 C3/C4 Flow No flow • Pipe blockage • Column dry out • Install low level alarm
Tower • Control valve • Possible dangerous • Check maintenance
shut concentration procedure and schedule
• Valve failed • No operation • Make bypass
• Tube leakage • Emergency plant shut
and blocking down
• Pump failure
Less flow • Pipe blockage • Column dry out • Install low level alarm
• Control valve • Changes in product • Check maintenance
shut quality procedure and schedule
• Valve failed • Make bypass
• Tube leakage • Emergency plant shut
and blocking down
Pump failure
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More flow • Control valve is • Flooding in the • Install high level alarm
fully opened column • Check maintenance
• Increasing • Changes in product procedure and schedule
pump capacity quality • Install control valves
• Control valve • Temperature • Install flow indicator
failure decrease • Make bypass
• Rise in bottom
liquid level
Reverse flow • Pressure inside • Column dry out • Install check valve
tower higher • No operation
than pressure
inlet
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reboiler • Column flooding • Attention to heat input
• Exchanger tube • Film boiling in and output control
failure column and reboiler
• High steam • Phase effect
pressure • Pressure changes
• Cooling water
in condenser
failure
• Reboiler control
failure
• Heating
medium leak
into process
Low temperature • Instrumentation • Pressure change • Install temperature
failure • Product loss indicator
• Less steam flow • Changes in product • Instruct operator on
from reboiler quality procedure
• Loss of heating • Ineffective • Upgrade isolation
(steam leakage) separating process • Attention to heat input
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• Low steam • Phase effect and output control
pressure and
temperature
• Ineffective
isolation
Pressure High pressure • Vapour pressure • Low efficiency of • Install high alarm
high separation pressure
• Pressure • Rupture of column • Install pressure relief
indicator or other related valve
controller fail equipment
• Product loss
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3.4 HAZOP FOR BUTENE FEED TANK: V-1202
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3.5 HAZOP FOR C7/C8 FEED PUMP: P-1204 A/B
Item Study Process Deviations Possible Causes Possible Consequences Action required
Node Parameters
(Guide
words)
1A Pump Pressure More ❖ Valve fail - open ➢ Pump will damage because of high Use pressure indicator
all the time pressure
Use by pass manual
❖ LIC that connected ➢ The system afterwards will not valve system
to the tower continue. Hence, no main product
Maintenance need to be
T-1202 fail and formed (Heptenes)
done regularly
valve fail to close
➢ When the level in the tower is so
low, high pressure may occur in
the pump and pump will damage.
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Less ❖ Valve fail - close ➢ Liquid level will keep increasing Use by pass manual
all the time valve system
➢ When the level in the tower is so
❖ LIC that connected high, it will cause overflowing tank Use pressure indicator
to the tower that lead to flooding
Maintenance need to be
T-1202 fail and
done regularly.
valve fail to open
Install level alarm
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Less ❖ Valve fail - open ➢ Can cause deadhead pump. If Use flow indicator
all the time prolonged, potentially causing
Use by pass manual
pump bearings and seals to fail
valve system
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4.0 FTA FOR SELECTED EQUIPMENT
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4.2 FTA FOR TUBE CORROSION REBOILER (E-1203)
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4.3 FTA FOR CATASTROPHIC PROPANE RELEASE
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4.4 FTA FOR BUTENE FEED TANK EXPLOSION (V-1202)
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4.5 FTA FOR C7/C8 FEED PUMP (P-1204 A/B) EXPLOSION
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5.0 ETA FOR SELECTED EQUIPMENT
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5.2 ETA FOR TUBE CORROSION REBOILER (E-1203)
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5.3 ETA FOR CATASTROPHIC PROPANE RELEASE
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5.4 ETA FOR BUTENE FEED TANK EXPLOSION (V-1202)
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5.5 ETA FOR PUMP (P-1205 A/B) EXPLOSION
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6.0 POSSIBLE MODIFICATIONS TO IMPROVE THE SAFETY OF THE
SELECTED PROCESS EQUIPMENT
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6.4 Butene feed tank (V-1202)
1) Locate the storage away from any sources of heat or ignition, for example
steam pipes.
2) All parts of the butene feed tank should be connected to one another and tp
common ground where it can prevent the accumulation of static electrical
charges.
3) Make the inlet of the butene feed tank at the bottom to avoid formation of
static electrical charges. It the inlet cannot be prevented on the top of the tank,
extend the pipeline until there is no difference between the inlet and the
bottom of the tank.
4) Connect the fill pipe electrically to the tank flange and the transfer pipeline. It
can deduce any static charge which is formed during filling. Eventually, it can
reduce the thermal expansion in the tank.
5) The tank and the piping system need to be made from welded carbon or alloy
steels. It is not recommended to locate the tank underground as it will cause
difficult in detecting leakage.
2) Install an adjustable speed drive (ASD) to control the pump if flow varies
over time.
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7.0 REFERENCES /APPENDIX
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