Detail Case Study

Prepared By
M/s. Kutch Chemical Industries Limited

Page : 1
HSE Department Rev. : 00

Kutch Chemical Industries Limited

Survey No 166/1,2,3, 171/1, 172,167,168,
Village : Padana
Gandhidham, Dist. Kutch

Hazard & Operability Study
(FOR DESUR DEPOT EXISTING FACILITIES AND PROPOSED FACILITIES)

PREPARED BY

VAIBHU SAFETY CONSULTANTS
FF-11, Akshat Complex,
Nr. Reliance Petrol Pump,
High Tension Road, Subhanpura,
Vadodara-390 023
Phone: 9825756467/9427838021 (M)
Ph : 0265-2395798

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ACKNOWLEDGEMENT

We express our sincere thanks to management of Kutch Chemical Industries Ltd
for providing unstinted support during the HAZOP Study without which the
HAZOP study could not have been possible. The courtesy extended to our team is
highly appreciated.

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CERTIFICATE

We are pleased to certify that this HAZOP Study Report of Company has been
conducted by us.

HAZOP STUDY is a legal requirement as per the rules 10 to 13 under Manufacture,
storage and import of Hazardous chemicals rules, 2000 and environment
(protection) Act, 1986.

It is obligatory of the occupier to carry out a "HAZOP Study", as required under
item no. (II) (2) of the format for application of the Site Appraisal Committee and as
per the Schedule 1 of the Factories Act under Section 2(CB) - Item No. 11 of the
Schedule.

The Executive Summary is given in the beginning to highlight the important
summary of our report and methodology of the HAZOP Study carried out.

FOR VAIBHU SAFETY CONSULTANT

Authorized Signatory

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CONTENTS

SECTION NO.

CONTENTS

NO. OF PAGES
1 Objective and Methodology of HAZOP Study

8
1.1 Objectives 8
1.2 Scope of The Work 8
1.3 Methodology 8
2 Introduction to HAZOP

10
2.0 Hazard and Operability Study 10
3 Introduction Of the Unit

13
3.1 Introduction of the unit 13
3.2 Details of Unit 13
3.3 Google map 20
3.4 Site Plan 21
3.5 Organisation chart 22
3.6 Details of storage of Hazardous Materials in Bulk 22
3.7 Facilities / System 28
3.8 Process Flow chart 29
4 HAZOP Sheets 49

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LIST OF TABLES

TABLE NO.

CONTENTS

Page No.
Table- 4.1 Hazop Study Worksheet (Transferring of
Chlorsulfonic Acid to service tank)
50
Table- 4.2 Hazop Study Worksheet (Charging of Acetanilide) 51
Table- 4.3 Hazop Study Worksheet (Reaction) 52
Table- 4.4 Hazop Study Worksheet (Dumping) 53
Table- 4.5 Hazop Study Worksheet (Reduction) 54
Table- 4.6 Hazop Study Worksheet (Condensation) 55
Table- 4.7 Hazop Study Worksheet (Esterification) 57
Table- 4.8 Hazop Study Worksheet (E. O. storage tank) 58
Table- 4.9 Hazop Study Worksheet (From outlet of storage
tank to inlet of batch tank)
61
Table- 4.10 Hazop Study Worksheet (Raw material to the storage
tank ( Day Tank ))
63
Table- 4.11 Hazop Study Worksheet (Reaction Process) 64
Table- 4.12 Hazop Study Worksheet (Chilling of the HCL) 65
Table- 4.13 Hazop Study Worksheet (Gas cleaning) 66
Table- 4.15 Hazop Study Worksheet (Melting of Sulfur) 68
Table- 4.16 Hazop Study Worksheet (Burning of sulfur with
air)
69
Table- 4.17 Hazop Study Worksheet (Catalyst convertor) 70
Table- 4.18 Hazop Study Worksheet (Rector) 71
Table- 4.19 (Gas mixture) 72
Table- 4.20 Hazop Study Worksheet (High Boiler fractional
Distillation Column)
74
Table- 4.21 Hazop Study Worksheet (Final Product Distillation
Column)
75
Table- 4.22 Hazop Study Worksheet (Reaction of Chlorine) 76
Table- 4.25 Hazop Study Worksheet (Distillation) 81

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HAZOP SUMMARY

HAZOP SUMMARY

SR. NO. OBSERVATION AREA SUMMARY
1 UTILITY SERVICES Utility is the heart of the chemical process industries. All the
critical equipment shall be connected with the D. G. Set.

Company has their own captive power plant.

Overhead water tank for cooling operation shall be provided.
Under worst case of GEB & DG failure cooling operation shall
not be suffered. Stand by pump for cooling shall be provided .
All the utilities line shall be provided with arrow indicators &
content . this not only help of for better production but also help
during the emergency it avoid the human error.

A system shall be devised to maintain the sufficient quantity of
water in the seal pot & scrubber to prevent escape of EO gas in
the atmosphere.

Common Dump tank shall be provided in the plant. The
capacity of the same shall be the 1.10 times the biggest reactor
in the plant.

Written check procedures are not available for the checking the
leak point in Vessel & piping system. Human errors may occurs
during the verbal check. Written procedures shall be developed.
Periodic inspection of the Sulfur burner to be ensured.

To handle the chlorine emergency chorine kit to be ensured and
maintained in tip top condition at all time.

Flange guards needs to be provided on Acid lines.

Non return Valve to be provided on pump discharge line.

Arrow indicator to be provided on pipeline.

Pump, storage tank & pipe line identification to be done.

Color code for pipelines to be provided as per IS 2379.

Periodic checking of the condenser to be followed

2 STORAGE OF CHEMICALS All the storage has been provided with the separate area. All
statutory norms are followed. It should be made restricted entry.
A register shall be maintained.
Double Static earthing to be provided to flammable material
storage tanks as well as pipelines and powder handling
machines.

Electrical earthing to be checked and record to be maintained
and resistance to be maintained below 1 OHMs .

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Safety valve Pressure gauges and other safety devises to be
maintained in working condition and testing and calibration to
be done once in a year.

Thickness measurement to be done for all storage tanks and
comparison records to be maintained.

Tank ID, content and capacity to be displayed on each tanks and
reactors.

3 INSTRUMENTATION Instrumentation has to play key role in the maintenance of
process parameters. All the interlocks shall be tested every
month. And the records shall be maintained. All the instruments
shall be calibrated before the date expires. Calibration date for
safety valve, shall be displays at site only.

Functioning of Instrumentation depend on the well supply of
air. Under no circumstances the air pressure shall be reduced.
The DMS & H2SO4 plant are DCS operated.

E. O. flow cutoff to be provided in connection with the
temperature rise in VS plant.
4 ENVIRONMENTAL The organization has taken care of environment by converting
all the by product into useful product. The concept of reduce,
recycle & reuse has been vigorously followed. The generation
of effluents is also well controlled.
5 ADMINISTRTION Standard Operating procedures to be prepared.

Work permit procedures to be followed for the handling of
hazardous chemicals.
6 GENERAL Use of Personal Protective Equipment (PPE ) are not found
during the various plant operation. PPE matrix shall be defined
for all the process activity.

Alarms for vacuum failure in the dehydration shall be
considered.

Stand by pump for reflux system shall be provided in distillation
section.

Hot oil circulation line shall be inspected at least once in a
month.

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CHAPTER I

OBJECTIVE AND METHODOLOGY OF HAZOP STUDY

1.1 Objective :

The specific objectives of the study are-

Identification and assessment of major hazards potential in the storage and handling of
petroleum products inside the depot.
Study of built- in- safety measures and operational safety precautions in practice.
Identification and assessment of major hazards potential in the process equipment.
Suggesting measures to reduce risk by reducing hazard and reducing probability.

1.2 SCOPE OF THE WORK

The principal objective of this study is to evaluate the potential hazards to the plant.

To evaluate the process safety system of plant from the safety point of view
considering the structural / electrical / instrumentation aspects.
To evaluate the system provided to protect fire & explosion in product pipe line and
system full proof.
Evaluate the maintenance & operation system of the Terminal.
Evaluate provided control parameters and instrumentation.
Suggest better system for safe operation & maintaining plant in a safe manner.

1.3 METHODOLOGY

Design data, built in safety systems are studied. Discussions are held with Officials.
Safety related individual system is discussed with HAZOP team member.

HAZOP exercise is conducted taking into consideration of each and every equipments,
storage tanks, Tank truck filling gantry, pump house, pipe lines, operating procedures,

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built in safety system, operating parameters and existing safety measures. Thus, this study
is mainly oriented towards actual risks rather than chromic risks.

Possible causes of the possible events will be derived and consequences effect of such
events will be discussed and required recommendation and follow-up sheet will be
generated for implementation purpose.

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SECTION II

INTRODUCTION TO HAZOP

2.0 Hazard and Operability Studies(HAZOP)

2.1 The basic concept of HAZOP is to have an exhaustive review of the plant layout and P& ID
of KCIL. HAZOP study highlights the hidden operability problems and identifies hazards,
which are likely to result from the expected intention of seemingly safe components or
methods of operation.

2.2 This work utilizes imagination of team members to visualize ways in which a terminal can
malfunction or mal-operated. Each part of the plant is subjected to a number of questions
formulated around a number of guide words which are derived from method of study
technique. In effect, the guide words are used to ensure that the questions which are posed to
test integrity of each part of the design to explore every conceivable way in which that
design could deviate from the design intention. This usually produces a number of
theoretical deviations and each deviation is then considered how it could be caused and what
would be consequences.

2.3 HAZOP is a brainstorming approach, which stimulates creativity and procedure for
generating ideas. Possible results of this study are :-
(a) Identify and examining many types of risks.
(b) Identifying non-optimum system reliability.
(c) Suggestive qualitative recommendations regarding control, strategy, material properties,
material releases alternative design option, operation and maintenance.

2.4 The important terms pertaining to HAZOP study are:-
Intention : - The intention defines how the part is expected to operate. This can
take a number of forms and can be either descriptive or
diagrammatic. In many cases, it will be a flow sheet (P & ID)

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Deviation : - These are departures from the intention which are discovered by
systematically applying the guide words.
Causes : - These are reasons why deviation might occur. Once a deviation has
been shown to have a conceivable or realistic cause, it can be treated
as meaningful.
Hazards : - These are the results of the deviations
Consequences : - These are the consequences, which can cause damage, injury or loss.

2.5 A list of guide words
Table- 3.1 list of guide words

Guide Words Meanings Comments
None Complete negation of
the intention
No part of the intention is achieved e.g.
no flow or reverse flow.
More of Quantitative increase More of any relevant physical
properties than there should be e.g.
higher flow (rate or total quantity)
higher temperature, higher pressure
higher viscosity, more heat, more
reaction etc.
Less of Quantitative decrease Less of any relevant physical property
than there should be, e.g. Lower flow
(rate or total quantity), lower
temperature, lower pressure, less heat,
less reaction etc.
Part of Quantitative decrease Composition of system different from
what it should be e.g. Change in ration
of components, component missing etc.
More than Qualitative increase More components present in the system
that there should be e.g. extra phase
present (Vapor, solid), impurities (air,
water, acids, corrosion products etc.)
Other than Substitution What else can happen apart from
normal operation e.g. Start up,
shutdown, high/low rate running,
alternative operation mode, failure of
plant services, maintenance, catalyst
change etc.

2.6 Guidewords are applied to the design intention. The design intention informs us what the
equipment is expected to do.

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NO
Yes
NO
2.7 A flow chart giving HAZOP procedure is given below:-

NO

NO

Yes

Select Line
Select deviation Eg.
More flow
Is more flow
possible ?
Is it hazardous or does it
prevent efficient
operation ?
Will the operator know
that there is more flow ?
What change in plant or methods will
prevent the deviation or make it less
likely or protect against the
consequences.
Is the cost of change justified
Agree changes.
Agree who is responsible for action.
Follow up to see that action has been taken.
Move onto next deviation
Consider other causes of
more flow
Consider other changes
or agree to accept
hazard.
What change in the plant
will tell him

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SECTION III

INTRODUCTION OF THE UNIT

3.1. COMPANY INTRODUCTION

M/s. Kutch Chemical Industries Ltd., is operating a manufacturing unit of various
chemicals and dye intermediates at Survey No 166/1,2,3, 171/1, 172,167,168, Village :
Padana, Gandhidham, Dist. Kutch

Produce unit is classified as Major Accident Hazards unit ( MAH Installation ) based on
the storage of the listed hazardous chemicals more than specified threshold
quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-1963 (2004).

Kutch Chemical Industries Ltd, with spot light on export market potential was founded in
2004 near the Global all weather ports of Kandla and Mundra. It consists of a well
integrated chemical complex consisting of Chlorination, Nitration, Sulphonation and Dyes
Intermediates products.

3.2. DETAILS OF UNITS

Sr.
No.
Particulars
1. Full Name & Address of
Unit
: Kutch chemical Industries limited
Plot no- 165,166/1&3,168,171/1&172
Village:Padana, Nr.Aquagel Chemicals,
Gandhidham, Dist Kutch
Gujarat.
2. Telephone No. : 02836-28551-52, Fax-02836-285233
3. Month & Year of
Establishment

: 10
th
J une 2002
4. Full name & Address of
the occupier
: Sh. Shivlal Goyal ( Director)
2, Sri Ram Society, Gotri Road Baroda
5. Full name & Address of
the Factory manager
: Sh. D.S.Purohit
Plot no 23, Ward -9B(D)
New Bharat Nagar, Gandhidham
Pin- 370201
6. Man Power

: 172 including all shift
G Shift- 31
A Shift- 47
B Shift- 47
C Shift- 47
7. No. Of shift & Shift timing : Total no of shift :- 04
General shift :- 09AM To 06 PM
First Shift A:- 07 AM To 03 PM

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Second Shift B:- 03 PM To 11PM
Night Shift C:- 11PM To 07AM
8. Environs (Nearest
Facilities)

9.
Meteorogical Data

Latitude 23 10N
Longitude 70 13 E

Temperature

Maximum 48 C
Minimum 7.2 C

Relative Humadity :

Maximum 100 %
Minimum 1 %

Annual Rain Fall :

Minimum 73.6 mm
Maximum 1393 mm (1979)

Seasonal wind directions :

Jan- Feb N / NNW / ENE
March Sept SW / WSW
Oct to Dec N / NNE

Wind Velocity :
Maximum 132 km/hr NNW (26.10.1975)
Minimum 100 km/hr NNW (26.10.1975)
Avg. Wind Speed 14 Km/hr

1. Railway Station : Gandhidham, Distance 20 KM

2. Police Station : Anjar, Distance 20 KM

3. Fire Station : Anjar , Distance- 20 KM

4. Hospitals : Anjar , Distance- 20KM
10. Total Land at Plant 50 ACRE

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11. Total Built-up area at the
Factory
30000 M2
12. Power connection Demand : 3000 KVA
13. DG Set KVA: 250 KVA
14. Power plant details : DG Set - 2.5 MW
Turbine 4.2 MW
15. Water Storage and source

Capacity in m3:20000 M3,
Source Gujarat water infrastructure limited
(GWIL)
16. Boiler

Type

Model no

Capacity

Licence
from
Gujarat
Govt.
Combi pack

CPB-80 8Ton/Hr GT 4879
IB-1478- 10 Ton/Hr GT 5516
Waste heat
Recovery
Maker no-
21943
AVU Make
25 Ton/Hr GT-5207
17. Chilled water plant

Particulars

Model No

Capacity

Location

VAM

------

150 TR

DMS
Plant
VAM SD30BHX/1 200TR OLD VS
VAM SD30BHX/1 200 TR MCB &
PNCB
Ammonia
compr 2 nos
KC6-3 150 TR MCB
Ammonia
compr 2 nos
KC6-3 150 TR PNCB
Ammonia
compr 2 nos
KC6-3 150 TR PDCB
Ammonia
compr 5 nos
KC6 300 TR New VS
Ammonia
compr 3 nos
KC6 180 TR OLD VS
Total 1480 TR
18. Cooling Tower

Particulars

Flow rate

T R Plants

Process
cooling water
4200M3/H 3260 Acid
Division
Process
cooling water
1300M3/H 1000 DMS
Plant
Process
cooling water
1200M3/H 1000 OLD VS

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Process
cooling water
1200M3/H 1000 MCB
Plant
Process
cooling water
1200M3/H 1000 Acetanilid
e plant
Process
cooling water

600m3/H 500 PNCB
Plant
Process
cooling water
600M3/H 250 PDCB
Plant
Process
cooling water
500M3/H 300 New VS
plant
Process
cooling water
1350M3/H 1100 TC Plant
Total 9410
19. Effluent treatment
Plant
Capacity: 50 M3
20. Fire water source Water reservoir (GWIL)
14 Fire Water Reservoir
capacity : M3
200M3
21. Department wise List
of fire extinguishers
with mapping if
available
Departments Total nos of
F/Extinguisher
Benzene storage 04 nos
Power plant 12 nos
PNCB Plant 16 nos
MCB Plant 07 nos
PDCB Plant 02nos
Ice plant 01 no
New VS Plant 09 nos
ETP 01 no
Acetanilide plant 06 nos
EO Storage 05 nos Capacity-25 kg
FO Storage 02 nos
VS OLD 06 Nos
CSA Plant 02nos
DMS Plant 18 nos
Methanol storage 04 nos
SAP Plant 15 nos
Boiler house 09 nos
ECC Room 10 nos as spare
Total 129 nos
22. SCBA sets
availability and
location mapping
Total Nos of SCBA Sets 08 Nos
Acid division C/R- 01No
Chlorine Shed- 02 Nos
DMS Plant- 01 Nos
TC Plant- 02 Nos

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Emergency Control centre- 02 nos
23. OHC facilities Occupational Health Centre is declared near main gate
and factory medical officer visit schedule is once in a
week.
Well equipment Ambulence VAN.
Stretcher-01
Oxygen cylinder with mask-01
First aid box- 10 nos in all departments
24. EMP Prepared as Per ISO-14000
25. EMP plan ( Action
Plan) one page
Prepared and displayed in all department
26. List of emergency facilities
A. Dry powder (50% of fire extinguishers ) 50 nos
B. CO
2
Cartridges ( 50% of fire extinguishers )
200 gms (10 kg DCP
50 nos
C. As above 2 Kg ( 75 Kg DCP ) 06 nos
D. Sand scoops 50 nos
E. Safety helmets 500 nos
F. Water curtain nozzles 20 nos
G. Stretchers 01 nos
H. First aid box with anti snake serum 10 nos
I. Rubber hand gloves 200 nos
J . Explosive meter 01 no
K. Fire entry suit w/o breathing apparatus 01 no
L. Resuscitator 05 no
M. Electric siren with 3 km range 01 no
N. Hand operated siren Nil
O. Water gel blandest NA
P. Red/green flags for fire drill Nil
Q. Pressure type self contained breathing apparatus
with spare cylinder (30 minutes)
08 nos.
R. Safety Shower 14 nos.
27. Fire Water Reservoir :- 200 M3
28. Other Source of Water :

Gujarat water infrastructure
limited , Anjar

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29. Fire Pump Details
Pump Detail Number of
Pump
Head Capacity
(Flow)
KW/HP
J ockey Pump 01 70 mtr 10.8 m3/h 10
Electrical Pump 01 70 mtr 270m3/h 120
Diesel Pump Nil Nil Nil Nil
Total 02 Nil Nil Nil
30. Hydrant System Details
Area / Plant Nos. Of Hydrant
with Hose Box
Nos. Of
Monitors
PNCB Plant Hydrant 07 nos
Hose box- 01 nos
01 no
MCB Plant Hydrant 01 nos
Hose box- 01 nos

Acid Division Hydrant 11 nos
Hose box- 03 nos
Nil
Old VS plant Hydrant 06 nos
Hose box- 05 nos
01 no
New VS Plant Hydrant 011nos
Hose box- 05 nos

Acetanilide Plant Hydrant 01no
Hose box- 01 no

PDCB Plant Hydrant 02 nos
Hose box- 01 nos

Power Plant Hydrant 05 nos
Hose box- 02 nos

Canteen Hydrant 01 no
Hose box- 01 no

DMS Plant Hydrant 02nos
Hose box- 02 nos

Total Hydrant 47 nos
Hose box- 30 nos

31. License & Approval:
A. Factory Inspectorate

Licence No : 018712
Validity : 31/12/2010
B. GPCB Consent No: 5991/3/5/2005
Validity : 31/1/2010
Note Application inward ID-
12531/Dated- 18/12/2009 for
renewal of consent
C. Solid waste Disposal

Member ship : TSDF,
Nandesari Baroda
D. Explosive
licence No :
Particulars Licence no Validity
Chlorine G/WC/GJ /06/109(G15607) 30/09/2011

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Ethylene oxide
old VS Plant
S/HO/GJ /03/718(SS5280) 31/03/2013
Ethylene oxide
New VS Plant
S/HG/GJ /03/1066(S32386) 31/03/2011
Furnace oil P/WC/GJ /15/2380(PII9928) 31/12/2010
Methanol P/HQ/GJ /15/4682(P120542) 31/12/2010
Benzene&
Toluene
P/HQ/GJ /15/4568(P20641) 31/12.2012

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3.3. Google Map:

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3.4. Site Plan:

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3.5. ORGANIZATIONAL SET UP

Safety setup organisation chart

3.6. DETAILS OF STORAGE OF HAZARDOUS MATERIALS IN BULK

NAME OF
HAZARDOUS
SUBSTANCE
MAX. STORAGE
CAP.[Qty.]
PLACE
OF ITS
STORAGE
OPERATING
PRESSURE
AND TEMP.
TYPE OF
HAZARD
CONTROL
MEASURE PROVIDED
Vinyl Sulphone Plant
Ethylene
Oxide
25 KL X 1 bullet
15 KL X 1 bullet
Licenced
Premises
A/G SS
10 Kg/ cm2
Ambient
Fire
/Explosion/
Toxic
Double Safety Valve
Nitrogen Blanketing
Double Static earthing
Dyke wall
Scrubber provided
J umper clips on flanges
Hydrant system
Fire extinguishers
Fencing and No Smoking
and prohibited area.
Tanker unloading procedure.
Shed provided on bullets.
Sprinkler provided on bullets.
SCBA sets available.
Safety shower.
Chloro
Sulfonic Acid
45 KL X 6 Nos
Tank

Tank farm
area
A/G MS
ATP
Ambient
Corrosive Level gauge provided.
Scrubber provided
Required PPEs provided to
Advise Company of safety
legislation & updates,
safety awareness, carry
out safety audits, update
safety policy, provide
training when required, to
provide investigations and
reports for any accidents.
Directors
Unit Head
VP Operation GM Operation Dy. Mgr ((Fire & Safety)
(General Shift only)
Fire & Safety Supervisor
(One in every shift)

Fireman
Two in each shift

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Chloro
Sulfonic Acid
(Proposed)
200 MT X 3 Nos. Do ATP
Ambient
Corrosive all employees
Double drain valve will be
provided to sulfuric Acid
storage tank
Full body protection will be
provided to operator.
Caution note and emergency
first aid will be displayed and
train for the same to all
employees.
Safety shower and eye wash
will be provided in storage
tank area and plant area.
Total close process will be
adopted for Sulfuric acid
handling.
Dyke wall will be provided to
storage tank
Caustic Lye 25 KL X 2Nos
Tank
Tank farm
area
A/G MS
ATP
Ambient
Corrosive
Caustic Lye 40 KL X6 Nos
Tank
Do ATP
Ambient
Corrosive
Sulfuric Acid 20 KL X 1Nos
Tank
Do ATP
Ambient
Corrosive
Hydrochloric
Acid
30 KL X 3Nos
Tank
Tank farm
area
A/G HDPE
ATP
Ambient
Corrosive
Acetanilide Plant
Acetanilide 600 MT Godown ATP,
Ambient
Combustible Flame proof plant, pumping
transfer, close process, etc.
Dyke wall
SCBA sets available .
Flame proof plant, pumping
Fire extinguishers
Flame arrestor provided on
vent line of the tank
Aniline 100 KL X 1 No
Tank
Tank farm
area
A/G MS
ATP,
Ambient
Flammable
Aniline 200 KL X 1 No
Tank
Do ATP,
Ambient
Flammable
Acetic Acid 100 KL X 2 No
Tank
Do ATP,
Ambient
Corrosive/
Flammable
Dil. Acetic
Acid
25 KL X 2 No
Tank
Do ATP,
Ambient
Corrosive
Ethyl Acetate 25 KL X 1 No
Tank
15 KL X 1No
Tank
Do ATP,
Ambient
Flammable
MCB, ODCB, PDCB, DCB Plant
Chlorine 209 Tonners Storage
Shed
10 Kg/cm2
Ambient
Toxic Chlorine Kit, Caustic Pit,
SBA sets, Cl2 Shed, Cl2
Hood, EOT, etc. Provided.
Chlorine 200 Tonners Storage
Shed
10 Kg/cm2
Ambient
Toxic
Benzene 40KLX4 Nos
Tank
Total : 160 KL
U/G Tank
MS

ATP Fire Flame proof plant, pumping
Dyke wall
Fire extinguishers
Hydrant system
Monochloro
Benzene
(MCB)
200KLX2Nos
Tank
Tank farm
area
A/G MS
ATP Fire
PNCB 90KLX 2 Nos
Tank
DO ATP Fire
ONCB 200KLX 1 No
Tank
DO ATP Fire
Dichloro
Benzene
(DCB)
200KLX 1 No
Tank
Tank farm
area
A/G MS
ATP Fire

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NB, PNT, ONT, Plant
Toluene 40KLX4 Nos
Tank
Total : 160 KL
U/G Tank
MS

Dyke wall
Fire extinguishers
Hydrant system
Benzene 40KLX4 Nos
Tank

Total : 160 KL
U/G Tank

MS
ATP Fire
Nitric Acid 20KLX3 Nos
Tank
MS A/G
Tank
ATP Corrosive Safety Showers provided
Caution note provided
Dyke wall provided
Level gauge provided.
Double drain valve provided
Scrubber provided
all employees
Sulphuric
Acid
20KLX 1 No
Tank
MS A/G
Tank
ATP Corrosive
PNT
(P-
NitroToluene)
200KLX1No
Tank
MS A/G
Tank
Dyke wall
Hydrant system
Fire extinguishers
Flame arrestor Provided.
ONT
O- Nitro
Toluene
200 KLX 1 No
Tank
MS
A/G(V)
Tank
ATP Fire
MNT
(Meta Nitro
Toluene)
90KL X1 No
Tank

200KLX 1 No
Tank
Total : 290 KL
MS A/G
(H) Tank
MS
A/G(V)
Tank
ATP Fire
NB
(Nitro
Benzene)
150KLX 1 No
Tank
ATP Fire
Sulphuric Acid Plant
Sulfur powder 5000 MT Storage
yard
ATP Fire Separate storage area.
Monitors provided
surrounding the storage area.
Automatic conveyer system
for charging in melter.
Oleum 65 % 250 MT X2 Nos
Tank
MS A/G
Tank

Atmospheric
Ambient
Scrubber provided
all employees
storage tank
Oleum 23% 250 MT X 1No
Tank
MS A/G
Tank

Atmospheric
Ambient
Corrosive
Oleum 65 % 100 MT X 2 Nos. MS A/G
Tank

Atmospheric
Ambient
Corrosive

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Page : 25

Liq Sulphur
Trioxide
MS A/G
Tank

Atmospheric
Ambient
Corrosive Caution note and emergency
employees.
handling.
storage tank
Sulphuric
Acid 98 %
1000 MT X 2
Nos. tank
MS A/G
Tank

Atmospheric
Ambient
Corrosive
CSA Plant
Chloro
sulphonic
Acid
50 KLX 3 Nos
Tank
140 KL X 01
Tank
MS A/G
Tank

Atmospheric
Ambient
Scrubber provided
all employees
storage tank
employees.
handling.
storage tank
Chloro
sulphonic
Acid
2000 MT X 2 Nos
Tanks
MS A/G
Tank

Atmospheric
Ambient
Corrosive
Dimethyl
Sulfate (DMS)

200 MTX 3 Nos.

MS A/G
Tank

Atmospheric
Ambient
Fire
Dimethyl
Aniline
(DMA)

100 MTX 2 Nos.

MS A/G
Tank

Atmospheric
Ambient
Fire
Diethyl
Sulfate (DES)

200 MTX 2 Nos.

MS A/G
Tank

Atmospheric
Ambient
Fire
Benzene
Sulphonyl
Chloride
100 MTX 2 Nos.

MS A/G
Tank

Atmospheric
Ambient
Fire
DASDA

100 MTX 2 Nos. MS A/G
Tank

Atmospheric
Ambient
Fire
Methanol 60KLX 4 Nos
Tank
MS A/G
Tank

Atmospheric
Ambient
Fire Flame proof plant, pumping
Hydrant system
Fire extinguishers
Ethanol 200 KL X 1 No.
tank
MS A/G
Tank

Atmospheric
Ambient
Fire

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Page : 26

Ammonia
Anhydrous
( Liquefied )
50 MT X 1 No.
Bullet
MS bullet 35
0
C
4 to 10
kg/cm
2

Toxic Flame proof equipment,
pumping transfer, close
process, etc.
Dyke wall
Scrubber provided
Hydrant system
Fire extinguishers
Safety Showers provided
Dyke wall provided
Scrubber provided
all employees
Hydrochloric
Acid
25 KL X 03 Nos A/G HDPE
Tank
Atmospheric
Ambient
Corrosive Safety Showers provided
Dyke wall provided
Scrubber provided
all employees
TC plant (PROPOSED)
Thyonile
chloride
150KL X 03 Tank SS
A/G Bullet
Atmospheric
Ambient
Scrubber provided
all employees
storage tank
employees.
handling.
storage tank
Chlorine 140 Toner Storage
Shed
10 Kg/cm2
Ambient
Toxic Chlorine Kit, Caustic Pit,
SBA sets, Cl2 Shed, Cl2
Hood, EOT, etc. Provided.
Scrubber provided .

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Page : 27

Sulpher
trioxide
100 MT X 02
Tank
MS Tank Atmospheric
Ambient
Dyke wall provided
Scrubber provided
all employees
Chlorinated Paraffin Wax CPW (PROPOSED)
HNP 65KLX 04 TANK MS Tank Atmospheric
Ambient
Flammable Safety Showers provided
Dyke wall provided
Scrubber provided
all employees
HCL 75KLX 6 TANK HDPE
TANK
Atmospheric
Ambient
Dyke wall provided
Scrubber provided
all employees
Chlorinated
Paraffin oil
20 KLX 03 FRP Atmospheric
Ambient
Dyke wall provided
Scrubber provided
all employees

Furnace Oil/
LDO
27 KLX 2 Nos
U/G tanks
MS Tank Atmospheric
Ambient
Fire Flame proof plant, pumping
Hydrant system
Fire extinguishers
HSD 21 KL Tank MS Tank Atmospheric
Ambient
Fire

3.7. Facilities / System for process safety, transportation, fire fighting system and
emergency capabilities to be adopted

Following facilities and system will be installed / implemented.

1. Total enclosed process system.
2. DCS operati on plant.
3. I nstrument & Plant Ai r System for control al l parameters.

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Page : 28

4. Hi gh level , l ow level, High pressure, l ow pressure, hi gh temp, hi gh
fl ow, low fl ow i ndicati on and cut off i nterl ocki ng provi ded on storage
as wel l as process reactors.
5. Safety valve, rupture di sk provided on reactor and pressure storage
tanks.
6. Static earthi ng and el ectric earthi ng (Double) wil l be provi ded.
7. J umpers for stati c earthing on pipeli ne fl anges of fl ammabl e chemi cal
provi ded.
8. Fl ame proof li ght fitti ng install ed where ever it is required.
9. Emergency handli ng equi pments li ke SCBA sets, Fire exti nguishers,
Gas mask, PPEs, Chl ori ne emergency Kit, chl ori ne hood, caustic pit,
Ai r l ine respi rator, provi ded.
10. Full fl edge ETP plant made and it will take care of li qui d effl uent of
the plant and fi nal discharge parameter will be mai ntained as per
GPCB norms.
11. Scrubbers provided on al l process vent and air monitori ng carried out
and parameters will be maintained as per GPCB norms. Fire Water
reservoi r for fire hydrant and sprinkl er system.
12. Storage tank area are away from the process plant and Separation
Di stance has been maintai ned.
13. Dyke wal l provi ded to all above ground storage tanks, coll ection pi t
wi th val ve provi ded.
14. Fl ame arrestor with breather val ve is install ed on fl ammable material
storage tank vent.
15. Li ghteni ng arrestor on all chimneys and buil di ng provi ded.
16. Fencing and cauti on notes and hazard i denti ficati on boards di splayed.
17. Onl y authori zed person are permi tted i n storage tank farm area.
18. Safety permi t for hazardous material l oadi ng unl oadi ng is prepared
and i mplemented.
19. Static earthi ng provision i s made at all l oadi ng unloading poi nts of
fl ammabl e chemi cal storage tank farm area.
20. TREM CARD provided to all transporters and trained for
transportati on Emergency of Hazardous chemi cals.
21. Fire hydrant system and water spri nkler system i nstal led at tank farm
area.
22. Caution note, safety posters, sti ckers and emergency preparedness
plan will be displayed.
23. Emergency faciliti es and medi cal emergency facilities are avai lable at
site. Occupational Health centre facility generated at factory premi ses
and paramedi cal staff i s avail able round the clock.
24. Wi nd directi on i ndicators are provi ded.
25. Safety Shower and eye wash are i nstalled at aci d/ al kali handli ng area.
26. Tel e Communi cati on system and mobile phone wil l be used i n case of
emergency situations for communi cati on.
27. Emergency siren i nstall ed at mai n gate as wel l as i n all plant.
28. Training programme are being conducted regul arl y and induction
trai ni ng are bei ng provi ded to al l empl oyees on chemical safety and
process safety.

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Page : 29

NHCOCH
3
+ 2Cl.SO
3
H
ACETANILIDE
NHCOCH
3
+
SO
2
Cl
HCl +
H
2
SO
4
CHLORO SULPHONIC ACID

3.1 BRIEF DESCRIPTION OF PROCESS AND FLOW CHART

3.1.1 Vinyl Sulphone & Vinyl Sulphone Condense:

Chloro Sulphonation:

Chloro Sulphonic Acid is charged into the sulphonation reactor. Acetanilide is then slowly
added to maintain the temperature below 80 C. The temperature is then maintained
between 50-60 C. The batch thus prepared is transferred to the storage tank.

Dumping:

Sulphonated mass is charged into the Reactor cooled with brine. Ice water is then added
slowly to remove all the HCl formed due to decomposition of excess Chloro Sulphonic
Acid. The HCl is scrubbed and absorbed in water to make HCl. Further Ice water is added
to dilute the concentrated Sulfuric Acid formed due to the decomposition of Chloro
Sulphonic Acid. Here we get of Sulfuric Acid of strength 30-40%.
The mass is then filtered out (ASC Cake).

Reduction:

Sodium Bi Sulphite slurry is added to the reactor. The pH is maintained neutral by adding
Caustic Lye. The ASC wet cake is then charged under controlled temperature and pH.
After addition is over the temperature is raised up to 50 C. The mass is then filtered and
transferred to condensation vessel.

Condensation:

The reduction mass in condensation vessel is maintained at 50C. Ethylene Oxide is slowly
added. The pH is maintained to 5-7 by adding dilute sulphuric acid. The material after
condensation is transferred to the Nutsch Filter. The Mother liquor is stored in storage
tank. The condensed product is then washed and dried.

Esterification:

The condensed product is charged in esterification reactor. Concentrated Sulphuric Acid is
added. The temperature is then raised and maintained at 160C for 4 hours. Vacumm is
applied to take out acetic acid vapors and being condensed. The product is then collected a
tank. The dried Vinyl Sulphone is pulverized and packed in PVC bags.

Chlorosulphonation:

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Page : 30

NHCOCH
3
+
SO
2
Cl
NaOH
+ NaHSO
3
NHCOCH
3
+
SO
2
Na
Na
2
SO
4
+
NaCl
NHCOCH
3
+
SO
2
Na
H
2
SO
4
+ H
2
O
O
H2C CH2
+
NHCOCH
3
SO
2
CH
2
CH
2
OH
+ Na
2
SO
4
ETHYLENE OXIDE
NHCOCH
3
SO
2
CH
2
CH
2
OH
+ H
2
SO
4
NH
2
SO
2
CH
2
CH
2
OSO
3
H
+ CH
3
COOH
VINYL SULPHONE
Reduction:

Ethoxylation:

Esterification:

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Page : 31

Process Flow Chart:
Acetanilide 2182
CHLOROSULPHONIC
ACID
10182
12364
Ice 14545 DUMPING(ICE)
26909
FILTERATION(Nutch) H2SO4 (35-40%)
12364 14545
SOD. BISULPHITE
SLURRY(30%)
6545
CAUSTIC LYE 2182
21091
PRODUCT FROM FILT
ETHYLENE OXIDE 1018
H2SO4 2269.00
24378.00
Salt
FILTER 17753
SODIUM SULPHITE
SALT
(BYPRODUCT)
8299
6625.00
ETP
CONDENSED PRODUCT 9454
6625.00
2262 MOISTURE LOSS
DRYER
4363.00
PRODUCT FROM
Dryer
H2SO4 1455 ESTERIFICATION
5818.00
ACETIC ACID
1818
VINYL SULPHONE
4000.0
CHLOROSULPHONATION
REDUCTION
ETHOXYLATION
MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE

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Page : 32

3.1.2 Sulphuric Acid

The process for the manufacture of sulphuric acid comprise the following steps:

1. Solid Sulphur after weighment is fed to sulphur melter which is provided with steam coils.
The ash content of the molten sulphur settles in the melter cum settler and molten sulphur
free of impurities is pumped to the sulphur burner where it is burnt with air. Sulphur is
converted in to SO2 in the sulphur burner as per the following reaction

S + O2 SO2

2. SO2 is further converted to SO3 in presence of Vanadium Pentoxide catalyst in the
converter as per the following reaction:
3.
SO2 + O2 SO3

The conversion of SO2 to SO3 is carried out in stages in all the five pass of the convertor.
The conversion is optimized by intermediate cooling of gases between the different stages
and also by interpass absorption of SO3 after 3
rd
pass of the convertor.

4. The gas from the 3
rd
& 5
th
pass of the convertor containing SO3 is cooled & then fed to the
interpass & final absorption tower where SO3 is removed by circulating Sulphuric Acid in
the absorption towers. The concentration of sulphuric acid is controlled by addition of
water in the pump tank.

5. Air for sulphur burner is routed through Air Filter to drying tower and further to suction
side of Centrifugal Air Blower. 98.5% acid is circulated through drying tower at 70C,
thus heating to 125C before entering sulfur burner. This system helps to increase
generation of steam and hence power generation.

6. SO2 emission during start up of the plant is controlled by a Venturi Scrubber using alkali
as scrubbing medium. The plant therefore does not cause any pollution either during start
up or during normal operation.

The process as described above has been divided into five main sections described as
follows:

Sulphur Circuit

The weighed quantity of sulphur of about 99.5% purity is fed to the first compartment
of sulphur melter. The heat for melting sulphur is provided through steam coils. The
optimum pressure to be maintained for melting sulphur in the first compartment is upto
7 kg/cm2 G.

The molten sulphur flows from compartment no. 1 to pumping compartment through
underflows/overflows. The sulphur pumps for feeding sulphur are fitted in pumping
compartment. The total time of retention in the compartments corresponds to more
than 72 hrs at normal rated production capacity of the plant. In order to achieve

Prepared By
Page : 33

optimum results, it is necessary that the feeding of sulphur to the melter should be
maintained at specified temperature of 135 C. All compartments are fitted with steam
coil to provide the necessary heat for maintaining the temperature of molten sulphur at
the desired level. Molten sulphur from the pumping compartment is pumped to the
sulphur burner through one of the submersible type sulphur pumps through specially
designed sulphur feeding gun. The rate of feed of sulphur to the sulphur burner is
controlled by operation of sulphur feed control valve. Drain lines have been provided
in the molten sulphur discharge line at two different points.
The optimum steam pressure for coils located in 2
nd
, 3
rd
, 4
th
through pumping
compartments of the sulphur melter is around 4 kg/cm2 G. This regulated steam
pressure is achieved through pressure reducing valve. Molten sulphur line starting from
the discharge flange of the sulphur pump to the inlet of the sulphur burner is suitably
steam jacketed to maintain correct temperature of molten sulphur fed to the sulphur
burner.

SO2 Scrubber
It is very important that SO2 emission during plant startup is controlled within
persmissible limits. This is achieved by use of a alkali scrubber located after the final
absorption tower where gas is scrubbed with circulating alkali solution.

DM and Water Softening Plants
For generation of steam of high quality DM water is required for this purpose RO
plant and DM plant will be installed.

The plant is provided with data logging system through DCS control circuits for
control of parameters like Acid concentration control, pump tank level control, Boiler
feed water level control, boiler feed water from deaerator temperature control. All the
output signals are fed to a computer and output data is collected based on reports to be
prepared including log sheets.

Chemical Reaction:

S + O2 SO2
SO2 + 1/2O2 SO3
SO3 + H2O H2SO4
Overall
S 3/2O2 + H2O H2SO4
M.W 32 48 18 98

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Page : 34

3.1.3 Oleum & SO3

Oleum (23%)

Oleum 23% is manufactured by absorbing SO3 gas with Sulphuric Acid.

H2SO4 + SO3 H2S2O7

Oleum 23% means free SO3 in the product is 23%, which is equivivalent to 105.17%
Sulphuric Acid. This way 23% Oleum is equivalent to 1.07 of 98% Sulphuric Acid.

The sulphur required for 1 ton of 23% oleum is 0.326 x 1.07 =0.349 ton.

Oleum (65%)

Oleum 65% means, the free SO3 in this product is 65% which is equivalent to 114.626%
sulphuric acid. This way the oleum 65% is equivalent to 1.17 times of 98% sulphuric acid.

The sulphur required for 1 ton of 65% Oleum 0.326 x 1.17 =0.381 ton

Liquid SO3

Liquid SO3 is =1.25 times of 98% Sulphuric Acid. The Sulfur required for 1 ton of liquid

SO3 =0.326 x 1.25 =0.41 ton.

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Page : 35

Sulphur
Metler
(135C)
163.25 MT
904341 M
3
Air Drying Tower
Furnace
(1100)
(Oxygen: 245 MT)
Water
WHB Steam Steam Turbine to Generate
4 MW Power
Convertor
(upto 3rd pass)
100 MT
DM Water
H2SO4 (98.5%)
Acid Pump Tank P
IPAB(Inter Pass
Absorption
Tower
99%
H2SO4
Convertor
(4th pass)
Oleum
Storage
(23% or 65%)
99% H2SO4
H2SO4
(98.5%) Storage
Final Absorption
Tower
Alkali
Scrubbe
r
Vent to
Atmosphere
Wastewater
500 MT/Day 0.8 KLD
Oleum
Tower
Oleum
Pump Tank
(Oleum 23%
or 65%)
PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)

Prepared By
Kutch Chemical Industries Ltd.
Page : 36

SO3 + HCl ClSO3H
(l) (g) (l)
80 36.5 116.5
1567 HCl Chilling
1567
Chilled HCl
H2SO4
Gas
Cleaning Bleed
1567
Dry HCl 99.90%
3433 Liq SO3
Reactor
100.00% Gas to Stack
Caustic
Scrubber
0.8 Castic Solution Wastewate To ETP
10% 0.8 KL/Month
5000
Chlorosulphonic Acid
MASS BALANCE OF CHLOROSULPHONIC ACID
Condenser SO3 Liquid
7500
Oluem Pump
Tank (23%)
8070
Oleum
Tower
(23%)
SO3
Convertor
(132 C)
PROCESS FLOW CHART OF SO3 LIQUID

3.1.4 Chloro Sulphonic Acid

The HCl gas is refrigerated and cleaned in gas cleaning tower. The dry HCl is reacted with
liq SO3 to get Chloro Sulphonic Acid. The unconverted gas is scrubbed in caustic
scrubber.

Chemical Reaction:

Mass Balance:

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Page : 37

3.1.5 Sulfonation (of ONT/PNT, Tobias, VS)

Take ONT/PNT in as sulfonator and charge 98% Sulphuric Acid and 65% Oluem in it
slowly. After completion of reaction blow sulfomass in another vessel containing water,
charge common salt, mix it, cool it and filter in neutsch. Material is then centrifuge. Collect
filterate as Spent Sulphuric Acid for sale. Sulphonated ONT/PNT from centrifuge is then
packed in HDPE bags and sent for sale.
For Tobias, Take Oleum (65%) in sulfonator, charge Tobias Acid slowly and after
completion of charging raise temperature and maintain it. Now cool the sulphonated mass
and blow it in Brine water. Allow for mixing, filter and give wash of brine water.
Centrifuge the mass and collect the wet cake as product and packed in HDPE bags.

Chemical Reaction (o-NT/p-NT):

98
178
o-Nitro Toluene Sulphonated Sulfuric Acid
o-NT
137 217 98
CH3
NO2
H2SO4
H2S2O7
CH3
NO2
SO3H
+ H2SO4

Chemical Reaction: (Tobias)

+ H2S2O7 + H2SO4
Tobias Acid (TA) STA (Sulfo Tobias Acid)
223 178 303 98
NH2
SO3H
SO3H
NH2
SO3H

MASS BALANCE:

ONT 137
H2SO4 98
H2S2O7 178
413
Water 18
Common Salt 117
(NaCl) 548
Spent Acid (25%)
Filteration (Water+Salt+Sulfuric Acid)
217 331
Centrifuge 2
(Recycle to Drawning Vessel)
Wet Cake
215
Sulfonator
Drawning
Vessel
MASS BALANCE OF SULPHONATION ONT/PNT

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Page : 38

3.1.6 BENZENE SULPHONYL CHLORIDE

Benzene is reacted with Chloro Sulphonic Acid in a agitated vessel at low temperature at
about 20 -25 C. Chloro Sulphonic Acid is used in excess for the reaction. The reacted
mass is then kept under agitation for some time. It is then transferred to another vessel
containing chilled water. During the addition, the vessel is cooled up to desire temperature
till the addition complete. The contents are kept under agitation for some time. The mass is
then separated. The acid layer is transferred to the storage tank for sale. The organic layer
is washed, dried & distilled under vacuum to get the product. The HCl gas evolved during
the reaction & isolation is send to CAS plant for making Chloro Sulphonic Acid.

Chemical Reaction:

C6H6 + HOSO2Cl C6H5SO2Cl + HCl
Benzene CSA BSC Hydrochloric Acid Gas
(l) (l) (l) (g)
M.W 78 116.5 176.5 36.5

Mass Balance/Flow Chart:

663 Benzene HCl gas
1980 CSA 310
2333
Isolation
Dilute H2SO4
1500
833
Distillation
Crude
Dimethyl
Sulphone
1485 15
Benzyl Sulphonyl Chloride
MASS BALANCE OF BENZYL SULPHONYL CHLORIDE
Reactor

3.1.7 Thionyl Chloride

Sulphur is charged in sulfur monochloride reactor along with chlorine in measured quantity
and reacted over a period of 12 hours to Sulphur Monochloride (SMC), which is stored for
further reaction. Thionyl Chloride reacted is fed with SMC, SO3 and Chlorine. Reactor is
fitted with fractionating column. TC gas thus produced is passed through 3 condenser, out
of which first condenser used cooling water and other two condenser use chilled water.
Crude TC is then sent to Distillation column as reflux. A part of crude TC is reacted with
sulfur to get pure Thionyl Chloride.

Prepared By
Page : 39

818 Sulphur
890 Chlorine
1708
2044 SO3 To Sulfuric Acid & SBS plant (Recycle)
890 Chlorine 1627
3015
2400
Product
600
Product
15
Total Product 3000
MASS BALANCE OF THIONYL CHLORIDE
SMC Reactor
TC Reactor
Condenser
Distillation
Column
Alkali Scrubber is provided to absorb SO2 when required; similarly chlorine scrubber
removes traces of chlorine. Byproduct is recycled back to sulfuric acid plant, where it is
converted to Sulphur Trioxide for reuse in TC Plant.

2S + Cl
2
S
2
Cl
2
Sulphur Chlorine Sulphur Monochloride (SMC)
64 70 134
S
2
Cl
2
+ 2SO
3
+ Cl
2
2SOCl
2
+ 2SO
2
134 160 70 236 128
SMC Sulphur Trioxide Chlorine TC
Overall Chemical Reaction:
2S + 2Cl
2
+ 2SO
3
2SOCl
2
+ 2SO
2
64 140 160 236 128
Chemical Reaction:

Mass Balance:

3.1.8 DASDA

Sulfuric Acid & Oluem (65%) are taken in Sulfonator, Para Nitro Toluene (PNT) is then
charged. The mass in then dumped in to the water, cooled and filtered in Neutsch filter.
The acid is then separated, The mass (PNTOSA) is then oxidized with sodium
hypochloride. After completion of the reaction common salt is charged at the room
temperature the mass is then filtered in Neutsch Filter .
Then reduction of PNTOSA is carried out with Fe, HCl and NH4Cl. Filter the reduction
mass & isolate the filterate using dilute H2SO4 & filter it in Neutsch filter. Material thus
prepared is DASDA. Which is then centrifuged and packed in the HDPE bags.

Prepared By
Page : 40

PNT 63
H2SO4 45
Oleum 82
190
Water 20
Salt 15
225
Neutsch Filter 58 To ETP
167
Centrifuge 30 ML(Recycle)
137 Drawning
Common Salt 15
Soda Ash 18
NaOCl 69
Water 25
264
206
201 Drawning
Fe 5
HCl 8
NH4Cl 15
229
Filter Press 27 To ETP
202
Isolation Vessel
202
176
170 Isolation Vessel
Product
DASDA
MASS BALANCE OF DASDA
Sulfonator
Drawning
Vessel
Oxidation
Reduction
Vessel
PNT(137) 98 178 PNTSA (217)
+ 2HCl + 3H2O
2NaOCl +H2O
217 149 18 474 73 54
Fe/HCl
NH4Cl
(DNSDA) Di-Sodium Salt (Nitro form) Di-Sodium Salt (Amino form)
414
+ H2SO4
414 370 DASDA
CH3
+
NO
2
H
2
SO
4
+ H2S2O7 2H2SO4
CH3
NO
2
+
SO3H
O2N
SO3Na
- C = C
H H
S
O
3
N
NO2
H2N
SO3Na
- C = C
H H
S
O
3
N
NH2
H2N
SO3Na
- C = C
H H
S
O
3
N
NH2 H2N
SO3H
- C = C
H H
S
O
3
H
NH
CH3
NO
2
+
SO3H
2
O2N
SO3Na
- C = C
H H
S
O
3
N
NO2
Chemical Reaction:

Mass Balance:

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Page : 41

3.1.9 Power Generation of 10 MW (Coal)

For power generation steam will be generated from the boiler, which is then sent to steam
turbine to generated the power. At the outlet of the turbine steam goes to condenser to
recover the water utilized and further sent back to the boiler. The fuel utilized for the boiler
will be Coal.
To generated 10 MW, a steam of 40 MTD required, which is generated from the coal based
boiler. The coal consumption for the required steam would be approximately 10 MTD.
For Power plant, separate coal yard will be made in which coal will be stored, from coal
yard the coal will be sent to crusher. The crushed coal is then sent to silo for ultimate feed
in to the combustion chamber.

Process Flow Chart:
High Pressure Steam
45 kg/cm
2
410C
Exhaust
0.1 kg/cm
2
100 C
Condenser Condensate back to
Boiler feed water
Turbine
Generator
Set

3.1.10 Sodium Bi Sulphite

Sodium Carbonate and Water is charged in the reactor. Sulphur Dioxide is then passed
slowly to the reactor. The mass is then allowed for continuous mixing. The material thus
prepared is Sodium Bi Sulphite.

Na2CO3 + 2SO2 + H2O 2NaHCO3 + CO2
106 64 18 208 28
Sodium SBS
Carbonate
Chemical Reaction:

CO2
Sodium Carbonate 106 28
SO2 64
Water 18
160
Reactor
MASS BALANCE OF SODIUM BI SULPHITE
Mass Balance:

Prepared By
Page : 42

1979 Liq SO3
DME Gas
1138
1524 Methanol Day Tank
Heat
Exchanger
Reactor
Containing
Al2O3
Catalyst(260C)
Reactor
386 Water To ETP
Condensation
Tank
Pure Dimethyl Sulphate 3000 Distillation
117
98% Spent Sulfuric Acid
MASS BALANCE OF DIMETHYL SULPHATE
3.1.11 Dimethyl Sulphate

Methanol from day tank in the plant is taken through metering pump passed through heat
exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum
catalyst, further it is reacted with liquid SO3. The ration of consumption of methanol +
SO3 for DMS produced is as follows:

SO3 =0.70 MT
Methanol =0.55 MT.

The moisture shall be collected out of Methanol and sent to ETP. After reaction of SO3 +
Methanol gas in a closed reaction , Which will have chilled water circulation in jacket. The
crude DMS formed is having a high acidity. The distilled and acid thus produced is 98%
Sulphuric Acid. This is a by product and will be sold.

260C
2 CH3OH CH3-O-CH3 + H2O
Catalyst(Al2O3)
Methanol Dimethyl Ether
2 x 32 46 18
CH3-O-CH3 + SO3 (CH3)2SO4
Dimethyl Sulphate
46 126
SO3 + H2O H2SO4
80 18 98
Chemical Reaction:

Mass Balance :

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260C
2 CH3OH CH3-O-CH3 + H2O
Catalyst(Al2O3)
Methanol Dimethyl Ether
2 x 32 46 18
CH3-O-CH3 + C6H5NH2 (CH3)2C6H5NH2
Dimethly Aniline
46 93 123
DME Gas
Aniline
1134
560
780 Methanol Day Tank
Heat
Exchanger
Reactor
Containing
Aluminium
Catalyst
Reactor
220 Water To ETP
Condensation
Tank
1694
1500 Pure Dimethyl Aniline Distillation
194
Wastewate to ETP
MASS BALANCE OF DIMETHYL ANILINE
3.1.12 Dimethyl Aniline

Methanol from day tank in the plant is taken through metering pump passed through heat
exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum
catalyst, further it is reacted with Aniline. The product is then distilled to get Dimethyl
Aniline
The moisture shall be collected out of Methanol and sent to ETP.

Chemical Reaction:

Mass Balance:

3.1.13 Diethyl Sulfate

Ethyl Alcohol and SO3 reacts in presence of catalyst Sodium Sulphate and Urea and
formed Ethyl Hydrogen Sulfate (EHS). This EHS mass is ammoniated by ammonia and
EHS gets converted into Diethyl Sulfate. Ammonia is passed in Ethyl Hydrogen Sulfate
mass. The product thus formed is crude Diethyl Sulphate.
Moisture content present in the Ethyl Alcohol reacts with SO3 and forms Sulphuric Acid.
Distillation of crude EHS takes place under vacuum. The pure DES is produced and
transported to the storage tanks.

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2C2H5OH + 2SO3 2C2H5OSO3H
Catalyst
Ethyl Alcohol Ethyl Hydrogen Sulfate
92 160 228
2C2H5OSO3H + NH3 (C2H5)2SO4 + NH4SO4
EHS Ammonia Diethyl Sulfate Ammonium Sulfate
228 17 154 114
896 Ethyl Alcohol
1558 SO3
354
2100
NH3
166
2266
Spent ST Tank
766
1500
Pure Diethyl Sulfate
MASS BALANCE OF DIETHYL SULFATE
Reactor (Catalyst:
Urea+Sod. Sulfate)
Cooler
Ammoniation Reactor
Distillation

Chemical Reaction:

Mass Balance:

3.1.14 Calcium Chloride

Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride.

2CaCO3 +4 HCl 2CaCl2 + 2 HCO3

Chemical Reaction:

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0.2
Water
5 Lime Stone Ventury Scrubber (Alkali)
ETP
4 HCl 0.2
9
Sludge to ETP
1
8 CaCl2
Clear Liquid
Mosture Loss
5
Dry CaCl2
Product
Reactor
Filter Press
MASS BALANCE OF CALCIUM CHLROIDE
Evaporator
Mass Balance:

3.1.15 Di Calcium Phosphate

Rock Phosphate is reacted with Hydrochloric Acid to generated Phosphoric Acid, which is
further reacted with Lime stone to get DCP which separated and crystallized.

Ca F2 3 ( Ca3(PO4)2) +14 HCl 7 CaCl2 +3Ca H(PO4)2 +2HF

Chemical Reaction:
3Ca (OH)2 6CaHPO4
DCP
Rock Phosphate 1800
HCl (30%) 3600
5400
Lime 200
5600
Hydrated Lime 200
Sodium Silicate 10
5810
Filteration Process Sludge
5310 500
Recycle to Reactor
to recover DCP 1500 Centriguge
3810
Dryer Mositure Loss
3000 810
Finished Product
Reactor
Neutralisation
Separation
MASS BALANCE OF DI CALCIUM PHOSPHATE
Mass Balance:

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3.1.16 Sulphur Mono Chloride

Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a reactor.

2S + Cl
2
S
2
Cl
2
Sulphur Chlorine Sulphur Monochloride (SMC)
64 70 134
Chemical Reaction:

95.5 Sulphur
104.5 Chlorine
200
MASS BALANCE OF SULPHUR MONOCHLORIDE
SMC Reactor
Mass Balance:

3.1.17 Sulphuryl Chloride

Sulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl Chloride.

Chemical Reaction
S
:

+ 3Cl
2
+ 2SO
3

3SO
2
Cl
2

32 210 160 402

Sulphuryl
Chloride
16 Sulphur
17.5 Chlorine
33.5
80 SO3
89.5 Chlorine
203
190
Product
13
Residue Product 10
3
Reactor
Reactor
Condenser
Distillation
Column
MASS BALANCE OF SULPHURYL CHLORIDE
Mass Balance:

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Water
860 Alumina Hydrate/Bauxite
456 Sulphuric Acid
1316
1316
456 Sulphuric Acid
Moulding
in to Slab
Reactor
Settling Tank
Reactor
MASS BALANCE OF ALUM
3.1.18 Aluminium Sulphate (Alum)

Aluminium Sulphate is manufactured by the reaction of Aluminia Hydrate and Bauxite
with Sulphuric Acid.

Bauxite is ground in the pulveriser to 90% passing through 200 mesh and elevated to batch
hopper through bucket elevator. Measure quantity of water is added in the lead bonded
reactor and slowly sulphuric acid is to be added in the reactor.. After getting the required
temperature in the reactor, slowly ground bauxite i.e added. After the addition of measure
quantity of bauxite/alumina hydrate, the agitator is kept on for about 45 minutes, solution
is then dumped in to the settling tank.

The decanted solution of Aluminium Sulphate is then taken to the reactor and the required
quantity of sulphuric acid is added after getting the required temperature Hydrated
Alumina is added slowly. After addition, Aluminum Sulphate is moulded in the trays with
the help of tray filling arrangements. The slabs after cooling are to be taken out from the
trays and stacked in the store.

2Al(OH)3 + 3H2SO4 Al2(SO4)3 + 6H2O
156 294 342 108

Chemical Reaction:

Mass Balance:

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350 Urea Reactor
3300 SO3/Oleum
(23-25%) 3650
R/C Mother Liquor
Mixing
5150
Separation Spent Acid
2400 2750
100 Water Make -Up
2500
Cyrstallisation
1500
1000
Packing/Bagging
Figure are in Ton/Month
MASS BALANCE OF SULFAMIC ACID
3.1.19 Sulfamic Acid

Urea & 23-25% Oleum are fed at controlled rates to reactor, which is cooled by chilled
water/brine and cooling water. The reaction products are diluted by mixing with recycled
mother liquor (available after separation of crystals of sulfamic acid). Temperature is
controlled during mixing by chilled water/brine. Dilute acid streams (70% sulfuric acid) is
separated after the mixing operation and is sold to SSP/Alum manufacturer.

NH2CONH2 + SO3 NH2CONHSO3H + CO2
Chemical Reaction:
NH2CONHSO3H + H2SO4 2NH2SO3H + CO2
Overall Reaction
NH2CONH2 + SO3 + H2SO4 2NH2SO3H + CO2
60 80 98 2 x 97 44

Mass Balance:

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SECTION IV

HAZOP SHEET

HAZOP SHEET

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VS PLANT
Table: 4.1 HAZOP STUDY WORKSHEET

Study Title Transferring of Chlorsulfonic Acid to service tank.
Drawing No. Revision No. NIL Date 08.07.2010
Hazop Team Mr. Deepak Chanchad
Part Considered Storage tank, Pump Activity Transferring of Chloro Sulfonic Acid to Service Tank.
Design intent PRES. TEMP FLOW VACU. Material : Chloro Sulfonic Acid
Amb Amb ---- Source : Formthe storage Tank

Parameter Guide
Words
Possible causes Possible
consequences
Measures/Existing facilities
safeguard
Action Required
Flow No 1. No material in the
storage tank.
2. Pump tripped.
3. Pump valve closed.

No material to service
tank.
Pressure gauge provided on the
pump discharge valve.
1. Level indicator to be
provided on service
tank.
2. Arrow indicators to be
provided on pipeline

Less 1. Valve partially closed.
2. Leakage in the pipe line.
3. Less material in the
storage tank.

More time taken to fill
the service tank.

More 1. Pump Ampere more.
2. Discharge valve fully
open than required set
value.

Early filling of
Service tank
1. Level indicator provided.
2. Vents are connected to
scrubber.

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Study Title Charging of Acetanilide
Part Considered -- Activity Charging of acetanilide
Design intent PRES. TEMP FLOW VACU. Material : Acetanilide
Nil Amb NA -- Source : Bag packing

Parameter Guide
Words
consequences
safeguard
Action Required
Charging No No material No process will take
place.
Material is charge under the
supervision.
Separate storage to be
identified with the
marking

Less 1. Human error.
2. Material weight is less
than what is mentioned
on the bag.

1. Disturbance in the
process.
2. More

More 1. Human Error
2. Material packing weight
is more than what is
printed on it.
1. Disturbance in the
process.
2. Product quality
may detoriate.
1. Charge batch to be
earmarked.
2. Identification of bag to
be done in local
language.

Wrong 1. Human error.
2. Wrong labeling.
3. Wrong supply of
material from supplier.

Disturbance in the
process.

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Study Title Reaction
Hazop Team
Part Considered Rector Activity Reaction
Design intent PRES. TEMP FLOW VACU. Material : Acetanilide +Chlorosulfonic.
----- 80 ---- ----- Source : Fromthe storage tank & Manual charging of bag.

Parameter Guide
Words
consequences
safeguard
Action Required
Pressure More 1. Chilled water supply
low.
2. More quantity of CSA.
3. No stirrer operation.
4. Entry of water in the
reactor
5. No scrubbing of HCL
water, Accumulation of
vapor in the reactor.
6. Choking in the scrubber.
Pressure &
temperature will go on
increasing.
Exothermic Reaction
will take place.
1. Vent provided to scrubber.
2. Pressure gage provided on
Reactor.
3. Temperature gauge provided
on reactor.
4. Safety valve & pressure gauge
are provided on reactor
cooling jacket.
5. Sight glass provided.
1. Standard operating
procedure to be
prepared.
provided on pipe line.
Less 1. Good cooling
2. Control Rate of Raw
material addition.
No process hazards
Temperature More As per pressure
Less Good cooling water flow No process hazards. It
is process
requirement.

Water Entry in
the reactor
Leakage Temperature &
Pressure will go on
increasing.
1. Thickness monitoring of the
reactor is carried out.
2. Hydro testing of the jacket at
periodic interval.

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Study Title Dumping
Drawing No. Revision No. Nil Date 08.07.2010
Hazop Team
Part Considered Dumping vessel Activity Dumping of sulphonated mass.
Design intent PRES. TEMP FLOW VACU. Material : Sulphonated mass.
Gravity 5 ---- ---- Source : Fromsulfonator

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More

1. No addition of ICE water.
2. Poor cooling of the
reactor.
3. Choking in the HCL
scrubber line.
1. Maximum
temperature will
be the ambient.
1. Temperature Gauge
2. Pressure gauge provided.
3. Total closed process
4. Safety valve provided on
Chilled water cooling line.
1. Only administrative
checks to be ensured.
2. SOP to be prepared.
Less Good cooling 1. It is good for the
process
2. No safety & health
hazards.

Pressure More Increase in temperature due
to above hazards.
No process & safety
hazards

Less
Flow More Not Applicable There is no flow
measurement as
sulphonated reaction
mass is directly
dumped in the
dumping vessel.

Less Not applicable
Other than
Part of No full charging Process delayed Physical inspection

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Study Title Reduction
Hazop Team
Part Considered Reduction Activity Reduction
Design intent PRES. TEMP FLOW VACU. Material SBS +Caustic Lye
50 Source From

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. Poor/No cooling.
2. Damaged insulation
3. Stirrer not
moving/stopped
4. More addition of
caustic.
5. Charging of normal
water.
1. Desired process
will not achieved.
2. Temperature will
rise.
1. Temperature Gauge
Visual check by the
operator

Less 1. Good cooling.
2. Controlled addition of
material in controlled
way.
No process & safety
hazards as it is
requirement of the
process.

Pressure More No effect on pressure
rise as it is only
neutralization &
reduction by adding
caustic lye.
No process & safety hazards
Less Not possible.

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Study Title Condensation
Hazop Team
Part Considered Condensation Rector Activity
Design intent PRES. TEMP FLOW VACU. Material : Reduction Mass +Ethylene Oxide
50 --- ---- ---- Source : Reduction & EO formstorage tank

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. Hot oil circulation is
more.
2. More hot material from
the reduction it self.
3. Flow of EO in case
above desired level.
Increase in
temperature &
pressure.
reactor & day tank
2. Rupture disc provided on
reactor & day tank.
3. Temperature & Pressure
gauge provided.
4. Stand by pump for the cooling
have been provided.
6. Temperature control at50 C by
providing chilling cooling &
hot oil circulation in reactor
jacket.
7. Dump vessel provided to
transfer reaction mass in case
pressurize & increase in
temperature.
8. Load shell tank provided
9. Nitrogen PRV skid provided
for the Nitrogen blanketing.
1. Visual check by the
operator
2. E. O. flow cutoff to be
provided in connection
with the temperature
rise.
provided on pipeline.
4. Nitrogen blanketing to
during reaction to be
provided.

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Parameter Guide
Words
consequences
safeguard
Action Required
Temperature Less Human error- Chilled water
circulation valve is open.

Desired process will
not achieve.
BMR is prepared & followed. Physical checks are
required.
Pressure More Increase in temperature due
to above mentioned causes
Temperature Increase. Pressure Gauge provided on
reactor & operator will take action
accordingly.

Less Not possible

Flow ( EO ) More 1. Human Error
2. Valve passed.

Increase in
temperature &
pressure.

1. Sight glass
2. Line Sight Glass Provided.
3. Flow meter provided on Inlet
of reactor.
4. Double mechanical seal in
stirrer
6. Flameproof fitting provision.
7. Double static earthing
provided.
8. J umpers provided on flange
joint.
9.

No/Less 1. No material
2. Valve jammed
3. Wrong setting of the
valve

Delayed in the
process.

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Study Title Esterification
Drawing No. Revision No. Date 08.07.2010
Hazop Team
Part Considered Esterification Reactor Activity Esterification
Design intent PRES. TEMP FLOW VACU. Material : Sulfuric Acid +Condensed product.
---- 160 Yes Source : FromCondensation

Parameter Guide
Words
Possible causes Possible consequences Measures/Existing facilities
safeguard
Action Required
Temperature More 1. Increase in flow of
Sulfuric acid.
2. J acket temperature is
more.
3. Less quantity of
condensed material.

1. Pressure will
increase.
2. PH may affected.

1. Temperature & pressure gauge
provided.
2. Safety valve & Pressure gauge
provided on Reactor jacket.
4. Vent are connected to
scrubber.
Physical & administrative
checks to be ensured.
Less 1. No heating in the jacket.
2. No flow of sulfuric acid.

1. No safety & health
hazards.
2. Desired process
temperature will
not achieved.
3. Delayed in the
batch cycle.

Pressure More As per the temperature

Less As per the temperature

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Study Title E. O. storage tank
Drawing No. NIL Revision No. NIL Date 28-06-2008
Hazop Team Deepak Chanchad
Part Considered Storage Tank Activity Storing of E. O.
Design intent PRES. TEMP FLOW VACU. Material : E. O.
N. A. N.A. Source : E. O. Storage tank

Parameter Guide
Words
safeguard
Action Required
Temperature

More

1. No chilled water supply.
2. Ambient temp high.
3. Poor insulation (water
entry inside insulation).
4. E. O. not consumed for
some days.

1. Development of
pressure in
Ethylene Oxide
tank.
2. Blow off from
Safety Valve.
3. Toxic & Fire
Hazards.
Explosion
Hazards.
Air pollution.
Leakage from
flange may occur.
4. Metallic
impurities.
5. In case
temperature is
more than 20 C
then
polymerization
may occur.
1. PSV provided.
2. Chilled water cooling
provided.
Safety Valve provided.
3. Rupture disc provided.
4. Insulation to tank provided.
5. Magnetic level type flow
indicator provided.
6. Ethylene Oxide gas sensor
monitoring systemprovided.
7. Pressure Gauge provided.
8. Fix Fire water monitor system
provided.
9. Sprinkle on Systemon EO
tank provided.
10. Hi temperature alarms
provided.
11. Chilling coil provided. To
storage tank covers 90 % in
the bottom2-3 tons E. O. left
without chilling.
1. To dilute the 1 liter of
EON, 18 liters water is
required. Considering
this sufficient quantity
of water shall be
ensured.
2. All flange joints shall
be checked regularly.

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Parameter Guide
Words
safeguard
Action Required
Temperature Less 1. Good Chilling.
2. Too cold atmosphere
during the winter.

1. Decrease in E. O.
Pressure.

1. Temperature Gauge provided.
2. Insulation provided.

Pressure More 1. N2 valve passing.
2. More temperature in the
storage tank.

1. Leakage from
flange may occur
2. Blow off from
Safety Valve.
3. Toxic & Fire
Hazards.
Explosion
Hazards.
Air pollution.

1. Pressure switch provided on
E. O. tank.
2. Inbuilt N2 pressure is 5.8
kg/cm2 so by human error N2
valve remains open than also
it will not rise up to 5.8
kg/came. Safety valve of
Storage tank set at 6.5 Kg/cm2

1. During the pop of
Safety valve it shall be
ensured the sufficient
quantity of water for
dilution.
2. In case Safety valve do
not set to its back
position after venting
the extra pressure (this
scenarios shall be
considered.)
3. Foamtype monitor
shall be considered.
4. Calibration for all
instruments shall be
done vigorously.

Less 1. Leakage from flange
joints,
2. Pump discharges less.
3. Mal functioning FCV
4. Valve partially closed.
In case activation of any
interlock than also the
flow will be low.

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Parameter Guide
Words
safeguard
Action Required
Flow More Covered under pressure 1. During the pop of
Safety valve it shall be
ensured the sufficient
quantity of water for
dilution.
2. In case Safety valve do
not set to its back
position after venting
the extra pressure (this
scenarios shall be
considered.)
3. Foamtype monitor
shall be considered.
Calibration for all
instruments shall be
done vigorously.
Less

Covered under pressure Process disturbance.
Spillage hazards

Reverse

Not Possible

No Safety hazards

Auto shut off valve provided.
Leakage of
water in
storage tank.

Other than Leakage from cooling coil

Moisture in E.O.
quality problemin
EO. Wastage of
material
Pressure gauge on the
outer side of the cooling
coil shall be provided.

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Study Title Fromoutlet of storage tank to inlet of batch tank.
Drawing No. 0 Revision No. NIL Date 28-06-2008
Hazop Team Mr Deepak Chanchad
Part Considered Storage tank & pump Activity Transferring of Raw material
Design intent PRES. TEMP FLOW VACU. Material : E. O.
Amb Source : Fromstorage tank

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More

1. Seasonal effect
2. Poor insulation of
pipeline.
3. Falling of hot water on
uninsulated line.
4. Incoming E. O. from
storage tank itself has
high temperature.
1. More pressure in
the pipeline may
give rise to
leakage.
2. Frompoor flange
joints, valve. Fire
& health hazards.
Insulation on pipeline & batch
tank provided.
1. To dilute the 1 liter of
EON, 18 liters water is
required. Considering
this sufficient quantity
of water shall be
ensured.
2. All flange joints shall
be checked regularly.

Less

1. Seasonal effect
2. lekage of chilled water
in E.O. from tank.
No workplace
Hazards. It the basic
requirement but High
moisture in E.O.
Wastage of E. O.

Safety valve provided on batch
tank.

Pressure More Covered under flow

Less Covered under flow

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Parameter Guide
Words
consequences
safeguard
Action Required
Flow More

1. N2 pressures more.
2. Valve failure
3. FIC mal function.
4. Human error.

1. Pressure rise in
batch tank.
2. Leakage in flange
joint.
3. Safety valve of
batch tank may
popup.
4. Tank filling
operation
completed in less
time.
Pressure gauge shall be
provided on batch tank.
Less

1. Choking in the excess
flow valve. (Holes are
choked.)
2. Low pressure of N2
itself.
3. Valve choked.

No safety hazards but
it will take more time
for filling operation.

Reverse No chances 1. NRV provided.
2. Auto shut off valve provided.

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ACETALININDE PLANT
Table 4.10 HAZOP STUDY WORKSHEET
Study Title Raw material to the storage tank ( Day Tank )
Drawing No. 0 Revision No. NIL Date 08.07.2010
Part Considered Storage tank & pump Activity Transfer
Design intent PRES. TEMP FLOW VACU. Material : Acetic Acid
Am Am Source : Fromstorage tank.

Parameter Guide
Words
consequences
safeguard
Action Required
Flow
Pressure
No

1. No material in the storage
tank.
2. Pump tripped.
3. Pump discharge valve
closed.
4. Heavy leakage in pipe line.
No material to service
tank.
Pressure gauge provided on the pump
discharge valve.

1. Non-returnable Valve to
be provided.
2. Arrow indicator to be
3. Stand by pump to be
provided.
4. Pump, storage tank &
pipe line identification to
be done.
5. Color code to be
provided.
6. Work permit procedure
to be followed for
handling of hazardous
chemicals.
7. PPE compliance to be
followed during handling
of acid.
More 1. Valve opened more than
set value
2. Human Error.
More material to the
service tank.

Reverse Not possible
Less SOP to be prepared.

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Study Title Reaction Process
Part Considered Storage tank & pump Activity Reaction
Design intent PRES. TEMP FLOW VACU. Material : Acetic Acid & Aniline +Acetic anhydride.
Am 130 Source : Fromthe storage tank.

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. Hot oil circulation
temperature is more.
2. Choking of pipeline of
inlet & out let of
condenser.
3. Poor cooling in
condenser.
1. Process
Disturbance.
2. (Reaction time
will be more.)
3. Product will char.

1. Pressure gauge & temperature
gauge to be provided.
reactors jacket.

provided.
2. Sand tray to be
provided for the
collection of storage.

Less 1. Ambient temperature is
low.
2. Good cooling.
3. Hot oil circulation
temperature is low.
Efficient process will
not take place.

Pressure More Atmospheric pressure
reaction
SOP to be prepared.

Less

Not possible
Power
failure
No process will take
place.
DG set provided.

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CHLORO SULPHONIC ACID PLANT


Study Title Chilling of the HCL
Part Considered Storage tank & pump Activity Chilling
Design intent PRES. TEMP FLOW VACU. Material : HCL
---- ---- ---- Source : FormMCB plant

Parameter Guide
Words
consequences
safeguard
Action Required
Chilling No

1. No supply of chilling
media.
2. Power failure
3. Insulation damaged.
4. Seasonal effect
5. HCL flow is low.
6. More impurities of
organics from the other
plant.

1. Poor chilling of
the HCL.
2. Process delayed.
1. Temperature controller is
provided.
2. Insulation provided on the
chiller.

More Not possible.

Reverse Not possible.

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Study Title Gas cleaning
Part Considered Activity Cleaning of HCL
Design intent PRES. TEMP FLOW VACU. Material : HCL
Source : Fromchilling section

Parameter Guide
Words
consequences
safeguard
Action Required
Cleaning No

1. No supply of HCL.
2. Cleaning media
circulation stopped.
3. Poor circulation.
4. H2SO4 exhausted.
1. No Health &
Safety hazards.
2. Quality of
cleaning of the
HCL will be
affected. (Moister
will not removed
and due to
moisture wet gas
will carry over in
the reaction.

1. Physical check for the
cleaning media which
is to be changed after
certain cycle.
2. Pump stop alarmto be
provided.
More Good quality of cleaning
media.
No process & safety
hazards.

Temperature More Choking in scrubber &
vapor. Accumulation in gas
phase.

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Part Considered Activity Reaction
Design intent PRES. TEMP FLOW VACU. Material : Dry HCL & SO#
3-5 kg
/cm2
Am As per
blower
--- Source : Fromthe storage tank.

Parameter Guide
Words
consequences
safeguard
Action Required
Flow More 1. HCL flow as per blower.
2. SO3 flow more than set
value.
3. Human error.
1. No process
disturbance.
2. Un reacted sulfur
trioxide generation
will be more.
1. Temperature indicator
provided.

Arrow indicators &
pipeline color code to be
provided.
Less/ No 1. Blower amp low.
2. Blower stopped
Process Delayed.
Temperature More Flow of HCL & SO3 are
more.
Increase in
temperature &
pressure.

Less Flow of HCL & SO3 are
less.
Decrease in pressure
& temperature

Power
failure
--- 1. Un-reacted gas
will come out
fromthe scrubber.
2. Circulation will be
stopped & reaction
will take place.
Captive Power plant.

Prepared By
Page : 68

SULFURIC ACID PLANT

Study Title Melting of Sulfur
Part Considered Storage tank & pump Activity Melting
Design intent PRES. TEMP FLOW VACU. Material : Sulfur
135 Source : Fromthe Sulfur storage tank.

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. Low quantity of sulfur
(Sulfur fed poorly.
2. Steamtemperature high.
3. Ambient temperature high.
Good for the process.

1. DSC operated plant.
2. Pressure indicator provided.
3. Temperature gauge provided.
4. Level indicator provided.
5. Closed process
6. Controls on flow. Temperature &
pressure are provided.
Interlocks between the Burner
temperature & steamflow is
suggested.
Less 1. Incoming steam
temperature low.
2. Ambient temperature low.
3. More quantity of sulfur fed
in the burner.

Pressure More

1. Temperature is very high.
2. Choking in the upward
stream.

Over pressurization may
affect on there factory
wall over a long run.

Pressure indicator provided.
Temperature gauge provided.
1. Physical checks to be
ensured.
2. Periodic inspection of the
Sulfur burner to be
ensured.
Less As per low temperature.
Sulfur & Steam Mixing Leakage in the steamcoil. Material will spoil. Temperature gauge & pressure gauge
provided.

Power
failure
---- Sulfur May jammed Captive Power Plant. Critical equipment should be
connected with the DG supply.

Prepared By
Page : 69


Study Title Burning of sulfur with air.
Part Considered Sulfur Burner Activity Pumping
Design intent PRES. TEMP Sulfur VACU. Material : Sulfur
1100 - ---- Source : Fromthe Sulfur storage tank.

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. Incoming air temperature
is high.
2. Efficient operation of
furnace.
No process hazards as it
is the process
requirement.
1. Temperature controller provided.
2. Glass window provided.
Arrow indicators to be
provided on fuel line.
Less 1. Poor incoming air
temperature
2. Poor flow of fuel.
Conversion process of
the SO2 will not take
place.

Pressure More 1. Incoming air flow is more
than set value.
2. Discharge of SO2 gas
restricted due to choking.
3. Rupture of partition wall.
4. More incoming pressure
fromthe sulfur melter.
Heavy leakage may
started formthe panel
door & also some time
rupture of furnace.

Less 1. No flow of air.
2. No sulfur fromthe melter.
No Health & safety
hazards.

Flow More As per more pressure.
Low As low pressure.
Power
failure.
J amming of sulfur
In burner.
DG set provided.

Prepared By
Page : 70


Study Title Catalyst convertor
Drawing No. 0 Revision No. Nil Date 08.07.2010
Part Considered Sulfur Burner Activity
Design intent PRES. TEMP FLOW VACU. Material : SO3, Vanadiumpentoxide.
Source :

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. Incoming air temperature
is high.
2. Efficient operation of
furnace.
No process hazards as it
is the process
requirement.
1. Temperature controller provided.
2. Glass window provided.

Less 1. Poor incoming air
temperature
2. Poor flow of fuel.

Conversion process of
the SO2 will not take
place.

Pressure More 1. Incoming air flow is more
than set value.
2. Discharge of SO2 gas
restricted due to choking.
3. Rupture of partition wall.
4. More incoming pressure
fromthe sulfur smelter.
5.
Heavy leakage may
started formthe panel
door & also some time
rupture of furnace.

Less 1. No flow of air.
2. No sulfur fromthe melter.
No Health & safety
hazards.

Flow More As per more pressure.
Low As low pressure.
Power
failure.
J amming of sulfur
In burner.
DG set provided.

Prepared By
Page : 71

THYONYL CHLORIDE PLANT

Study Title Rector
Part Considered Activity Reaction process
Design intent PRES. TEMP FLOW VACU. Material : Chlorine & Sulfur
105 Source : FromStorage

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. More quantity of Catalyst,
2. More Charge quantity of
either Chlorine & Sulfur
3. Hot oil temperature is more.
Pressure & temperature
will go on increasing.
1. Temperature gauge & pressure
gauge provided.
2. Rotometer provided for the
chlorine control.
4. Safety valve provided.
5. Cooling & chilling arrangement
with alternative provided.
6. Chlorine PRV station provided.
7. In case of increase of
temperature chlorine charging
supply will closed.
8. In case of increase of pressure
raw material charging supply
will closed.
provided.
be done.
4. Color code to be
provided.
5. Work permit procedure
to be followed for
handling of hazardous
chemicals.
of acid.
Less 1. Less quantity of catalyst.
2. Hot oil temperature is less
or less quantity of HO is
fed due to leakage valve
partially closed.
Reaction time will
increase.

Prepared By
Page : 72

Parameter Guide
Words
consequences
safeguard
Action Required
Pressure More

As per temperature
Less

Flow More Human error.
More charging of material.

Pressure &
temperature will go on
increasing.

Power
failure
No GEB supply. Captive power plant provided.

Prepared By
Page : 73


Study Title Gas mixture
Part Considered Activity Gas Mixing
Design intent PRES. TEMP FLOW VACU. Material : Chlorine, SO2 & SDC
Source : FromStorage

Parameter Guide
Words
consequences
safeguard
Action Required
Temperature More 1. More quantity of Catalyst,
2. More Charge quantity of eithe
Chlorine & Sulfur
3. Hot oil temperature is more.
4. More SO2 fromthe holder
tank.
gauge provided.
2. Rotometer provided for the
chlorine control.
4. Safety valve provided .
5. Cooling & chilling arrangement
with alternative provided.
6. Chlorine PRV station provided.

1. Non returnable Valve to
be provided.
provided.
be done.
5. Color code to be provided.
6. Work permit procedure to
be followed for handling
of hazardous chemicals.
of acid.
8. Periodic checking of the
condenser to be followed.
Less 1. Less quantity of catalyst.
2. Hot oil temperature is less
or less quantity of HO is fed
due to leakage, valve
partially closed.
Reaction time will
increase.
Pressure More As per temperature
Less 1. Human error.
2. More charging of material.

Flow More No GEB supply. Pump circulation will
stop.

Power failure Captive power plant provided.

Prepared By
Page : 74


Study Title High Boiler fractional Distillation Column
Part Considered HBFC, Condenser, Heat Exchanger & Carbon bed. Activity Distillation
Design intent PRES. TEMP FLOW VACU. Material : Crude TC
Source : Fromthe Crude TC Reciever.

Parameter Guide
Words
safeguard
Action Required
Temperature More Good Heating

1. No process hazards.
It is part of the
requirement.
2. It will accelerate the
distillation process

gauge provided.
4. Cooling & chilling
arrangement with alternative
provided.
5. Chlorine PRV station
provided.

1. Non return Valve to be
provided.
provided.
pipe line identification
to be done.
5. Color code to be
provided.
6. Periodic checking of
the condenser to be
followed.
Less Poor Heating No distillation will take
place. Process delayed.

Pressure More Not possible -----
Less Not Possible -----
Flow More Not possible -----
Power
failure
No GEB supply. Distillation will not
achieve.
Captive power plant provided.

Prepared By
Page : 75


Study Title Final Product Distillation Column
Part Considered HBFC, Condenser, Heat Exchanger &
Carbon bed.
Activity TC Distillation
Design intent PRES. TEMP FLOW VACU. Material : Crude TC
Yes Yes Source : From HBFC.

Parameter Guide
Words
consequences
safeguard
Action Required

1. No process
hazards. It is part
of the requirement.
2. It will accelerate
the distillation
process

gauge provided.
provided.

1. Non returnable Valve
to be provided.
provided.
to be done.
the condenser to be
followed.
Less Poor Heating No distillation will
take place. Process
delayed.

Pressure More Not possible -----
Less Not Possible -----
Flow More Not possible -----
Power
failure
No GEB supply. Distillation will not
achieved.
Captive power plant provided.

Prepared By
Page : 76

MONOCHLORO BENEZEN PLANT


Study Title Reaction of Chlorine
Design intent PRES. TEMP FLOW VACU. Material : Chlorine & Benzene
Source : Fromthe storage tank

Parameter Guide
Words
consequences
safeguard
Action Required

Temperature More 1. More quantity of
chlorine due to wrong
setting of Rotometer.
2. Rotometer malfunction
3. Poor cooling of reactor.
4. Ambient temperature is
high.
5. More flow of benzene
due to human error.

1. Flame Proof fitting are
provided.
2. Rota Meter is provided.
provided to all equipment.
4. J umpers are provided on all
the pipe line joint.
5. Benzene flow cut off at high
temperature in reactor have
been provided.
6. Temperature controllers are
provided in front of Operators
cabin.

1. To handle the chlorine
emergency chorine kit
to be ensured.
2. Chlorine detectors to
be provided.
Less 1. Flow of chlorine is less.
2. Rotometer malfunctions.
3. No benzene flow or
choking in spray
nozzles.
4. Chlorine sprayer got
choked.

Prepared By
Page : 77

Parameter Guide
Words
consequences
safeguard
Action Required

Pressure More As per flow

Less As per flow

Flow More 1. Rotometer failure
2. More flow fromthe
chlorine header itself.
Temperature will go
on increasing

Less 1. Rotometer malfunction.
2. Less flow fromthe
chlorine itself.
3. Valve closed.
Process delayed.
Power
failure
1. No supply due to
electrical fault
2. & also the captive power
plant not running.
Captive power plant provided. 1. Chlorine supply to be
closed immediately as
it leads to
environmental hazards.
Un reacted chlorine
will go to the
atmosphere.
2. DG set to be provided
& all critical
equipment shall be
connected with the DG
supply.

Prepared By
Page : 78

DMS PLANT


Design intent PRES. TEMP FLOW VACU. Material : Methanol
Yes 260 No Source : Fromthe Heat exchanger & condenser

Parameter Guide
Words
consequences
safeguard
Action Required

Temperature More 1. Hot oil circulation is
more.
2. More temperature of the
methanol gas.
3. More charging of the
catalyst.
4. Ambient temperature is
more.

1. Pressure will go
on increasing.
2. No process
hazards.
3. It is the part of
requirement.

1. DSC Plant operation
2. Flow control valve provided
on the methanol.
3. Flame Proof fitting are
provided.
provided to all equipment.
5. J umpers are provided on all
the pipe line joint.
6. Safety Valve & Pressure
gauge are provided on Hot oil
circulation circuit.
1. Calibration of all
instruments to be
carried out.
3. Annual shut down to
be carried out and
corroded plant to be
replaced.
4. Thickness monitoring
of the vessels to be
carried out.
Less Low catalyst quantity of
catalyst due to human error.
1. Process delayed.
2. DMS gas will not
produced.

Pressure More As per flow

Less As per flow

Prepared By
Page : 79

Parameter Guide
Words
consequences
safeguard
Action Required

Flow More 1. Pump Ampere more.
2. Valve fully open
3. In the system.
4. Human error.

Less 1. Pump amp low
2. Leakage in the pipe line.
3. Valve partially closed in
the HE & condenser
system.
4. No material in the
storage tank.

Power
failure
1. No GEB supply.
2. Sudden failure in the
electrical system.
Process disturbance. Captive power plant provided.

Prepared By
Page : 80


Part Considered Activity Chilling Reaction
Design intent PRES. TEMP FLOW VACU. Material : SO3 & Methanol
Yes No Source : Fromthe reactor.

Parameter Guide
Words
consequences
safeguard
Action Required

Temperature More 1. Not Possible.
2. Chilling process
1. DCS operated plant.
2. Closed process
3. Pressure gauge provided on
the chilled water jacket.
4.

Less 1. Good chilling effect.
2. Winter days.
3. Good insulation
1. Good for the
process.
2. No safety hazards

Pressure More Not possible

Less Not possible

Flow More Not possible

Less Not possible.

Power
failure
1. No GEB supply.
electrical system.
Process Disturbance Captive power plant provided.

Prepared By
Page : 81


Study Title Distillation
Part Considered Activity Distillation
Design intent PRES. TEMP FLOW VACU. Material : DMS vapour.
Yes No Source : Fromthe reactor.

Parameter Guide
Words
consequences
safeguard
Action Required


1. No process
hazards. It is part
of the requirement.
2. It will accelerate
the distillation
process
gauge provided.
provided.
5. Chlorine PRV station
provided.

1. Non returnable Valve
to be provided.
provided.
to be done.
5. Color code to be
provided.
the condenser to be
followed.
Less Poor Heating No distillation will
take place. Process
delayed.
Pressure More Not Possible
Less Not Possible
Flow More Not Possible
Less Not Possible. Captive power plant provided.
Power
failure
1. No GEB supply.
electrical system.
Process Disturbance

Prepared By
Page : 82

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M/s. Kutch Chemical Industries Limited

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