Alangilan Campus

College of Engineering – Department of Chemical Engineering

HAZOP ANALYSIS for Production of Maleic Anhydride via Oxidation of Furan

Company: SCB Chemical Solutions

Location: Barangay Kuya, Maramag, Bukidnon

Facility: Area 300: Maleic Anhydride Production

PHA Method: HAZOP

PHA Type: Initial

Process: Oxidation

Date: May 20, 2023

Process Description: The Area 300 which is the Maleic anhydride Production of the SCB
Chemical Solutions manufacturing plant will utilize the obtained furfural from the sugarcane
bagasse. In this area, distillation columns are present to separate the desired product from other
substances that will be sent to wastewater. In this area, the main process is oxidation wherein the
furan derived from the furfural will be sent into the oxidation reactor that will produce the maleic
anhydride. With the use of oxygen gas and addition of catalyst, this process is made possible. The
oxidation reactor will operate at 240℃ and 101.325kPa to produce the maleic anhydride of its
required purity, which will also be subjected into drying as this product will be marketed as powder.

Chemicals: Oxygen Gas, Furan

Purpose: The purpose of this analysis is to determine the deviation that may occur during
operation of the reactor which may pose a threat to human and environment and may results to
undesirable effect to the manufacturing plant itself.
 Alangilan Campus

College of Engineering – Department of Chemical Engineering

Scope: The HAZOP study identifies the hazards and operability issues that may arise from the
operation of the oxidation reactor as well as the supply of oxygen gas to the reactor.

Objectives: To identify the hazards of the oxidation reactor in producing the maleic anhydride and
create the necessary actions if these hazards occurred.

Project Notes:

DESIGN REVIEW

1. From the distillation column, furan will be pumped to the oxidation reactor. Two pumps
are available wherein the other one is reserved. Valves are also placed to control the
flow of the fluid.
2. The oxygen tank will supply the needed oxygen for the reaction, this will be
compressed first before it reaches the oxidation reactor. Flow transmitter and flow
controller are placed to regulate the stream of oxygen.

Assumptions:

1. The oxidation reactor is working properly at its designated operating conditions.

2. The oxygen gas tank is maintained at its proper level.
3. Instruments such as flow transmitter and control, temperature and pressure controller
are working properly.
4. The pipelines connecting the equipment are free of leaks and blockages.
 Alangilan Campus

College of Engineering – Department of Chemical Engineering

Table 1. Nodes selected for HAZOP Analysis.

Node Operating Parameters

Pressure: 101.325kPa
1. Furan to Oxidation reactor (R-302) and Temperature: 240℃
associated pumps.
Capacity: 34.96m3
Pressure: 101.325kPa
2. Oxygen gas tank (TK-302) and Temperature: 25℃
associated lines
Capacity: 34.96m3
Pressure: 101.325kPa
3. Oxidation reactor (R-302) operation and
Temperature: 240℃
flow to next equipment.
Capacity: 68.43m3

Figure 1. Piping and Instrumentation of Oxidation of Furan

Study Title: Production of Maleic Anhydride via Oxidation Pages:
Drawing No.: 01 Date: May 20, 2023
Meeting Date: May 18,
HAZOP Team: Aycardo, Geoffry M., Benitez, Maria Soledad B., Besas, Angelica P., Cusi, Hanna Jane T.
2023
Part Considered: Oxidation reactor, Oxygen tank and associated pumps and pipelines
Materials: Furan, Oxygen Gas, Catalyst Activity: Oxidation
Design Intent: HAZOP for Oxidation
Reactor (R-302) Destination: Rotary Drum
Source: Distillation column and Storage tank
Dryer
Node 1
Furan to Oxidation reactor (R-302) and associated pumps
Element Flow
Risk Matrix
Guideword Deviation Possible Cause Consequences Safeguards Recommendations
F S R
1. Full-opening of 1. Overflowing of
1. Flow controller
valves. fluid in the oxidation
More flow in the should be available,
2. High Flow. reactor.
More pumps to the 1. None B IV M and high flow alarm
3. Opening of 2. Operational
oxidation reactor active in the control
reserved pump. problems.
room
3. Release of
1. Closing of valves
due to air.
2. Distillation 1. Flow controller
column failure. should be available,
3.Pump loop open and low flow alarm
Less to no flow in
failure. 1. Operational active in the control
Less/No the pumps to the 1. None B I L
4. Leakage on problems. room.
oxidation reactor
pipeline or pipeline 2. Pipe leak
fracture. detection instrument
5. Reverse flow due or sensor installation.
to low power
operating of pumps.
Node 1
Furan to Oxidation reactor (R-302) and associated pumps
Element Pressure
Risk Matrix
Guideword Deviation Possible Cause Consequences Safeguards Recommendations
F S R
1. Pressurization in
1. Pressure
1. More pressure the pumps, pipes,
1. Pump loop controller and
More on the input line and and reactor. 1. None C IV M
closed failure. transmitter should be
reactor. 2. Equipment
available.
damage.

1. Pressure
1. Depressurization controller and
1. Less pressure on 1. Pump loop open in the pumps, pipes, transmitter should be
Less the input line and failure. and reactor. 1. None C IV M available.
reactor. 2. Pipeline fracture. 2. Equipment 2. Check the low
damage. pressure alarm if
working properly.
Node 2
Oxygen gas tank (TK-302) and associated lines
Element Level
Risk Matrix
Guideword Deviation Possible Cause Consequences Safeguards Recommendations
F S R

1. Possible flooding
in the pipelines
connecting to the 1. Check the level
Higher level in the 1. There is a closed oxidation reactor. 1. Level controller. controller and
More C III M
oxygen tank. circuit failure. 2. Possible damage 2. Level transmitter. transmitter if working
in the pipes, properly.
compressor, and
valve.

1. Check the level

1. Possible
Lower level in the 1. There is an open 1. Level controller. controller and
Less operational C III M
oxygen tank. circuit failure. 2. Level transmitter. transmitter if working
problems.
properly.
Node 3
Oxidation reactor (R-302) operation and flow to next equipment.
Element Pressure
Risk Matrix
Guideword Deviation Possible Cause Consequences Safeguards Recommendations
F S R
1. Pressurization in
1. Check for
the pumps and
1. Pump loop pressure controller
More pressure on pipelines. 1. Pressure
closed failure. and trasmitter if
the material input 2. Equipment controller.
More 2. Abrupt power A IV M working properly.
and reactor damage. 2. Pressure
consumption of 2. Reassess and
operating pressure 3. Operational transmitter.
equipment. rectivate the safety
problems.
system.
4. Unit shutdown.
1. Depressurization 1. Check for
in the pumps and pressure controller
1. Pump loop
More pressure on pipelines. 1. Pressure and trasmitter if
closed failure.
the material input 2. Material damage controller. working properly.
Less 2. Leakage on A I L
and reactor 3. Operational 2. Pressure 2. Confirm if low
pipeline or ruptured
operating pressure problems. transmitter. pressure alarm in
pipeline.
4. Low discharge of active in the control
fluid. room.
Node 3
Oxidation reactor (R-302) operation and flow to next equipment.
Element Temperature
Risk Matrix
Guideword Deviation Possible Cause Consequences Safeguards Recommendations
F S R
1. Equipment
damage. 1. Check for
1. Environmental 1. Temperature
Higher operating 2. Operational temperature
factors such as hot controller.
More temperature of the problems. C IV M controller and
weater to not well- 2. Temperature
equipment 3. Material trasmitter if working
ventilated room. transmitter.
contamination. properly.
4. Unit shutdown.
1. Check for
temperature
controller and
1. Inappropriate 1. Temperature
Lower operating trasmitter if working
opening of the 1. Operational controller.
Less temperature of the A I L properly.
deviation valve on problems. 2. Temperature
equipment 2. Well-ventilation of
line. transmitter.
area.
3. Inspection and
verification of valve.
 Table of Risk Matrix

Risk Assessment Frequencies

Matrix A B C D E
V M M H H H
Severities

IV M M M H H
III L M M M H
II L L M M M
I L L L M M
Severity Frequency Risks
I Low A Unlikely
II Moderate B Remote (1) Low
III Average C Casual (2) Moderate
IV Critical D Likely (3) High
V Catastrophic E Frequent