7.

0 Health and Safety

Health and safety are crucial aspect that are focused on recognising, evaluating and control
the hazards connected to processes. It is important to ensure that the safety precautions are
taken to reduce the risk associated during the production of methanol from syngas.

7.1 Hazard and Operability Study (HAZOP)

The main objective of HAZOP study is to provide efficient solutions to reduce the risk by
identifying possible hazards and operability concerns before they might cause accidents or
other problems. Table below showed the HAZOP analysis for reactor, R-102 and heat
exchanger, HE-104.
Table 7.1 HAZOP for reactor, R-102

Possible
Parameter Deviation causes Consequences Action required
When temperature Regular
HE-101 decreases, the reaction rate maintenances,
Low duty decreases, the reaction install low pressure
temperature decreases cannot reach the optimum alarm
temperature Implement safety
measures such as
automatic
shutdown system
to prevent any
damage
Temperature
of reactant
When temperature is too Regular
HE-101 high, overheating will occur, maintenances,
High duty the catalyst may deviate, install high pressure
temperature increases equipment failure may occur alarm
and lead to explosion Install emergency
cooling system
 7.2 HAZOP for reactor, R-102

Parameter Deviation Possible causes Consequences Action required

Pipeline Regular maintenances
No flow blockages No reaction occurs
Pipeline Install a flow control
leakages Equipment damage system
Less flowrate of
reactant into Conversion of reactant
Less flow reactor is low Regular maintenances
Pipeline
blockages Product yield also low
Flow rate
Pipeline
of reactant
leakages
Explosion of reactor
Failure of the occur due to very high
High flow process fluids pressure Regular maintenances
Install a pressure relieved
High pressure valve to release the
in the reactor pressure

Table 7.3: HAZOP for heat exchanger, HE-104

Paramete
r Deviation Possible causes Consequences Action required
Reduce the heat Regular
Less flow Pressure drops transfer maintenances
increase the steam
pressure, install flow
equipment failure control system
Flowrate Reduce the
of utilities Pressure and temperature and
temperature of steam Reduce heat transfer pressure of the
high flow increases efficiency steam
Increased wear and
tear on heat
exchanger
Corrosion Reduce heat transfer Regular
Corrosion
of tube Fouling occurs efficiency maintenances
Using corrosion-
resistant materials
High temperature and Potential leaks lead for heat exchanger
pressure to equipment failure tube
7.2 Hazard analysis (HAZAN)
Hazard analysis is a methodology used to identify and analysis possible risks and hazards
related to process. Identification of hazard sources, assess the likelihood of accidents and
development of measures to prevent or reduces the risk are the objectives of HAZAN study.
Table 7.4, 7.5 and 7.6 have showed the HAZAN analysis for reactor, heat exchanger and
pipelines.
7.4 HAZAN for reactor, R-102

Risk
Node Hazards Consequences Severity Frequency score Control
Install control
Failure in Overheating and system with
cooling water increase in high and low
supply pressure 4 3 7 flow alarm
Explosion occur
Contamination
of reactants or Decrease the Regular
products yield 3 3 6 maintenance
Reduced
Reacto
product
r
Equipment
damage and Install reflief
leading to leaks valves to
Overpressure or even released excess
in the reactor explosion 4 2 6 pressure
Install
automatic
shutdown
systems

7.4 HAZAN for heat exchanger, HE-104

Risk
Node Hazards Consequences Severity Frequency score Control
Install
Overheating emergency
Oversupply and pressure shutdown
of steam increase 3 3 6 system
Install flow
Equipment controller and
Heat damage and temperature
exchanger explosion alarm
Insufficient Increase Install
of heat steam temperature
supply consumption 2 3 5 alarm system
Allow more
Reduce heat utility to
efficiency flow through
 Severit
Node Hazards Consequences y Frequency Risk score Control
Pipeline Corrosio Pipelines Regular inspection of
s n leakage occur 2 3 5 pipelines
Pressure
decreases and
flowrate for
steam also Coating to pipelines can
decreases prevent corrosion
Reduced the
Fouling flow rate 2 3 5 Regular maintenances
Chemical treatment can be
increase the used to remove fouling
pressure drop deposits
7.4 HAZAN for Pipelines
8.0 Process control and Operability
Process control refers to the techniques or strategies that used to manage, maintain and
adjust the process variable involved in manufacturing process to ensure that it is operating at
desired conditions. The process control system normally involved with valve, sensors and
controllers in order to adjust the parameters like temperature, pressure or flow rate.

8.1 Temperature control system

8.2 Pressure control system

8.3 Flow control system

8.4 Emergency/ Shut down system

8.5 PID drawing

Valve Type
Numbe of Fail
r valve Function of valve position Reason
Gate Regulate and control the
FVC-001 valve reactant flowrate Closed To cut off the reactant flow rate
Globe Regulate and control the steam
FVC-002 valve flowrate Closed To cut off the steam supply
Gate Regulate and control the
FVC-003 valve reactant flowrate Closed To cut off the reactant flow rate
Globe Regulate and control the steam
FVC-004 valve flowrate Closed To cut off the steam supply
Gate Regulate and control the Release the excessive product to
FVC-005 valve product flowrate Open flow through
Gate Regulate and control the cooling Allow the cooling water flow
FVC-006 valve water flowrate Open through for cooling
Gate Regulate and control the boiling Allow the boiling water flow through
FVC-007 valve water flowrate Open for cooling
9.0 Costing
CAPEX
OPEX

10.0 Utilities and Waste management