DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITI MALAYA

Safety, P&ID, and HAZOP Report

Esterification Reactor for The Reduction of FFA

Content in the Production of Biodiesel from
Sludge Palm Oil.
2022
MEMBERS OF GROUP 12

IR. DR. TEOH WEN HUI

SUPERVISOR OF CHEMICAL ENGINEERING INTEGRATED DESIGN PROJECT 2

RAFLI ROZAAN ZUHDI MUHAMMAD NAUFAL

17205377/1 FADHLURRAHMAN
17204761/1
VISHWESH PRAKASH MUHAMMAD IMRAN BIN
17207517/1 MD ARIFF NOOR
17122507/2
NURUL FARAHIN
BINTI BADARUDDIN
17086451/2
 TABLE OF CONTENTS
1 Introduction ...................................................................................................................... 1
2 Industrial Hygiene ........................................................................................................... 2
2.1 Component’s chemical and physical properties ..................................................... 2
2.1.1 Methanol ............................................................................................................. 2
2.1.2 Tripalmitin.......................................................................................................... 4
2.1.3 Triolein ................................................................................................................ 6
2.1.4 Trilinolein ........................................................................................................... 8
2.1.5 Palmitic Acid .................................................................................................... 10
2.1.6 Oleic Acid .......................................................................................................... 12
2.1.7 Linoleic Acid ..................................................................................................... 14
2.1.8 Stearic Acid....................................................................................................... 16
2.1.9 Fatty Acid Methyl Esters................................................................................. 18
3 Control Techniques........................................................................................................ 20
4 Occupational Safety & Health (OSH) .......................................................................... 21
5 Waste management & Disposal Considerations ......................................................... 24
5.1 Glycerol .................................................................................................................... 24
5.2 Biodiesel.................................................................................................................... 25
6 Material Handling and storage ..................................................................................... 26
6.1 Sludge palm oil ........................................................................................................ 26
6.2 Methanol .................................................................................................................. 29
6.3 Biodiesel.................................................................................................................... 32
6.4 Sulphuric acid .......................................................................................................... 35
7 Accidental Release of Materials .................................................................................... 39
8 First Aid Measures ......................................................................................................... 42
9 Piping and Instrumentation Diagram (P&ID) ............................................................ 44
10 HAZOP ........................................................................................................................... 45
10.1 Introduction ......................................................................................................... 45
10.2 Objectives ............................................................................................................. 45
10.3 Methodology ......................................................................................................... 46
10.4 HAZOP Team ...................................................................................................... 46
10.5 Operating Conditions of the reactor .................................................................. 47
10.6 Scoring guidelines & legend................................................................................ 48
11 HAZOP WORKSHEET ................................................................................................ 57
12 Conclusion ...................................................................................................................... 68
13 References ....................................................................................................................... 69
 TABLE OF TABLES

Table 1: Methanol Physical and Chemical Properties. .............................................................. 2

Table 2: Tripalmitin Physical and Chemical Properties ............................................................ 4
Table 3 : Triolein Physical and Chemical Properties................................................................. 6
Table 4 : Trilinolein Physical and Chemical Properties ............................................................ 8
Table 5 : Palmitic Acid Physical and Chemical Properties ..................................................... 10
Table 6: Oleic Acid Physical and Chemical Properties ........................................................... 12
Table 7: Linoleic Acid Physical and Chemical Properties ...................................................... 14
Table 8 : Stearic Acid Physical and Chemical Properties........................................................ 16
Table 9: Fatty Acid Methyl Esters (FAME) Physical and Chemical Properties. .................... 18
Table 10: Control Techniques .................................................................................................. 20
Table 11: Occupational Safety and Health for Workers .......................................................... 22
Table 12: Occupational Safety and Health for Management. .................................................. 23
Table 13: Material Handling and Storage for Sludge Palm Oil. .............................................. 26
Table 14: Material Handling and Storage for Methanol. ......................................................... 29
Table 15: Material Handling and Storage for Biodiesel. ......................................................... 32
Table 16: Material Handling and Storage for Sulphuric Acid. ................................................ 35
Table 17: Accidental Release Measures .................................................................................. 39
Table 18: First Aid Measures ................................................................................................... 42
Table 19: Reactor Operating Conditions ................................................................................. 47
Table 20: Guide Word Description .......................................................................................... 48
Table 21: Common HAZOP Parameters ................................................................................. 50
Table 22: Score Guide for Probability of Occurrence ............................................................. 51
Table 23: Score Guide for Environmental Impact ................................................................... 52
Table 24: Score Guide for Impact on People ........................................................................... 54
Table 25: Score Guide for Safeguard Failure Probability ....................................................... 55
Table 26: Risk Rating Description ........................................................................................... 56
Table 27: HAZOP Worksheet .................................................................................................. 57
1 Introduction
Safety is an essential factor to consider in the design and operation of a process plant. In continuation of design of process plant and reactors for
biodiesel production, safety and effects of the process are to be assessed in order to ensure the plant’s working environment and the safety of its
workers. This component should be held to the upmost attention and must be used to reduce and/or fully eliminate any potential accidents in
workplace, avoiding any fatalities. Hence, in this report elements such as material handling, waste management, first aid measures, industrial
hygiene and HAZOP analysis will be thoroughly covered to assess the hazards, environmental impacts, risk levels with a P&ID.

1
2 Industrial Hygiene

2.1 Component’s chemical and physical properties

2.1.1 Methanol

Methanol is a volatile liquid with significantly heavier vapours than air. It may travel some distance to the source of ignition before flashing
back. It is a primary alcohol made comprised of the methyl and alcohol groups. It is an aliphatic alcohol that is produced naturally by volcanic
gases, bacteria, and flora.

Table 1: Methanol Physical and Chemical Properties.

Molecular formula CH4 O

Chemical structure

Molecular weight 32.042 g/mol

Boiling point 64.7°C

Melting point -97.8°C

2
 Flash point 9.7°C

Vapor pressure 127.2 mmHg at 25°C

Solubility Miscible with water, ethanol, ether, benzene, most organic solvents, and ketones

Appearance Colourless gas

Odour Faintly sweet pungent odour, similar but somewhat milder and sweeter than ethanol.

pH 7-8.3

3
2.1.2 Tripalmitin

Tripalmitin is a triglyceride derived from the fatty acid palmitic acid.

Table 2: Tripalmitin Physical and Chemical Properties

Molecular formula C51 H98 O6

Chemical structure

Molecular weight 807.339 g/mol

Boiling point 320°C

Melting point 66°C

Flash point 286.1±23.8 °C

4
Vapor pressure 127.2 mmHg at 25°C

Solubility Soluble in EtOH, (C2H5)2O, C6H6, CHCl3, Insoluble in water

5
2.1.3 Triolein

Triolein is a symmetrical triglyceride composed of three oleic acid units and three glycerol units. The majority of triglycerides are asymmetrical,
resulting from the combination of fatty acids. 4–30 percent of olive oil is composed of triolein.
Table 3 : Triolein Physical and Chemical Properties

Molecular formula C57 H98 O6

Chemical structure

Molecular weight 885.4 g/mol

Boiling point 554 ° C

Melting point -4 °C

Flash point 303.00 °C

6
Vapor pressure 1.15X10-9 mm Hg at 25 °C

Solubility Insoluble in water, Soluble in chloroform, ether, carbon tetrachloride and slightly soluble in alcohol.

Appearance Colorless to Yellow to Orange clear liquid

Odor Odorless

pH

7
2.1.4 Trilinolein

1,2,3-trilinoleoylglycerol is a triglyceride formed by acylation of the three hydroxy groups of glycerol with linoleic acid

Table 4 : Trilinolein Physical and Chemical Properties

Molecular formula C57 H98 O6

Chemical structure

Molecular weight 879.3844 g/mol

Boiling point 816.55 °C°C

Melting point -5 °C

Flash point 303.00 °C

8
Vapor pressure 2.9 mmHg at 25°Cat 25°C

Solubility Soluble in Chloroform, Dichloromethane, Ethyl Acetate, DMSO, Acetone, etc.

Appearance Colorless to Yellow to Orange clear liquid

Odor Odorless

pH 5-6

9
2.1.5 Palmitic Acid

Palmitic acid is a saturated long-chain fatty acid with a backbone of 16 carbon atoms. Palm oil and palm kernel oil are natural sources of palmitic
acid, as are butter, cheese, milk, and meat. According to the NCI Thesaurus, palmitic acid is a metabolite of Escherichia coli (strain K12, MG1655)
Table 5 : Palmitic Acid Physical and Chemical Properties

Molecular formula C16 H32 O2

Chemical structure

Molecular weight 256.42 g/mol

Boiling point 351.5°C

Melting point 61.8°C

Flash point 302.6 °C

Vapor pressure 3.80e-07 mmHg at 25°C

Solubility Soluble in ethanol, acetone, benzene; very soluble in chloroform; miscible with ethyl ether; insoluble in
water

10
Appearance Colorless or white solid

Odour Virtually odorless

pH 5-6

11
2.1.6 Oleic Acid

The omega-9 fatty acid oleic acid It is something that the body can create. It can also be present in food. The highest concentrations are seen in
olive oil and other culinary oils. Oleic acid is most typically utilized for heart disease prevention and cholesterol reduction.

Table 6: Oleic Acid Physical and Chemical Properties

Molecular formula C18 H34 O2

Chemical structure

Molecular weight 282.5 g/mol

Boiling point 286.111°C

Melting point 29.2 °C°C

Flash point 189 °C°C

12
Vapor pressure 1.40e-06 mmHg at 25°C

Solubility Practically insoluble in water; sol in chloroform; ether; fixed & volatile oils; alcohol; benzene

Appearance Colorless or nearly colorless liquid

Odour Peculiar Lard-like odor

pH 5-6

13
2.1.7 Linoleic Acid

Linoleic acid is a polyunsaturated essential fatty acid that is mostly found in plant oils. It is involved in the manufacture of prostaglandins as well
as cell membranes. NCI Thesaurus (NCIt) Linoleic acid is an octadecadienoic acid with Z (cis) stereochemistry and two double bonds at
positions 9 and 12.

Table 7: Linoleic Acid Physical and Chemical Properties

Molecular formula C18 H32 O2

Chemical structure

Molecular weight 280.4 g/mol

Boiling point 365.2 °C

14
Melting point -8.5 °C

Flash point -

Vapor pressure 8.68e-07 mmHg at 25°C

Solubility Very soluble in acetone, benzene, ethyl ether, and ethanol.

Appearance White or slightly yellow crystal masses, or white to slightly yellow powder

Odour Slight odor suggesting tallow

pH 5-6

15
2.1.8 Stearic Acid

Stearic acid is a saturated long-chain fatty acid with an 18-carbon backbone. In addition to its presence in cocoa and shea butter, stearic acid may
be found in many other animal and plant fats.
Table 8 : Stearic Acid Physical and Chemical Properties

Molecular formula C18 H36 O2

Chemical structure

Molecular weight 284.5 g/mol

Boiling point 383 °C

Melting point 68.8 °C

Flash point 113 °C

Vapor pressure 7.22e-07 mmHg

Solubility Insoluble in water

16
Appearance White or slightly yellow crystal masses, or white to slightly yellow powder

Odour Slight odor suggesting tallow

pH 5-6

17
2.1.9 Fatty Acid Methyl Esters

Trans esterification of lipids with methanol yields fatty acid methyl esters (FAME), a kind of fatty acid ester. Transesterification of vegetable oils
yields FAME, the majority of the molecules in biodiesel. In addition, they are used to produce biodiesel and detergents.
Table 9: Fatty Acid Methyl Esters (FAME) Physical and Chemical Properties.

Molecular formula C2 H3 O2 − R

Chemical structure

Molecular weight 271 g/mol (average)

Boiling point 613 °C (average)

Melting point 44 °C

Flash point 113 °C

Vapor pressure 0.0041 mmHg

18
Solubility Insoluble in water

Appearance Colorless liquid

Odour Fruity smell

pH -

19
 3 Control Techniques
Table 10: Control Techniques

Potential Hazards

Occupational
Exposure Health Hazard Flammability limits Fire Hazards
Limit

Threshold Limit
LFL UFL Fire Fighting
Components Value Rating Additional Notes Additional Notes Reactivity Fire Hazard Flammability
(vol%) (vol%) Media
(TLV-TWA)

Direct Fire Hazard.

Could cause acute toxicity (oral,
Methanol 200 ppm 2 dermal, inhalation) and specific
toxicity to organ (single exposure)
Highly flammable liquid and vapour. Gas/vapor flammable Cool tanks/drums with water spray/remove them into
Highly flammable with air within explosion limits. safety. Do not move the load if exposed to heat. Take
6.7 36 0 3
liquid and vapour account of toxic fire-fighting water. Use water
Indirect Fire Hazard. moderately and if possible, collect or contain it.

May be ignited by sparks

This chemical is not considered

Heating causes rise in pressure with risk of bursting. Water spray, alcohol resistant foam, Dry
FFA N/A 0 hazardous by OSHA Hazard 6 36.5 0 1
Hazardous combustion products: Carbon oxide extinguishing powder, Carbon dioxide
Communication Standard.

May cause irritation from eye

contact and skin contact. Can also
be harmful if ingested. Inhalation of Not a flammable
Triglycerides N/A 1 N/A N/A 0 Not possible to catch fire due to its non-flammable nature. 0 N/A
the material may cause irritation to chemical
mucous membranes and upper
respiratory tract.

Breathing Methyl Acetate can cause

pulmonary irritation, resulting in
coughing and/or shortness of
breath. Higher levels of exposure
Methyl Ester 200 ppm 2 3.11
can result in a buildup of fluid in
the lungs a medical emergency
characterized by acute shortness of
breath.
Dry chemical, CO2, water spray or alcohol-resistant
foam. Do not use dry chemical extinguishers to
Flammable liquid, control fires involving nitromethane. Water spray,
Behavior in Fire: Vapor is heavier than air and may travel a
16 hence, it is easy to 0 3 fog, or alcohol-resistant foam are all options. Avoid
considerable distance to a source of ignition and flash back.
catch fire. shooting straight or steady streams at the product.
Move undamaged containers away from the fire zone
if it is safe to do so.

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4 Occupational Safety & Health (OSH)
Occupational health and safety is a broad issue that includes a large range of specialised fields. It is the fundamental objective of
occupational safety and health to guarantee that all employees are physically, mentally, and socially healthy. Preparation and preservation of work
environments that minimise or eliminate the risk of injury to workers, the prevention of health deviations among workers due to their working
conditions, and the protection of employees in their workplaces from health-related risks are all. Thus, in this section, we'll discuss some safety
advice and precautions that may be taken throughout the procedure in order to prevent any accidents. In spite of the fact that biodiesel is not
regarded a hazardous chemical, the production process may be dangerous owing to the use of flammable materials, which can result in several
hazards, such as fire or explosion, if no safety measures are taken.

21
 Table 11: Occupational Safety and Health for Workers

WORKER’S RESPONSIBILITY

1. Report any incident that happened in the plant including injury and accident to the OSH department.

2. Always practice “safety first” when handling hazardous chemical substances while following the rules and guidelines provided.

3. Keep the work area free of hazards by following all reasonable safety direction provided by the supervisor.

4. Do not undertake any task if it is not safe to be completed and stop immediately if become aware of the unsafe situation.

5. Comply with all work, health, and safety rules, procedures, and instructions (WHS).

6. Assist in any incident investigation or workplace inspection and actively support WHS consultation.

7. Always wear safety device, personal protection equipment (PPE) throughout the operation.

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 Table 12: Occupational Safety and Health for Management.

MANAGEMENT’S RESPONSIBILITY

1. OSHA standards, rules, and regulations must be adhered to in order to provide a workplace free of significant recognised threats.

2. Inspect the working environment to confirm that it complies with all relevant OSHA rules.

3. Inspect and maintain tools and equipment used by employees to ensure that they are safe and that they are used safely.

4. Color codes, posters, labels, or signs may be used to inform employees to possible hazards and changes.

5. Assist in the creation or revision of operational procedures and the dissemination of such procedures to the workforce in accordance
with health and safety requirements.

6. Educate employees on safety procedures in a language and jargon they can easily understand and practise

7. Medical exams should be performed anytime there is a complaint of an accident.

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5 Waste management & Disposal Considerations

5.1 Glycerol

Glycerol is created as a byproduct of the biodiesel production process. According to the MSDS, glycerol is not a toxic or dangerous combination.
Glycerol is not classified as hazardous by the Globally Harmonized System (GHS). Glycerol is often thought of as a non-hazardous material that
doesn't need any special handling techniques, and this is generally maintained. There may be no restrictions on flushing glycerol down the toilet
if local rules let it. Glycerol, on the other hand, is the complete opposite. It's possible that even after the sink has been fully cleaned, there is still a
risk of fire. It's best to have this item properly disposed of by a professional junk removal service. An incinerator with an afterburner and scrubber
may first dissolve or mix it with a flammable solvent, such as gasoline, to make it easier to burn. All environmental laws, both federal and state,
as well as municipal, must be followed. As a result, the glycerol used to make biodiesel may fetch as little as 2.55 cents per pound. Innovative and
value-added glycerol uses should be the focus of glycerol manufacturers.

Crude glycerol produced in biodiesel facilities may be disposed of in a number of ways. Large-scale biodiesel producers can transform crude
glycerol into a natural form that may be used in the food, pharmaceutical, or cosmetics sectors. Small businesses, on the other hand, can't afford
to perform their own filtration since it's too expensive. Large refineries generally buy their crude glycerol in order to improve the quality of the
product. The biodiesel business has created an oversupply of crude glycerol as a consequence of excessive production.

Glycerol has been studied extensively in a variety of different circumstances. Glycerol may be used and disposed of in a variety of ways, including
combustion, composting, feeding animals, thermochemical conversions, and biological conversions. It has been shown that crude glycerol can be
burned (Johnson & Taconi, 2007). For large biodiesel producers, however, this method is out of reach. According to Brown (2007a), biodegradable
glycerol may also be used to increase biogas generation in anaerobic digesters (Holm-Nielsen et al. 2008). In dairy cows, glycerol generated from
biodiesel was shown to be ineffective in preventing ketosis (DeFrain et al., 2004).

24
5.2 Biodiesel

The water solubility of biodiesel is generally 15–25 times higher than that of diesel (He et al., 2007). Compared to D-2 diesel, the water content
grows at a rate of 22.2 parts per million per degree Celsius, which is more than nine times faster. Microbial growth or ester hydrolysis may occur
in biodiesel because of its high water content. As compared to petrol fuel, biodiesel spills into natural bodies of water (e.g., lakes, rivers, and
groundwater aquifers) more quickly. The alkyl esters' hydrolysis, which yields methanol, may be a contributing factor to the undesired buildup of
biodiesel in waterways (Tyson, 1998). Additionally, the biodegradation process of biodiesel lowers oxygen, which may harm aquatic life. As a
result of biodiesel's greater solubility in water compared to petroleum diesel, marine animals are better protected against suffocating in the case of
fuel spills (Nguyen & Otsuka, 2016). (Yaqoob et al., 2021). Toxicology and biodegradability, particularly if they enter the aquatic environment
by mistake, are of issue with pure biodiesel and petro/biodiesel mixes even if they are safer than Petro diesel.

Typically, waste is generated in the washing column and the methanol recovery column. Impurities in biodiesel are washed away by water or
dissolved in it in the washing column, and the wastewater settles at the bottom and is subsequently disposed of at a wastewater treatment facility.
Additionally, treated water can be recycled back into the water storage tank if cost savings are desired. The wastewater that still contains methanol
less than 10% should be further treated if before disposal. Large manufactures of biodiesel can reuse and recycle waste by dedicating additional
cash toward the purchase of specialized treatment equipment. By product (crude glycerol) with a purity greater than 80% can be sold to a crude
glycerol refiner for additional purification before being used commercially (Bart et al., 2010).

25
6 Material Handling and storage

6.1 Sludge palm oil

Sludge palm oil is a byproduct of the palm oil milling process, when oil leaks into waste streams. As a biodiesel feedstock, it is non-edible,
inexpensive, and plentiful.
Table 13: Material Handling and Storage for Sludge Palm Oil.

Safe handling precaution

General precaution • If you accidentally inhale fumes or breakdown products, go outside into the fresh air.
• Handle in accordance with good industrial hygiene and safety practice.
• In the event of contact with the eye, flush it with water or an authorized eye wash solution.

Hygiene measure • Employ engineering measures to maintain airborne levels below exposure limit criteria or
recommendations. When there are no appropriate exposure limit limits or guidelines, use solely with
proper ventilation. Local exhaust ventilation may be required for some operations.

• Protect your eyes by using eyewear that has been approved by appropriate regulatory standards, such
as NIOSH (US) and EN 166. (EU)

Condition for safe storage

26
Incompatible products • Strong acid
• Strong alkali
• Strong oxidizing agent
• Pro-oxidants

Incompatible materials Direct sunlight, heat

Heat and ignition source Avoid open flames, hot surfaces, and sources of ignition.

Prohibitions on mixed storage Water

Storage area • Ensure adequate dry, well ventilated storage area between 50 – 120F.
• Keep in a cool sheltered place.

Special rules on packaging Do not use pressure to empty drums.

Packaging materials Storage in Bulk

In stainless steel or food grade epoxy walled closed containers at 10°C above the melting point of the oil. •
If the oil is kept for an extended period of time, nitrogen can be used as an inert headspace gas to extend its
life.

27
Stackable Product Storage.

Store in a cool, dry place, preferably off the floor, and away from direct sunlight.

28
6.2 Methanol

Methanol is a hazardous alcohol that is utilised in industry as a solvent, insecticide, and alternative fuel source. Methanol is used as one of the key
reactants in the esterification and transesterification processes in biodiesel manufacturing in this project. It's a deadly material that can go into your
eyes, skin, lungs, and digestive system. Excessive exposure can result in death. Workers' health might be jeopardized by exposure to methyl
alcohol. Dose, duration, and job all have a role in determining the degree of harm. As a result, it is critical to comprehend the safety precautions
and how to handle them properly.

Table 14: Material Handling and Storage for Methanol.

Safe handling precaution

General precaution • Use spark- and explosion-proof appliances and lights. Take electrostatic charge precautions.
• Keep clear from open flames or heat.
• Keep a safe distance from ignition sources/sparks.
• Take frequent measurements of the concentration in the air.
• Work in a local exhaust/ventilation system.
• Remove contaminated garments right away.
• Before using, thoroughly clean and dry the installation.
• Do not pour the garbage down the drain.

Hygiene measure • When using this product, do not eat, drink, or smoke.

29
 • Before eating or smoking, and before leaving work, wash your hands and other exposed areas with
mild soap and water.
• Before reusing infected clothes, wash it.

Condition for safe storage

Incompatible products • Strong oxidizers

• Strong bases
• Strong acids
• Acid anhydrides
• Acid chlorides

Incompatible materials Solar radiation. Sources of heat Ignition sources.

Heat and ignition source Keep away from any source of heat.

Prohibitions on mixed storage Flammable materials agents of oxidation powerful acids

Water/moisture. (strong) bases. halogens. amines.

Storage area • Store in a cool, dry place.

• Containers need to be ventilated.
• Store items away from sources of high heat, such as fireplaces or other open flames.

30
 • Make sure the container is well-sealed before storing.

Special rules on packaging Protect delicate packaging by encasing it in sturdy containers

Packaging materials • Steel

• Stainless steel
• Iron
• Glass

31
6.3 Biodiesel

It is a renewable, biodegradable fuel that is manufactured in the United States from vegetable oils, animal fats, or restaurant grease. A biomass-
based diesel and a complete advanced biofuel are both in compliance with the Renewable Fuel Standard (RFS). In certain circles, renewable diesel
is referred to as "green diesel," however the two terms are not interchangeable. Biodiesel is the end product of this project's process using sludge
palm oil. Our understanding of how to store and control this molecule is essential.

Table 15: Material Handling and Storage for Biodiesel.

Safe handling precaution

General precaution • Avoid skin, eye, and clothing contact.

• Use only in locations with adequate ventilation.
• Avoid using tobacco products.
• Don't spray mists into your lungs or inhale fumes.
• Do not use any tools that might cause a spark to fly.

Hygiene measure • Follow proper industrial hygiene and safety practises while handling.
• Recycled clothes should be thoroughly cleaned before re-use.
• In between breaks and after handling the product, be sure to thoroughly clean your hands.
• Do not eat, drink, or smoke while using.
• Do not flush into the water supply or the sanitary sewage system.

32
 Condition for safe storage

Incompatible products • Strong acids

• Oxidizing agent

Incompatible materials Sunshine, heat, fire and sparks may cause skin irritation.

Heat and ignition source Remove all sources of ignition.

Prohibitions on mixed storage These metals will hasten degradation if in contact with biodiesel

• Copper
• Brass
• Bronze
• Lead
• Tin
• Zinc

Storage area • Do not store near or with any of the incompatible materials.

33
 • Keep tightly closed in a dry, cool, and well-ventilated place.

Special rules on packaging Store in original container, cold and dark conditions.

Packaging materials • Aluminum

• Steel
• Fluorinated polyethylene
• Fluorinated polypropylene
• Teflon®
• Fiberglass

34
6.4 Sulphuric acid

Sulphuric acid is used to neutralize the base catalyst employed in the transesterification reactor in the manufacturing of biodiesel. The salt Na2SO4
will be formed as a result of the reaction. The 2012 OSHA Hazard Communication Standard considers this substance to be dangerous. – (29 CFR
1910.1200). To ensure the safety of this toxic material, adequate storage must be implemented.

Table 16: Material Handling and Storage for Sulphuric Acid.

Safe handling precaution

General precaution • Keep clear from open flames/heat.

• Take frequent readings of the concentration in the air.
• Respiratory protection gear may be used in the open or with local exhaust/ventilation.
• Follow all applicable laws and regulations. Remove contaminated clothing as soon as possible.
• Remove stains and odors from soiled clothing and keep the area sanitary.
• Before using, make sure the installation has been well cleaned and dried.
• Do not use the toilet to dispose of waste.
• Never dilute acid with water or add water to this product. Acid and water should always be mixed
together.

Hygiene measure • You should wash your hands and other exposed parts of your body with soap and water before you
eat, drink, or smoke.
• Before reusing infected clothes, wash it.

35
 • Do not eat, drink, or smoke while using this product.

Condition for safe storage

Incompatible products • Strong base

• Metal

Incompatible materials Materials that may catch fire

Heat and ignition source Do not go too close to a source of hot air.

Prohibitions on mixed storage Keep away from

• Combustible materials
• Reducing agents. (strong) bases
• Highly flammable materials
• Metals
• Cellulosic materials
• Organic materials
• Alcohols, amines
• water/moisture

36
Storage area • Storage should be done in a dry location.
• Floor-level ventilation is necessary.
• Keep secured.
• Provide a container for collecting spillage.
• No unauthorised people are permitted entry.
• Comply with all legal standards

Special rules on packaging Store in a closed, dry, clean and properly labeled container.

Protect delicate packaging in sturdy containers.

Packaging materials Suitable Materials:

• Stainless steel
• Carbon steel
• Polyethylene
• Polypropylene
• Glass
• Stoneware/porcelain

37
Materials to avoid:

• Monel steel
• Lead
• Copper
• Zinc

38
7 Accidental Release of Materials
In an operational plant, it is reasonable to assume that there will be spillage or accidental release of materials in some form. The effects of such
releases depend upon the level of hazard these materials pose and other factors such as flammability, exposure limit and environmental effects.
This type of spillage can occur due to human error or faulty design and handling, or errors that have not been accounted for.

Accidental release measures consist of guidance on how to react to spills, leaks, or releases, such as containment and cleaning techniques, in order
to minimize or decrease exposure to people, property, or the environment. It may also contain rules defining procedures for major and small spills
if the amount of the spill has a significant effect on the risk. These strategies serve in preventing adverse effects on both individuals and the
environment.

The table below discusses these measures for the biodiesel plant for all the components used in it , in the event of a leakage or spillage.

Table 17: Accidental Release Measures

Accidental release
Details
Measures

Protective Equipment.

For Plant Operators • Use spark and explosion proof equipment.

&Non-Emergency • Corrosion proof suit in case sulfuric acid is released

personal Emergency procedures:

• Shutdown and apply necessary control measures.

39
 • Contaminated area must be specified, marked, and announced.
• Evacuate all unnecessary personnel
• Ensure pressure controllers are functional and allow coolant to flow.
• Check for flames and other measurable increase in values.
• Contain the place and notify further contamination

Protective Equipment.

• Adequate protection from oils heat and corrosive substances must be provided.
• General PPE such as masks gloves etc must be worn.
• Contaminated area must be noted to avoid slipping.
For Emergency
Emergency procedures:
responders
• If possible, stop the leak through manual means with minimal contact
• Provide exhaust ventilation and other controls to guarantee that airborne or volatile compounds are ventilated
out and to limit exposure.
• Spilled chemicals can be restored in labelled containers.

• Chemicals must not reach the waterway through drains or sewers

Environmental
• Must not be released into environment
Precautions
• In case of larger spillage or release, emergency and environment agencies must be notified.

40
 • Leak maybe stopped through manual means and shutdown procedures
• Leaked substances carefully collected in containers
• In the case of triglycerides and oil, this may be contained and collected with sand or earth over them
Containment methods
• In case of acid area must be neutralized with proper ventilation through alkaline mediums.
• Absorb the above through clay absorbents
• Follow proper disposal methods preceding the above.

41
8 First Aid Measures
When someone is hurt, first aid is the first and most critical assistance they get. As seen above, a process plant's safety may be affected by a variety
of factors. Human health repercussions are one of these factors. The effects of plant components on eye and skin contact, inhalation, and ingestion
must be considered in the case of an accident. When a person is exposed to a chemical, unskilled first responders should provide first assistance.
The following table details the effects of different biodiesel plant chemical exposure and interaction.

Table 18: First Aid Measures

Hazard Occurrence First Aid Measure

• Wear chemical protective equipment

• Protect unexposed eye
Eye contact
• Rinse eyes that came in contact for 15-30 minutes
• Consult a physician if discomfort continues

• Soap and water must be used to clean the affected area

• Constantly flushed with clean water if it is a highly corrosive substance
Skin contact
• Remove all contaminated clothing for disposal or reuse.
• Immediately transport to a medical facility if exposed area is large.

Inhalation
• Safely remove or contain source of exposure if possible

42
 • Move the afflicted individual away from contaminated region to a region with fresh air.
• Use the buddy system and keep the afflicted rested.
• Consult a physician if discomfort continues

• Rinse the mouth completely.

Ingestion • Dilute mouth with water or milk if substance isn’t an acid.
• Immediately transport to medical facility if irritation persists and is too much.

43
 FUNCTION IDENTIFIER
FIRST LETTER SUCCEEDING LETTERS
REF MEASURED VALUE READOUT/FUNCTION MODIFIER
A ALARM
C CONTROL
D DIFFERENCE
F FLOW
H HAND HIGH
I INDICATE
L LOW
P PRESSURE
T TEMPERATURE TRANSMIT
TO V VALVE
DISTILLATION
COLUMN LEGENDS
D-101

TO
FLARE
OUTLET
STREAM

FROM
COOLING
WATER
TANK
T-101

PIPELINE TAG NUMBER

TYPE OF INSULATION

MATERIAL CLASSIFICATION

LINE INDE CODE

TO UNIT AREA CODE

CONDENSER CONVEYED FLUID

C-101 LINE SIZE NPS

CONVEYED FLUID PIPE MATERIAL

SM Sludge Palm Oil + Methanol 304LNST 304 LN STAINLESS STEEL

ME Methanol + Methyl Esters +

Triglyserides + small trace of FFA + CSAPI5L CARBON STEEL API 5L GRADE B.
Water. GB

CW Cooling Water

INSULATION MATERIAL

N No Insulation

PROJECT TITLE:
BIODIESEL PRODUCTION FROM
SLUDGE PALM OIL
CLIENT:
DEPARTMENT OF CHEMICAL
FEED ENGINEERING, UNIVERSITI MALAYA
SITE:
FROM
NISHINOYA SDN. BHD
M-101
KULIM, KEDAH
DRAWING TITLE:
R101 ESTERIFICATION P&ID - 01

UNIVERSITI MALAYA
DEPARTMENT OF
CHEMICAL ENGINEERING
JALAN PROFESOR DIRAJA
UNGKU AZIZ, 50603
KUALA LUMPUR,
MALAYSIA.
DRAWN: FARAHIN CHECKED: RAFLI
APPROVED: NAUFAL SCALE: NOT TO SCALE
SHEET: 001 REVISION: 001
DRAWING NUMBER: G12-IDP-PID-01
DATE:
07 JUNE 2022
THIS DRAWING IS SUBMITTED SOLELY
FOR INTEGRATEDN DESIGN PROJECT 2
OF THE DEPARTMENT OF CHEMICAL
ENGINEERING, UNIVERSITI MALAYA
10 HAZOP

10.1 Introduction

A Hazard and Operatability (HAZOP) assessment is a planned and methodical review of a proposed or existing process or operation in order to
identify and evaluate risks that might jeopardise personnel or equipment or hinder efficient operation. HAZOP The method's core components
HAZOP developed from the need to identify hazards linked with the chemical industry's handling of hazardous substances. The objective of the
technique is to identify hazards and minimise or eliminate potential sources of risk utilising the stated processes.

10.2 Objectives
HAZOP in this process plant aims at being the assessment for both safety (based on consideration of risks) and operability, ensuring the required
quality of the product biodiesel. The objectives of conducting this study are to:

• Define nodes and streams where study is conducted on the P&ID

• Form the HAZOP team
• Define all parameters and scoring guidelines of the system
• Fine tune process control methodology for the reactor
• Define safe operating procedures for the esterification reactor and related nodes
• Devise and tune safe operating limits for the esterification reactor and related nodes.

45
10.3 Methodology

To undertake the HAZOP research, a team must be assembled and criteria must be established based on location, operating circumstances in
relation to the environment, safety guards, and the effect of this process plant on humans. The reactor's operating conditions must be assessed, and
the HAZOP research will be undertaken based on the biodiesel plant's P&ID's identified Nodes. Along with the established criteria, a list of often
used guiding words will be included and utilised in the report. Scoring and risk assessment will be based on likelihood of occurrence, effect on
individuals and the environment, and failure of safety measures. The risk rating will assess the danger levels of the plant's numerous situations and
events. This will establish a level of prudence and serve as a contingency plan for practically all potential mishaps, whether they involve people
or the environment. The research will also examine how these circumstances impact the production or productivity of biodiesel as a whole.

10.4 HAZOP Team

1. Rafli Rozaan Zuhdi
2. Muhammad Naufal Fadhlurrahman
3. Nurul Farahin binti Badaruddin
4. Vishwesh Prakash
5. Muhammad Imran bin Md Ariff Noor

46
10.5 Operating Conditions of the reactor

Table 19: Reactor Operating Conditions

Operating Conditions of Streams

Parameters
Reactor Inlet (Stream) Reactor Outlet (Stream )

Phase Liquid Liquid

Temperature (°C) 105 105

Pressure (kPa) 600 600

Flow rate (kgl/hr) 3000 3000

47
10.6 Scoring guidelines & legend

Table 20: Guide Word Description

Guide word Description

More Quantitative increase in a parameter

Less Quantitative decrease in a parameter

No Design intentions are not achieved

As well as Occurrence of an additional activity

Part of Certain Design intentions achieved

Reverse Opposite of design intention occurs

Other than Substitution of intended activity

Early/late Intended timing is different

Before/after Sequence is out of order

48
Faster/slower Step is not done in the right timing

Where else Applicable for different flows, transfers and destinations

Different from Component type is different from intended

49
 Table 21: Common HAZOP Parameters

Parameters Guide Words

Flow rate No, reverse, more(high), less(low), as well as, other than

Temperature High, low

Pressure High, low

Level No, High, low

Reaction No, fast, slow, other than, (unwanted reaction)

Start-up/shut down Fast, slow, other than (action missed)

Time More, less, other than (wrong time)

Viscosity High, low

Composition As well as

Communication No, more, less, as well as, other than

50
Probability of occurrence score (Score O)

Table 22: Score Guide for Probability of Occurrence

Score Order of magnitude (frequency or likelihood) Qualitative

+1 A few times a year. Expected to happen on a regular basis or often.

0 Every year. Possibly occurring on a single or several occasions during the course of a
plant's life.

-1 Probability is 10% every year. Probably happens more than once in a plant's life span.

-2 Annually, there is a 1% possibility. It's unlikely, but it might happen within the plant's lifespan.

-3 a one-in-a-thousand-year chance If this occurred within the plant's life span, it would be quite unusual.

-4 An annual probability of one in ten thousand Extremely unlikely, or at least not anticipated

51
Environmental Impact score (Score E)

Table 23: Score Guide for Environmental Impact

Score Effects expected to occur exclusively on-site Effects expected to occur off-site

6 • Devastating release to the institution

• Consequences in the long run
• Significant fines/penalties are likely.

• Significant release
5 • Devastating release to the institution
• A significant change to the environment
• Consequences in the long run
• The long-term consequences are probable.
• Significant fines/penalties are likely.
• Penalties and fines are probable.

• Minor release to facility/outside help needed

4 • Releasing a large quantity of hazardous materials
• Short term impact likely
• The long-term consequences are probable.
• Legal/public relation consequences
• Penalties and fines are probable.
• Internal resources were used to handle this major release.
3 • Minor release to facility/outside help needed
• Neither a legal nor a public relations problem.
• Effects will be felt quickly.
• Legal/public relation consequences
• Internal resources were used to handle this minor release.
2 • Internal resources were used to handle this major release.

52
 • Neither a legal nor a public relations problem. • Neither a legal nor a public relations problem.

• Impact on the environment is doubtful

1 • Internal resources were used to handle this minor release.
• Neither a legal nor a public relations problem.
• None
0 • Impact on the environment is doubtful

53
Impact on people score (P)

Table 24: Score Guide for Impact on People

Score Unlikely, however a single person on- Likely to affect 1-2 people on-site Likely to affect 5-20 people on-site or
site may be impacted. off-site

6 - - Death

5 - Death Immediate damage; long-term

consequences for health

4 Death Immediate damage; long-term Lost time and a serious injury

consequences for health

3 Immediate damage; long-term Lost time and a serious injury An injury that needs medical attention.
consequences for health

2 Lost time and a serious injury An injury that needs medical attention. Unserious harm

1 An injury that needs medical attention. Unserious harm Probably unlikely

0 Unserious harm Probably unlikely Unlikely

54
Perceived risk of protection breakdown (Score SG)
Table 25: Score Guide for Safeguard Failure Probability

Score Probability of safeguard failure Example

0 100% • No
• No safeguard
• Operator
• Operator in difficult position

1 10% • A single operator with sufficient time (>5 minutes) fails to do the proper action. One in
ten times

2 1% • Single
• Single set hardware, functionally tested
• Automatic
• Automatic shutdown procedure

3 0.1% • Passive
• Passive protection (explosion disk)
• Combination

55
 • Combination of score 1&2

4 0.01% • Two separate hardware platforms

Risk rating and prioritization

Table 26: Risk Rating Description

Risk Risk rating Descriptions

level score

1 -4 to -1 Due to established protections, there is little chance of harm.

2 0 to 3 Risk management procedures are necessary, however the risk is low.

3 4 to 8 It's a high-risk situation, but precautions must be taken to mitigate it.

4 9 to 13 Unless risk management procedures and extra safety precautions have been taken to decrease the risk and hazard,
this component or method cannot be used.

56
 11 HAZOP WORKSHEET
Table 27: HAZOP Worksheet

Study title: Production of Biodiesel from SPO Date: 07/06/2022

Node: Trickled Multi-tubular Packed Bed Reactor Drawing Number: G-09-P&ID-01

Node Description: Reaction in Trickled Multi-tubular Packed Bed Reactor Equipment line: -

Design Intent Material: Methanol, Triglycerides, methyl esters Activity: Esterification of FFA Content in the Production of Biodiesel from Sludge Palm Oil

Source: Mixer Destination: Distillation Column

Node/Stream Parameter Guide Deviation Causes Score Consequences Score Score Safeguard Score Risk Risk Actions
Word (O) (E) (P) (SG) Rating Level

A. Reactor Flow No No Flow of reactant 1. Control Valve Fail to -3 • No Reaction occurs. 0 0 a) Regular checking and 4 -3 1 i. Instruct operator
Inlet into the reactor close and malfunction. • Pressure decrease in maintenance on the on necessary
line before vessel valve. procedures when
could lead to b) Install Flow controller alarm rings.
rupture of the pipe. indicator to notify the ii. Use manual bypass
• Product Yield operator in an event of valve
reduction the flow falls below or iii. Regular Checking

• Pressure decreases above the threshold and maintenance

in the reactor level. on the valve.

possibly damage c) Introduce manual

reactor. bypass valve.

2. Blockage in pipeline -2 See 1 0 0 Covered by a), and b) 3 0 2 Covered by (i),(ii),(iii)

d) Regular Checking and iv. Regular Checking

maintenance on the and maintenance
pipeline on the pipeline.

3. Signal lost and valve -3 See 1 0 0 Covered by a), b), c) 4 0 2 Covered by (i), (ii),(iii).
malfunction. e) Install Back-up
controller

57
 4. No reactant supply -4 See 1 0 0 Covered by b) 2 -4 1
from the tank f) Introduce Tank Level
Control in the sludge
palm oil tank.

5. Pipeline rupture -4 See 1 3 3 Covered by b), and d) 3 3 2 Covered by (i),

(ii),(iii),(iv).
• Hot Reactants can
cause Skin burn that v. Pipeline materials
later can cause selection should be
infection. checked.
• Area surrounding
the pipe is
contaminated and
slippery.

Low Low Flow of 6. Full or partial Blockage -2 See 1 0 0 Covered by b), c), and d) 2 0 2 Covered by (ii), (iv)
Reactant into the in Valves and pipelines
• Reverse flow can
reactor
occur.
• Desired flow ra2e
does not achieve.

7. Leakage of Pipe -2 See 1 and 5 1 0 Covered by b), and d) 3 2 2 Covered by (ii), (iv), (v).

8. Control valve failed to -3 See 1 0 0 Covered by a), b), and c) 1 -2 1 Covered by (i), (ii), (iii)
respond or partially
open.

High Excess Flow of 9. Control valve failed to -3 • Reactor temperature 1 1 Covered by a), and b). 2 -1 1 Covered by (i), (iii)
Reactant into the close. increase due to
reactor. reaction occurs
more aggressive.
Possibly cause
runaway reaction.
• Damaged pipe
caused by the High

58
 pressure of the
reactant

10. Controller fails and the -3 See 9 0 0 Covered by b), and e). 2 -1 1 Covered by (i), (iii)
valve becomes open.

Reverse Reverse Flow of 11. High pressure in the -4 See 1 first bullet, 1 1 Covered by b) 2 2 2 Covered by (i), (iii)
reactant. reactor.
• Pipe damaged due g) Install Check-Valve
to the increase in
the pressure inside
the pipe.

Pressure Low Inlet pressure 1. Low/less flow of -3 • Covered in ‘Low 0 0 a) Install Pressure 4 -3 1 Covered in ‘Low Inlet
decrease. reactant into the Inlet Flow’ controller indicator to Flow’
reactor notify the operator in
an event of the
pressure falls below or
above the reaction
pressure condition.

Covered in ‘Low Inlet

Flow’

High Inlet pressure 2. High flow of reactant -3 • Covered in ‘High 1 1 Covered in ‘High Inlet 3 3 2 Covered in ‘High Inlet
Increase. into the reactor. Inlet Flow’ and Flow’ and ‘Reverse Inlet Flow’ and ‘Reverse Inlet
3. Backflow of reactant flow. ‘Reverse Inlet Flow’ Flow’
Flow’

Temperature Low Inlet temperature 1. Low temperature of -3 • Target conversion 0 0 a) Install Temperature 3 -3 1 i. Instruct operator
decrease. Reactants flow inlet cannot be achieved. controller indicator to on regular check
from the mixer. • Product yield notify the operator in on the conditions
reduction. an event of the of the mixer
• Reaction rate temperature falls outlet.
decreases. below or above desired ii. Regular checking
temperature. on the temperature
and flowrate.
Covered by ‘Low Mixer
Outlet Temperature’

59
 2. Faulty instrumentation -1 See 1 Covered by ‘Low Mixer 2 -1 1 Covered by (i) and (ii)
and control. Outlet Temperature’

High Inlet Temperature 3. High temperature of -3 • Catalyst will be 2 1 Covered by a) 3 -1 1 Covered by (i), (ii)
Increase, Reactants flow inlet damaged and reduce Covered by ‘High Mixer
from the mixer. the conversion. Outlet Temperature’
• Pressure in reactor
will increase.
• Output flow will
exceed the desired
temperature

B. Coolant Flow No No coolant flow 1. Control valve fails and +1 • Heat is not absorbed 2 2 a) The operator may be 1 2 2 i. When the
Inlet through reactor closes by the reactor, hence alerted by installing a alarm goes off,
the temperature rises flow indicator and low give the
as a result. flow alarm. operator
• There is a risk of a b) Put in a manual instructions on
reactor exploding bypass valve. what to do.
due to a thermal
runaway.
• Unwanted side
effects may become
more common.
• Coolant builds up in
the storage tank,
creating pressure.
See 1
2. When the controller +1 2 1 Included in a) and b) 2 2 2 Included in by (i)
fails, the valve is shut c) Set up a backup
off.
See 1
3. A complete -1 2 1 Included in a) 2 -1 1 Included in (i)
obstruction of the ii. Routine pipe
pipe. line inspection

60
 and
maintenance

4. Pipe burst -2 • Contaminated areas 1 0 Included in a) 3 -4 1 Included in (i), (ii)

might result from
d) Regular Checking iii. Check
coolant spills.
and maintenance on suitability of
the pipeline pipe
construction
material
See 1
5. The pump is turned 0 2 2 Included in a) 3 1 2 Included in (i)
off (motor fault, loss e) Regular maintenance iv. Regular
of drive, impeller of pump inspection and
corroded away) f) Install back-up pump maintenance on
pump

More Excess coolant flow 6. Increased coolant flow +1 • As more heat is 0 0 Included in b) 3 2 2 Included in (i)
through the reactor due to malfunction in absorbed into the g) Install a flow indicator
cooling water pump. reactor, the reaction and an alarm for high
rate lowers. flow to notify the
• The goal of operator .
achieving the target
conversion was not
met.
• Cooling of reactor
• Product yield is
reduced.
See 6
7. Controller fails and +1 0 0 Covered by a), b), c), and 2 -2 1 Covered by (i)
opens the valve g)

Reverse Backflow of coolant 8. High pressure in +1 • Damage to the pipe 1 1 Covered by a) 3 -2 1 Covered by (i)
reactor occurs as the h) Install a check
pressure in the pipe valve to prevent the
rises. flow going the other
direction.

61
 • More or less heat is
absorbed due to the
lack of coolant flow
entering the reactor.
• Possible thermal
runaway

See 8
9. Pump failure 0 1 1 Included in a), d), (e) 2 1 2 Included in (i)
See 1
Less Low coolant flow 10. Control valve failed +1 2 2 Included in a), b) 4 1 2 Included in (i)
through the reactor

See 1
11. Partial blockage of 0 2 1 Included in a) 3 1 2 Included in (i), (ii)
pipe

See 1
12. Leakage of pipeline -1 2 1 Included in a) 2 0 2 Included in (i), (ii)

See 1
13. Failure of a pump 0 2 2 Included in a), d), and (e) 2 1 2 Included in (i), (iv),

v. Check pump
power
requirements
Increase in reactor
Other In addition to the 14. Contamination of 0 0 0 (h) Prepare back-up coolant 2 -1 1 vi. Renew coolant
temperature as a
than coolant, there are cooling source and the from time to
result of inadequate
other materials. function of cooling is time to avoid
cooling
lost cooling
function loss.

Pressure Low Decrease in coolant 1. A low flow rate of -3 Included in ‘Low coolant 1 1 Included in ‘Low coolant 3 -1 1 Included in ‘Low coolant
inlet pressure coolant inlet flow’ inlet flow” inlet flow’

2. Pump Failure 0 Included in ‘Low coolant 1 1 Included in ‘Low coolant 3 -1 1 Included in ‘Low coolant
inlet flow’ inlet flow’ inlet flow’

62
 High Pressure at the 1. High Flow of Coolant -3 Covered in ‘Low coolant 0 0 Covered in ‘Low coolant 3 -2 1 Covered in ‘Low coolant
coolant intake rises. inlet inlet flow’ inlet flow’ inlet flow’

C. Reactor Temperature Low Low operating 1. Malfunction in the +1 • A decrease in the 0 0 Covered in “Coolant Inlet 3 -3 1 i. Covered in
Vessel temperature inside cooling water pump which reactor operating Flow (a), (d), and (e)” ‘Excess coolant
the reactor vessel causes overflow of cooling temperature as excess inlet flow’
water heat is being removed ii. Instruct
by coolant operator on
• A decrease in the procedures
reactor rate of reaction when alarm
• Reduced conversion rings.
rate by the reactor
• Reduced yield of
product is achieved

High High operating 2. Malfunction in the -3 • An increase in the 2 2 Covered in “No coolant 3 3 2 iii. Covered in ‘Low
temperature inside cooling system controller reactor operating inlet flow (a), (b), and (c)” and No coolant
the reactor vessel which closes cooling valve temperature as less/no inlet flow’
heat is being removed iv. Instruct the
by coolant operator on how to
• Possible thermal handle an alert
runaway which can when it comes in.
cause explosion of
reactor
• Damage of catalyst
used

3. Faulty reading from -1 See 2 2 2 3 2 2 Covered by (iii) and (iv)

thermometer transmitter
instrument

4. Rupture of cooling water -1 See 2 2 1 Covered by “No coolant 3 3 2 Covered by (iii) and (iv)
inlet pipe Inlet Flow (a) and (d)”

63
 5. No cooling water supply
from the tank
0 See 2 2 2 • Install Flow controller 2 3 2 Covered by (iii) and (iv)
indicator to notify the
operator in an event of
the flow falls below or
above the threshold
level.
• Introduce tank level
control in cooling
water tank

Pressure Low Low operating 1. Decrease in reactants -2 Covered in “low Reactor 0 0 Covered in “low Reactor 4 -2 1 Covered in “low Reactor
pressure inside the inlet/outlet flow rate inlet flow” inlet flow” inlet flow”
reactor vessel into the reactor

High High operating 2. Increase in reactants Covered in “high Reactor 2 2 Covered in “high Reactor 4 3 2 Covered in “high Reactor
pressure inside the inlet/outlet flow rate inlet flow” inlet flow” inlet flow”
reactor vessel into the reactor

D. Reactor Flow No No flow of product 1. Control valve fail closed/ -1 • Excess pressure build- 2 1 a) Regular checking and 3 2 2 i. Checking and
Outlet out the reactor malfunctioned. in reactor maintenance on the maintenance of
• Low pressure in pipe valve. valve in calculated
due to reactant (SPO b) No/low Flow indicator intervals
build-up) control installed to ii. Operator to be
• Excess pressure notify the operator of made aware of
difference can cause flow decrease. necessary
pipe damage. c) Introduce manual procedures when

• Product yield decreases. bypass valve. alarm rings.

iii. Use of bypass
valve during
failure of main
control valve.

2. Control signal lost +1 See 1 1 1 Covered by ( a) , ( b ), ( c ) 4 -1 1 Covered by (i), (iii)

causing valve to fail close d) Install backup iv. Use the installed
controller backup controller

64
 3. Total blockage of pipe -1 See 2 2 1 Covered by ( b ) 2 3 2 Covered by (i) , (ii)

• Can lead to leakage or v. Conduct regular

explosion due to maintenance on
pressure build-up. outlet pipes.

4. Rupture of pipe
1
-2 • Contamination of area 2 2 Covered by (a), (b) 3 2 Covered by (i) , (ii)
due to spillage. vi. Ensure suitable
• Scatter of product and material is used
pipe material which is a for pipe
fire hazard. construction
• Leakage of Hot
reactants which may
result in burns.
• Loss of valuable product
output.

Low Low flow of product 5. Failure of control valve 0 Covered in ‘no product 0 0 3 -2 1
out of the reactor flow’

6. Partial blockage of pipe. 0 Covered in ‘no product 1 0 Covered by (a), (b) 4 2 2 Covered by (i), (iii), (iv)
flow’

• Less product yield with

sedimentation in pipe
lining

7. Leakage of pipe -1 Covered in “no product 1 1 Covered by (a), (c) 3 0 2 Covered by (i), (ii), (v),
flow” (vi)

High High flow of product 8.Control valve fail -2 • Increase of pressure in 1 0 e) Install a high flow 3 -1 1 Covered by (i) , (ii), (iii)
opened pipes thereby
out the reactor meter with an alarm to
damaging them, alert the operator. when
• Excess feed nay lead to the flow is higher than
more pressure build up threshold level

65
 9. Controller signal -1 See 8 1 0 Covered by (a) , (c), -1 1
lost and valve opens

Reverse Backflow of product 10. Pressure in reactor too -2 Covered in ‘low flow of 1 1 Covered by “low flow of 3 -4 1 Covered by “low flow of
into the reactor low product out the reactor’ product out the reactor product out the reactor

Pressure Low Outlet Pressure 1. Low/less flow of outlet -3 Covered in ‘Low flow of 0 0 Covered by “low flow of 4 -1 1
decrease from the reactor. product out of the reactor’ product out the reactor

High Outlet Pressure 2. High/increase flow of -3 Covered in ‘High flow of 1 0 Covered by “low flow of 3 0 2
Increases outlet from the reactor product out of the reactor’ product out the reactor

E.Coolant Flow No No coolant flow out 1. Total blockage of pipe -1 • As coolant 2 2 a) Install no/low-flow 2 0 2 (i) When the alarms
Outlet of the reactor accumulates in the indicator with alarm to go off, walk the
reactor, the pressure alert the operator when operator through
rises. the flow is lower than the steps.
• When the pressure threshold level. (ii) Ensure that pipes
increases, explosion and tubes are
may occur as it inspected and
exceeded the maintained on a
operating pressure regular basis.

Less The flow of coolant 2.Leakage of tubes in -1 • Contamination of 0 0 Covered by (a) 3 0 2 Included in (i),(ii)
out of reactor reactor; coolants may enter product and cause
decreases the product stream the quality of the
product to decrease.
• Increased pressure
in product stream.
• Workers' skin may
be burned if hot
outlet coolants leak
from the reactor and
splash on them.

3.Leakage of pipeline -1 See 2 0 1 Covered by (a) 2 -3 1 Included in (i),(ii)

66
 (iii)Check suitability of
the material of the
pipe

More Not possible -3 0 0 4 -4 1

Other Other material 3. The coolants mixed -1 • The coolant is 2 2 4 3 2 Included in (ii)
than besides the coolant with reactants in the contaminated, and (iii) Check the
reactor shell due to cooling function is suitability of the
the leakage of lost material built for
reactor • Temperature of the the reactor’ s
reactor increases tubes.
due to ineffective (iv) Replace the
cooling coolant regularly

Temperature Low Decrease in existing 1. Less reaction -1 • Covered by “low 1 0 (a) Install temperature 3 1 2 (i) Coolant outflow
coolant’s temperature occurred inside the reactor outlet indicator temperature is
reactor hence less temperature" checked often by
heat is absorbed the operator ,
Included in the scope
of ” low reactor outlet
temperature"

High Temperature of 2. More heat is -1 • Included in the 1 0 Included in (a) 3 1 2 Included in (i)
coolant is increased absorbed as a result scope of "high Included in the Included in the scope of“
of the increased reactor outlet scope of “ high high reactor outlet
reaction in the temperature" reactor outlet temperature”
reactor. • Included in the temperature”
Included in (i)
3. The coolant has scope of “other than
been polluted, and in coolant inlet Included in (a) Included in the scope of
as a result, no flow” Included in the “other than in coolant inlet
longer provides scope of “other than flow”
cooling. in coolant inlet
flow”

67
12 Conclusion

This study contains a comprehensive safety assessment of the biodiesel production process facility. Because most hazards can be mitigated by
control techniques, it may be argued the reactor/process facility is low-risk.

To sum it up, no matter what industry you work in or how big or small your company is, you must prioritise workplace safety. When working in
a chemical facility that includes a reactor, everyone on the ground is at danger if safety procedures are not followed. There is a significant
difference between the cost of injury prevention and the cost of injury and hospitalisation. Because the product yield does not satisfy the client's
expectations, the downstream of chemical facilities might be disrupted, resulting in a financial loss for the firm because of this. The quality and
trust of a company's workforce may be improved as well as the productivity of its workers by implementing workplace safety measures. Having
more trust in the company's security would make them more loyal and provide a better work environment. The importance of a safe work
environment should be emphasised at all levels of the chemical process industry, from the top down.

68
13 References
Bart, J. C. J., Palmeri, N., & Cavallaro, S. (2010). 13 - Valorisation of the glycerol by-product from biodiesel production. In J. C. J. Bart, N.
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SAFETY, PID, AND HAZOP
ORIGINALITY REPORT

15 %
SIMILARITY INDEX
9%
INTERNET SOURCES
3%
PUBLICATIONS
11%
STUDENT PAPERS

PRIMARY SOURCES

1
Submitted to University of Malaya
Student Paper 7%
2
repository.upenn.edu
Internet Source 1%
3
www1.nyc.gov
Internet Source 1%
4
Submitted to University of South Florida
Student Paper 1%
5
ir.canterbury.ac.nz
Internet Source 1%
6
mylakerlink.socc.edu
Internet Source <1 %
7
Submitted to King Fahd University for Petroleum and Minerals
Student Paper <1 %
8
Submitted to University of Wales Swansea
Student Paper <1 %
9
sds.staples.com
Internet Source <1 %
10
link.springer.com
Internet Source <1 %
11
www.criticalthink.info
Internet Source <1 %
12
www.vectorchemicals.com
Internet Source <1 %
13
scholar.lib.vt.edu
Internet Source <1 %
14
worldwidescience.org
Internet Source <1 %
15
Submitted to Durban University of Technology
Student Paper <1 %
 <1 %
16
Submitted to University of Central England in Birmingham
Student Paper

17
rgd.mcw.edu
Internet Source <1 %
18
ataman-kimya.com
Internet Source <1 %
19
C. Hlongwane, I. G. Delves, L. W. Wan, F. O. Ayorinde.
"Comparative quantitative fatty acid analysis of triacylglycerols
<1 %
using matrix-assisted laser desorption/ionization time-of-flight
mass spectrometry and gas chromatography", Rapid
Communications in Mass Spectrometry, 2001
Publication

20
archive.org
Internet Source <1 %
21
Submitted to Kuwait University
Student Paper <1 %
22
dc.indymedia.org
Internet Source <1 %
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Burdock, . "Fenaroli's Handbook of Flavor Ingredients, Fifth
Edition", Fenaroli s Handbook of Flavor Ingredients Fifth Edition,
<1 %
2004.
Publication

24
Hu, Lian, Deqi Chen, Yanping Huang, Le Li, Yiding Cao, Dewen
Yuan, Junfeng Wang, and Liangming Pan. "Investigation on the
<1 %
performance of the supercritical Brayton cycle with CO2-based
binary mixture as working fluid for an energy transportation
system of a nuclear reactor", Energy, 2015.
Publication

25
Submitted to Wright State University
Student Paper <1 %
26
en.unionpedia.org
Internet Source <1 %
27
Submitted to University of Arizona
Student Paper <1 %
28
en.wikipedia.org
Internet Source <1 %
29
www.kenneyandross.com
Internet Source
 <1 %
30
www.venturafoods.com
Internet Source <1 %
31
digital.lib.washington.edu
Internet Source <1 %
32
ljscleaningsolutions.com
Internet Source <1 %
33
www.bulkactives.com
Internet Source <1 %
34
www.frackfreeeastyorkshire.com
Internet Source <1 %
35
Submitted to Aston University
Student Paper <1 %
36
Pranav Shah, Kejal Chavda, Bhavin Vyas, Shailaja Patel.
"Formulation development of linagliptin solid lipid nanoparticles
<1 %
for oral bioavailability enhancement: role of P-gp inhibition",
Drug Delivery and Translational Research, 2020
Publication
37
extension.psu.edu
Internet Source <1 %
38
onlinelibrary.wiley.com
Internet Source <1 %
39
tandfonline.com
Internet Source <1 %
40
Federico Galli, Nicolas A. Patience, Daria C. Boffito. "Chapter 9
High-Temperature Conversion of Fats: Cracking, Gasification,
<1 %
Esterification, and Transesterification", Springer Science and
Business Media LLC, 2018
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