Tối Ưu Hóa và Vận Hành Các Quy

Trình Công Nghệ Hóa Học

(Optimization and Operation of
Chemical Processes)

Chapter 5. Common Hazards in

Chemical Processing Plants
 Tài liệu tham khảo
 Ian Sutton (2014). Plant Design and Operations, Gulf Professional Publishing
 Center for Chemical Process Safety, (2016). Introduction to Process Safety for
Undergraduates and Engineers, Wiley, USA
 1: General Unit Operations and
Their Failure Modes

This section describes the process hazards of common

unit operations and types of equipment found in chemical,

biochemical, petrochemical facilities

 Pumps, Compressors, Fans

Pumps, compressors and fans are used to move fluids from

one point to another. In doing so, they impart energy, in
the form of pressure and temperature, to the fluid being
moved. If they are run with the inlet and or outlet blocked
they can heat the contained fluid. As rotating equipment
items, they will have seals around rotating shafts, whose
failure can lead to leaks.
 Pumps, Compressors, Fans

 Pumps, compressors and fans are used to move fluids from

one point to another. In doing so, they impart energy, in the
form of pressure and temperature, to the fluid being moved. If
they are run with the inlet and or outlet blocked they can heat
the contained fluid. As rotating equipment items, they will
have seals around rotating shafts, whose failure can lead to
leaks.
 Common failure modes for pumps and compressors include
stopping, deadheading and isolation, cavitation/surging,
reverse flow, seal leaks, casing failures, and motor failures
 Pumps, Compressors, Fans

What is a Mechanical seal?

Mechanical seal—provides a leak-tight seal on a pump; consists

of one stationary sealing element, usually made of carbon, and one
that rotates with the shaft.
Mechanical seal system có tác dụng ngăn ngừa sự rò rỉ của lưu
chất qua lỗ tròn qua đó thanh truyền động đi xuyên qua (từ motor
đến buồng bơm)
Pumps, Compressors, Fans
Pumps, Compressors, Fans
Pumps, Compressors, Fans
 Heat Exchange Equipment
 Failures in heat transfer equipment can lead to loss of
temperature control, contamination of one of the fluids or loss
of containment. Temperature is frequently a critical process
variable, so failure of this equipment due to fouling, plugging,
or loss of the heat transfer fluid supply can lead to serious
consequences.
 Due to its nature, heat exchange equipment can see thermal
stress due to temperature gradients. This can lead to loss of
containment. Leaks due to corrosion or erosion are another
common failure mode. Failure to keep the fluids separate due
to tube leaks can result in reactive chemical incidents or release
of a toxic or flammable material into the low pressure side
where it can escape elsewhere, such as at a cooling water
tower.
Heat Exchange Equipment
Heat Exchange Equipment
 Mass Transfer Equipment

Distillation, stripping and absorption frequently involve

flammable materials; therefore, loss of containment can result in
fires and explosions. High temperatures are used, especially in the
reboilers, to drive the distillation/stripping; therefore the thermal
stability of the materials being handled needs to be understood.
Loss of cooling to a reflux condenser can affect the composition
of materials in a distillation, which again leads to the need to
understand the effect of composition on the thermal stability
characteristics of the material being handled. High levels of liquid
in columns can lead to plugging of internals, high pressure, and
loss of containment. Higher liquid loading on trays can result to
damage to trays and result in more serious temperature upsets.
 Mass Transfer Equipment
Packing material fires. Hydrocarbon residue that remains on
column packing can self-ignite at elevated temperatures when
exposed to the atmosphere.
Adsorption. Adsorption processes are exothermic. Carbon bed
adsorbers are subject to fires due to this overheating. If a
flammable mixture of fuel and oxygen are present, the heat
released by adsorption or reaction on the surface of the carbon
may pose a fire hazard
Extractors. Extractors will contain two immiscible fluids plus
some materials being transferred from one phase to another. Loss
of containment can result in flammable or toxic releases. Failure
of level control in extractors can result in the wrong material
being sent to downstream equipment, leading to high levels or
pressure in downstream equipment.
Mass Transfer Equipment
Mass Transfer Equipment
 Mechanical Separation / Solid-Fluid Separation
Mechanical separators are used to separate solids from liquids or
gases. Typical equipment includes:
 Centrifuges
 Filters
 Dust collectors
Common failure modes for centrifuges include mechanical
friction from bearings, vibration, leaking seals, static electricity,
and overspeed. Static charges can occur from the flow of the
slurry and liquor into the unit, and the high speed of centrifuges.
Static charges can accumulate due to the use of synthetic,
nonconductive filter media. Both mechanical friction and static
can ignite flammable liquids if used.
Dust collectors are the equipment item most frequently involved in
dust explosions. Common failure modes for dust collectors
include loss of containment due to failure of the filter media,
plugging of the filter media, and loss of grounding of filter bags.
 Reactors and Reactive Hazards
The key process safety concern in the design of reactors is
runaway reactions. Runaway reactions occur when the heat
generation rate from an exothermic reaction exceeds the rate at
which heat can be removed, causing an uncontrolled rise in
temperature. Then, the reaction rate will accelerate (runaway)
and may result in an excessive gas evolution or a vapor pressure
increase that, in the absence of adequate overpressure relief
protection, can rupture the reactor. If overpressure
relief protection is adequate, then there will be loss of
containment through the relief device.
The temperature rise can also favor additional exothermic
reactions. If this occurs, the composition may shift to produce a
more toxic off-gas.
 Reactors and Reactive Hazards
Common failure modes for reactors include: agitation failure,
cooling system failure, mischarges (too much or too little of a
reactant charged), or the wrong reactant charged, or reactants
charged in the wrong order, and reactant quality (wrong
concentration, reactant beyond shelf life).
During the reaction, the reactants and solvents need to be well
mixed for the reaction to proceed as planned and for efficient
input or removal of heat. Thus loss of agitation can be a cause
of a runaway reaction. A subset of agitator failure is starting an
agitator too late. This allows a buildup of reactants that then
suddenly are brought into contact with each other. Loss of
cooling or insufficient cooling can likewise be a cause of a
runaway reaction.
 Reactors and Reactive Hazards

Examples of mischarges leading to runaway reactions would

be an undercharge of a solvent meant to absorb some of the
heat of reaction, or overcharging a material that could result
in a more exothermic reaction than the system was designed
for. Charging a reactant that is at a higher concentration than
expected is an example of this. Many reactions involve a
catalyst. Using a catalyst that is past its recommended shelf
life or undercharge of a catalyst can lead to the buildup of
unreacted material that can then react and liberate more heat
than the reactor was designed for
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Fired Equipment
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