6.

1 Environmental Impact Analysis

6.1.1 Environmental Impact Analysis

Environment Impact Analysis (EIA) is a comprehensive approach to project

evaluation where environment factors in addition to economic and technical
consideration are given appropriate consideration in the decision making process. The
purpose of an EIA study is to determine the potential environmental, social and health
effects of a proposed development. EIA compares various alternatives for a project and
seeks to identify the one which represents the best combination of economic and
environment cost and benefits.

EIA can ensure that the subjectivity and duplication of effort are maintained and
the short term and long term consequences of inappropriate decisions are avoided. In
order to be effective, EIA should be implemented in the early stages of projects
planning and design. Instead of utilizing it after the design stage is completed, it should
be an integral component in project design. The EIA procedure should be applied to all
actions likely to have a significant environment effect. It should have following
objectives:

• Ensure environmental factors are considered in the decision making

process
• Ensure that possible adverse environment impacts are identified and
avoided or minimized
• Inform the public about the proposal

1
Quantities of Waste Discharges from the Plant

Waste minimization is our top significance selection in prevention of future

hazardous waste problems. By using materials more efficiently, industry can reduce the
generation of the waste and achieve the desirable protection of human health and the
environment. At the same time, the costs of waste management and regulatory
compliance can be lowered and long-term liabilities and risks can be minimized.

But the regulatory requirements and the cost of complying with them that make it
difficult for industry to give waste minimization the priority and resources it deserves if
it is to have broad implementation. In practice, waste minimization is sometimes
subordinated to pollution control, even though reducing waste can be most effective
way to prevent environmental risk. Pollution control has dominated over waste
reduction for a long period of time and is only being reserved. There are several
approaches to pollution prevention and waste minimization:

i. Improving process technology and equipment that alter the primary

sources of waste generation.
ii. Improving plant operations, such as housekeeping, material handling
and equipment maintenance and monitoring and waste tracking;
automating process equipment and integrating mass balance calculations
into process design.
iii. Recycling a potential waste or portion of it on the site where it is
generated.
iv. Substituting raw materials that introduce fewer hazardous substances or
smaller quantities of such substances into production process.
v. Re-designing or reformulating the end products. Recycling is usually
the step before pollution control, which may make it the easiest to
recognize and implement. However, there are important economic limits
to recycling and often other waste reduction opportunities offer
greater benefits.

2
 Summary of Waste from Plant

The waste water from the bottom of quench tower must be decanted and sent for
further processing before discharge.

Table 6.1: Summary of waste from each source.

Flow rate Composition of waste
Source of Waste Mole flow rate (kmol/h)
(ton/hr) water
V-101 Bottom of 1243.11
Water, H2O 69061.59
Quenching Tower
V-102 27.58 Nitrogen, N2 56.01
Hydrocarbon
2.46 Carbon Dioxide, CO2 46.12
Absorption
Column 1.48 O2 1969.90

Waste Management & Pollution Control

Waste management is predictable that must be solved in all chemical process

plant and need to be dispose wisely. It is required to be ensured that such waste give
least impact to environment. Wastes from an industry whether is in solid, liquid, gas or
mixture form must not exceed levels at which they are considered harmful. There are
several waste treatment are required by law such as solid waste treatment, waste water
treatment, sewage treatment.

It is seldom possible to convert 100% of the raw materials into sale able products,
so there is almost always some waste or residual. It is follows the second
thermodynamics law, which state that, more entropy is generate when the work is
increased. Direct discharge of waste produced from plant to environment may cause of

3
pollution and destroy the balancing of the ecosystem. Therefore, there were need some
proper planning of waste management include it waste treatment unit, ways to dispose
and also the cost of waste operating.

Most of chemical plant will discharge waste water from their manufacturing plant.
When water is fed into a process or the produces water, waste water is usually one of
the process effluents. This waste water may contain lot of chemical or waste that can
give bad impact to the environment. So that, before discharge it into river, it must be
treated well and comply the parameters with Environmental Quality Act 1974, in order
to follow the standard of waste water discharge from Department of Environment
(DOE). For this chapter, the waste treatment strategy for Butadiene plant has been
planned carefully in order to meet the regulation of Environmental Quality Act 1974
(amended 1996) Malaysia. Before the wastes are discharged to the environment, some
consideration must be done:

 Consider the economic aspect, whether the waste can be recover and sell as a
product or not.
 Consider the waste properties, whether it can be discharged directly to the
environment or we need to treat it first.
 Consider from the safety reason, whether it is dangerous to the environment or
not.

Objective of Waste Minimization and Treatment

Waste minimization and treatment plant must fulfill the objectives below:

I. Protect the public health and worker’s health.

II. Reduce potential environment liabilities.
III. Save money by reducing waste treatment and disposal cost, and other operating
costs including utility costs.
IV. Meet state and national waste minimization policy goals

4
 Butene

Air Steam
Oxidative Dehydrogenation

1243.11 ton/hrs

Waste
Quench Tower Water
Water
Treatmen

31.52 ton/hrs

Flue gas
Absorption Tower Flue treatment
Gas company

Butadiene

Figure 6.1: Flowchart of the waste discharge from butadiene plant.

5
6.1.2 Treatment of Waste

Method of Waste Disposal

For our plant, we have proposed several methods to dispose our waste based on
the type of wastes in our plant. In the production of Butadiene, it considers two types of
wastes which are gaseous and liquid.

Waste Water

The method use for dispose the liquid waste is the waste water treatment. This is
because the liquid waste product is the water. So, the best method to treat the waste
water to is through the waste water treatment. In waste water treatment, it consist two
stages of treatment which are primary treatment and secondary treatment. In primary
treatment, it will undergo five treatment processes which are screening, grit removal,
equalization, sedimentation (solid-liquid separation) and flotation. While for secondary
treatment, it will undergo the biological treatment that are first is activated sludge
process and second is trickling filter process.

For a biological wastewater treatment, it based on agitated and activated. It known

as the suspended growth process which is the microorganism is suspended in the liquid
wastewater. The term activated is comes from the fact that the particles are teeming
with bacteria and protozoa. Activated sludge is different with the primary sludge, in that
the sludge contains many living microorganisms which stimulate their growth though
used of organic compound as food. As the microorganism grow and are mixed by the
agitation of the air, the individual organism clump together (flocculate) to form an
active mass of microbes (biological floc) called activated sludge. The meaning of the
sludge is any solid, semisolid or liquid waste water that settles to the bottom of
sedimentation tank. Whereas activated sludge is the sludge particles produced by the
growth of microorganism in aerated tank as a part of the activated sludge to treat
wastewater. The advantages of activated sludge are it requires less space than the
biological filter. Then, the final effluent of high quality is produced such that it does not
require high dilution for disposal.

6
 Then, for the trickling filters, it consists of a bed of a highly permeable medium to
which microorganisms are attached and through which wastewater is percolated or
trickled. The examples of bed coarse material are stones, slats or plastic materials
(media), over which waste water applied. This is because the microorganism that
biodegrade the waste form a film on the media and this process is known as the attached
growth system. Wastewater is typically distributed over the surface of the rocks by a
rotating arm. The purpose of the media is to provide large amount of surface area where
the microorganism cling and grow, in the slime on the rocks as they feed on the organic
matter. It is also not primarily a filtering or straining process.

6.1.3 Hazard and Operability (HAZOP) Study

An important element of any system for the prevention of major accidents is

conducting a hazard and operability study (HAZOP) at the detail design stage, of the
plant in general and the operating and safety control systems in particular. HAZOPs
seek to minimize the effect of an atypical situation in the operation/process by ensuring
that control and other safety systems such as functional safety (e.g. emergency safe
shutdown) are in place and work with a high level of reliability to achieve a safe
outcome from a situation that could have resulted in a major accident.

The HAZOP process is used to identify potential hazards and operational

problems in terms of plant design and human error. The technique is applied during
final design of the process and plant items before commencement of construction.
HAZOPs have also proven to provide financial benefits to the plant owner/operator by
minimizing the time and money spent in installing add on control and safety systems,
the need for which may become evident at the time of plant commissioning in the
absence of a HAZOP.

Before the study is conducted, the details information about the entire process
must be available including process flow diagram (PFD) and process and

7
instrumentation diagram (P&ID), detailed equipment specifications, material of
constructions, energy and material balance as performed in previous tasks. The full
study requires a committee of cross-section of experience plant, laboratory, technical
and safety professionals. A list of guide word is shown in Table 6.2.

Table 6.2: Guide words used for the HAZOP procedure

GUIDE WORDS MEANING COMMENTS

NO, NOT NONE The complete negation No part of the design intention is
of the intention achieved but nothing else happens
MORE, Quantitative increase Applies to quantities such as flow
HIGHER, rate and temperature and to activities
GREATER such as heating and reaction
LESS, LOWER Quantitative decrease Applies to quantities such as flow
rate and temperature and to activities
such as heating and reaction
AS WELL AS Qualitative increase All the design and operating
intentions are achieved along with
some additional activity, such as
contamination of process streams
PART OF Qualitative decrease Only some of the design intentions
are achieved some are not
REVERSE The logical opposite of Most applicable to activities such as
flow or chemical reaction. Also
applicable to substances, for
example, poison instead of antidote
OTHER THAN Complete substitution No part of the original intention is
achieved – the original intention is
replaced by something else
SOONER THAN Too early or in the Applies to process steps or actions
wrong order
LATER THAN To late or in the wrong Applies to process steps or actions
order
WHERE ELSE In additional locations Applies to process locations, or
locations in operating procedures
In this task, HAZOP study were being carried out the all the equipment used in
the production of butadiene. The equipment are Blower, Furnace, Mixer, Reactor, Heat
Exchanger, Condenser, Pump, Quench Tower, Absorption Tower and Stripping Tower.
8
MIXER

Process: mixing the outlet feed from H-101, C-101 and H-102
Section: Mixer M-101
Item STUDY GUIDE
NOTE PARAMETER WORDS CAUSES CONSEQUENCES ACTIONS
1A • Stirrer motor malfunction • No mixing • Interlock with feed line
stirrer agitation None • Power failure • Possible accumulation of • Training should be
unreacted materials given to the operators
1B • Stirrer motor controller • None • Check motor
Higher fails functioning
• High motor speed
2A • rupture in pipeline or • pressure build up in the • Regular inspection on
equipment pipeline the pipelie
• clogging at inlet pipeline • loss of cooling, possible • By-pass pipeline is
pipeline flow None • controller fails and runaway installed
closes valve • Place controller on
critical
instrumentation list
2B • clogging at outlet stream • damage part in the reactor • maintenance on
higher
• flow control valve fail • lower conversion of pipeline

9
 open butadiene • install an alarm for
warming
• installation of safety
valve to divert the flow
2C • Leakage in the pipeline • Leakage in the pipeline • Install a by-pass
• Flow control valve fail causes explosion pipeline
lower close • Maintenance on
• Partially plugged in the pipeline
pipeline
2D • Contaminants in pipeline • Incorrect operation of • Install filter with
• Impurities from the system maintenance
As well as
product • Feed stream impurities

2E • Process control upset • Gas entrainment

Part of • Incorrect feedstock •
specification • Install check valve
2F • Too high pressure in the • Pressure build up in the • Regular inspection on
reverse mixer pipeline the pipelie
• Backflow due to high • Failure of process fluid • By-pass pipeline is

10
 backpressure inlet valve installed
• Install check valve
2G • wrong material is chosen • Depends upon the • Plant procedure to
substitution, requires provide check on
testing potential material chosen before
Other than
substitution based on charging of material
availability of other
material at site
2H • Poor communication • Corrosion in the mixer • Proper SOP follow and
between the crew is to be discussed
Faster Corrosion in the batch
mixer Proper SOP follow
and is to be discussed
2I • Operator error • Temperature rises • regular inspection on
Slower
• possible runaway the pipeline

11
Reactor
Process: Butadiene production from n-butene by using oxidative dehydrogenation process
Section: REACTOR R-101
STUDY GUIDE
Item PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS
1A • rupture in pipeline or • pressure build up in the • Regular inspection on
equipment pipeline the pipeline
• clogging at inlet pipeline • loss of cooling, possible • By-pass pipeline is
Inlet
flow No • controller fails and runaway installed
pipeline
closes valve • Place controller on
critical
instrumentation list
1B • clogging at outlet stream • damage part in the reactor • maintenance on
• flow control valve fail • lower conversion of pipeline
open butadiene • install an alarm for
higher
warming
• installation of safety
valve to divert the flow
1C • Leakage in the pipeline • Leakage in the pipeline • Install a by-pass
lower
• Flow control valve fail causes explosion pipeline

12
 close • Maintenance on
• Partially plugged in the pipeline
pipeline
1D • Contaminants in the • More pressure in reactor • Install higher alarm
pipeline • Blockage in pipeline pressure
As well as
• Regular inspection on
the pipeline
1E • Valve leakage • The ultimate product will • Prior test is to be
Part of be of less quality than the conducted, QA/QC
desired product performed
1F • Too high pressure in the • Pressure builds up in the • Regular inspection on
mixer pipeline the pipeline
Reverse • Backflow due to high • Failure of process fluid • By-pass pipeline is
backpressure inlet valve installed
• Install check valve
1G • Water sources • May cooling ineffective • Install temperature
Other than contaminated • Effect the reaction alarm low
• Impurities in feed line
1H Faster • Wrong material is • It forms non-uniform • Discuss roles and

13
 chosen from plant or mixture if the recipe not responsibilities of all
poor communication followed properly the crew members
1I • Operator error • Temperature rises • regular inspection on
Slower
• possible runaway the pipeline
2A • plugged cooling pipeline • loss of cooling, possible • Regular inspection on
• controller fails and runaway the pipelie
Cooling
flow No closes valve • By-pass pipeline is
pipeline
• cooling water service installed
failure
2B • flow control valve fail • reactor cools • maintenance on
open • reactant concentration pipeline
higher
builds • install an alarm for
warming
2C • partially plugged cooling • Leakage in the pipeline • Place valves on critical
line causes explosion instrumentation list
• partial water source
lower
failure
• control valves fail to
respond

14
2D • Contaminants in water • corrosion • install filter with
As well as
supply maintenance procedure
2E • partially plugged cooling • Leakage in the pipeline • Place valves on critical
line causes explosion instrumentation list
• partial water source
Part of
failure
• control valves fail to
respond
2F • Failure of water source • Loss of cooling • Install cooling water
resulting in backflow • Possible runaway flow meter and low
Reverse
• Backflow due to high flow alarm
pressure
2G • Cooling started early • Effect the process • Regular inspection on
Faster
the control system
2H • Operator error • Temperature rises • interlock between
Slower • possible runaway cooling flow and feed
reactor
3A • Failure of temperature • Lower conversion of • Regularly checkup the
Temperature Higher transmitter and controller butadiene control system of the
reactor

15
 • Insufficient cooling water • Reactor deactivated or • Training should be
damage given to the operators
• Immediate shut down
3B • Failure of temperature • Build up reactant in the • Regularly checkup the
transmitter and controller catalyst bed control system of the
Lower • Higher heat transfer from • Incomplete reaction reactor
steam to reactor • Install low temperature
alarm
• Failure of temperature • Lower conversion of • Regularly checkup the
transmitter and controller butadiene control system of the
Reactor • Catalyst bed deactivated reactor
temperature Higher
itself or damage • Training should be
given to the operators
• Immediate shut down
4A • Failure of temperature • Build up reactant in the • Regularly checkup the
controller catalyst bed control system of the
Lower • Higher heat transfer from • Incomplete reaction reactor
steam to reactor • Install low temperature
alarm

16
5A • Inadequate volume of
vents
Higher
• Incorrect vent set pressure
Pressure
for vents
• Relief valves isolated
• Thermal overpressure
5B • Low flow rate of reactant
• Pressure drop existence in
Lower the catalyst bed
• Inadequate mixture of
steam and butadiene
• Pressure build up can • Installation of relief
cause explosion or rupture valve
the reactor • Regular check up on the
• Exploding pipeline
• Chemical breakdown • Pressure sensor placed
on the inlet pipeline
• Gas release • The control system
• Priming should be well designed
• Exploding and suits the operating
• Imploding requirements of
equipment used.

17
QUENCH TOWER

Process: Separation of water from product gas mixture

Section: Quench Tower V-101
STUDY GUIDE
Item PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS
1A • rupture in pipeline or • no cooling and separation • Bypass valve installed
Water
equipment (pump P-101)) effect • Interlock with feed line
input
• clogging at inlet pipeline • regular check up on
pipeline Flow No
(stream • controller fails and closes control system elements
11) valve (V-22)

1B • controller fails to control • excess water enter the • regular check up on

the opening of valve (V-
Higher 22)
• valve opened too wide
• High motor speed
1C • controller fails to control
the opening of valve (V-
22)
Lower • valve opened too narrow
• Low motor speed
vessel V-101, flooded and control system elements
exceed the limit of water • Check motor
level functioning
• ineffective scrubbing • recycle stream installed
• insufficient water to cool • regular check up on
the product gases and control system elements
remove water content • Check motor
• ineffective scrubbing functioning

1D • Too high pressure in the • Pressure build up in the • Regular inspection on

Reverse
mixer pipeline the pipeline

18
 • Backflow due to high • Failure of upstream • By-pass pipeline is
backpressure process units installed
• Install check valve
2A Vessel • slow flow of water input • unable to stop the • Alarm system installed
• fast flow of product gas reactions of the reactants • regular check-up and
input • undesired side reactions maintenance on the
• pump failure and side products control system (on
• Water content remains in water inlet flow)
gaseous form installed
• failure in the separation • scheduled and regular
Temperature Higher and removal of water from check-up on the
the product mixture operations and
• gaseous product with high efficiency of the pump
content of water P-101
• check valve, by-pass
valve installed
• recycle stream installed
after the pump
2B • Fast flow of water • flooded or the level of • regular check-up and
• Failure of the flow water in the vessel over maintenance on the
transmitter and controller the height limit control system (on
on the upstream inlet gas • ineffectiveness in water inlet flow)
(stream 11) separation of water from installed
• Failure of the pump P-101 the gas products • scheduled and regular
Lower
check-up on the
operations and
efficiency of the pump
P-101
• check valve, by-pass
valve installed

19

3A Pressure • Failure of the flow
transmitter and controller
on the upstream inlet gas
(stream 11).
• Failure of the pump P-101
• fast flow of product gas
(stream 11) and slow flow
of water input (stream 15)
Higher
3B • Failure of the flow
transmitter and controller
on the upstream inlet gas
(stream 11).
Lower • Failure of the pump P-101
• slow flow of product gas
(stream 11) and fast flow
of water input (stream 15)
• Overpressure in the vessel
due to overflow of product
gas inlet
• Insufficient amount of
water in the vessel to cool
down the product gases
for water separation,
temperature increases and
build up high pressure in
the vessel
• Excess amount of water
build up, flooded or
causes the level of water
in the vessel over the
height limit
• ineffectiveness in
separation of water from
the gas products by
limiting the time for the
scrubbing of the gas
• recycle stream installed
after the pump
• Alarm system installed
• Relief valve (V-24)
installed
• Regular check-up and
maintenance on the
control system (on
water inlet flow)
installed.
• scheduled and regular
check-up on the
operations and
efficiency of the pump
P-101
• check valve, by-pass
valve installed
• recycle stream installed
after the pump
•
• Relief valve (V-24)
installed
• Regular check-up and
maintenance on the
control system (on
water inlet flow)
installed.
• scheduled and regular
check-up on the
20

4A • Failure on pump
• clogging of inlet pipeline
Level No
4B • Failure of the flow
transmitter and controller
on the upstream inlet gas
(stream 11) .
• Failure of the pump P-101
• Excess water input
Higher
4C Lower • Failure of the flow
products
• no cooling and separation
effect
• Overflow. The excess
amount of water build up,
flooded or causes the level
of water in the vessel over
the height limit
• ineffectiveness in
separation of water from
the gas products by
limiting the time for the
scrubbing of the gas
products
• slightly increased the
operations and
efficiency of the pump
P-101
• check valve, by-pass
valve installed
• recycle stream installed
after the pump
• regular check upand
maintenance on control
system elements
• Drain valve installed
• Regular check-up and
maintenance on the
level control system
installed.
• scheduled and regular
check-up on the
operations and
efficiency of the pump
P-101
• check valve, by-pass
valve installed
• recycle stream installed
after the pump
• Regular check-up and
21
 transmitter and controller
on the upstream inlet gas
(stream 11).
• Failure of the pump P-101
• Insufficient of water input •
temperature in the vessel maintenance on the
leads to insufficient heat level control system
for water removal from installed.
the gas products • scheduled and regular
no significant effect check-up on the
operations and
efficiency of the pump
P-101

5A Water Flow • rupture in pipeline or • Excess amount of water • Maintenance and

outlet control system element build up, flooded or replacement of control
(stream ( level transmitter) causes the level of water elements (transmitter,
13) No • clogging at pipeline in the vessel over the I/P inducer etc.)
• controller fails and closes height limit
valve (V-25)

5B • controller fails to control • pressure inside the vessel • regular check-up on the
the opening of valve (V- too low operations and
Higher
25) efficiency control
system elements
5C • controller fails to control • slow removal of water • regular check-up on the
the opening of valve (V- • Excess amount of water operations and
25) build up, flooded or efficiency control
Lower
causes the level of water system elements
in the vessel over the
height limit
5D • controller fails to control • unable to remove water • check valve and drain
Reverse the opening of valve (V- valve installed
25)

22
• vessel is under pressure

23
Heat Exchanger

PROCESS: HEAT TRANSFER

SECTION: HEAT EXCHANGER
ITEM STUDY PARAMETER GUIDE CAUSES CONSEQUENCES ACTION
NOTE WORDS
1A • Failure of inlet heating • Fluid temperature is not • Install temperature
None water valve to open increased accordingly indicator before and after
the fluid line.
1B • Failure of heating water • The temperature of the • Install temperature
inlet valve to close output fluid is too high indicator before and after
High the fluid line.

Hot • Install the temperature

water Flow alarm loggers.
inlet
1C • Pipe blockage • Temperature of the • Set the temperature alarm
Low
• Pipe leakage fluid remain constant • Install the flow meter
1D • Failure of fluid inlet • Product off set • Install check valve
Reverse
valve
1E • High pressure at the • Did not get the desired • Install check valve
Faster
water inlet temperature of the

24
 output fluid
1F • Low pressure at the • Slower the process • Install the flow sensor
Slower water inlet

2A • The sensor of the • The flow of the fluid • Change the pressure sensor
pressure broke become faster.

Pressure Higher • The efficiency of the

heat exchange become
lower.
2B • The error in the sensor’s • The rate of heat • Change the pressure sensor
Lower signal exchanger become
higher
3A • Failure of the water • High pressure in the • Upgrading the
None outlet valve to open shell and no heat maintenance
transfer occur
3B Hot • Failure of the water • Less heat transfer • Replace the valve with the
Water Flow
High outlet valve to close between the hot water new valve
Outlet
and the cold oxygen
3C • Product feed pump • Temperature rise in • Clean the pipeline, conduct
Low failed. column. regular maintenance
• Controlling valves fail to • Drop in liquid level in • Check the pipeline and

25
 respond column. replace the pipeline if
• Pipe leakage. • Overheating of required
• Partially clogged distillation column.
pipeline • Diminished flow rate of
mixture

4A • Failure of the • Cause the outer shell to • Replace the old sensor
High
temperature sensor have high temperature with the new sensor
Temperature
4B • Failure of the • Less heat transfer rate • Replace the old sensor
Low
temperature sensor with the new sensor
5A • The sensor of the • The flow of the fluid • Change the old pressure
pressure broke becomes faster. sensor with the new sensor
Shell
High • The efficiency of the
heat exchange becomes
Pressure
lower.
5B • The error in the sensor’s • The rate of heat • Change the old pressure
Lower signal exchanger become sensor with the new sensor
higher
6A
Chemical • Failure of the inlet valve • The desired temperature • Install the flow sensor and
None
Flow to open can’t be achieved replace the broken valve
Mixture
6B High • Failure of the inlet valve • The temperature of the • Install temperature

26
 Inlet to close output stream is lower indicator before and after
than the desired the oxygen pipe.
temperature • Install the temperature
alarm loggers.
6C • Pipe leakage • Rate of heat exchanged • Set the temperature alarm
Low
become higher
7A • The sensor of the • The flow of the fluid • Change the old pressure
pressure broke become faster. sensor with the new sensor
High • The efficiency of the
heat exchange become
Pressure
lower.
7B • The error in the sensor’s • The rate of heat • Change the old pressure
Lower signal exchanger become sensor with the new sensor
higher

27
Condenser

Process: Condensation of the mixture

Section: CONDENSER
STUDY GUIDE
Item PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS
1A • inlet flow stops • Pressure surges • Install a by-pass
No
Condenser • Flow control valve fail • draining pipeline
level
itself close • Maintenance on
pipeline
1B • Outlet of waste water • leakage • maintenance on
blocked • flooding pipeline
More
• Inflow grater that outflow • corrosion • install an alarm for
control failure warming
• installation of safety
valve to divert the flow
1C • inlet flow stops • Pressure surges • Install a by-pass
• Flow control valve fail • Draining pipeline
Less
close • Maintenance on
pipeline

28
1D • Incorrect operation system • Gas entrainment • Regular inspection on
As well as
• Valve leaking • leakage the operation system
2A • Failure of temperature • Effect the process • Regularly check up the
transmitter and controller • Heating medium control system of the
Inlet
Temperature Higher • Cooling water failure leak into the reactor
pipeline
process • Training should be
given to the operators
2B • Failure of temperature • Loss of heating • Regularly check up the
controller control system of the
Lower condenser
• Install low temperature
alarm
3A • Gas breakthrough • Thermal • proper maintenance and
Outlet
pressure higher • Inadequate volume to overpressure operator alert
pipeline
vents • imploding
3B • Undetected leakage • Drainage • install check valve
Lower
• Control system failure • scaling

29
Absorption Tower

Process: Separation of butadiene from product gases

Section: Absorption Tower V-102
STUDY GUIDE
Item PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS
1A Product Flow No • Failures of Blower C-102 • vessel under pressure • Regular maintenance on
gas inlet the equipment
(stream • replacement of blower
19)
1B Higher • Blower motor over speed • vessel overpressure • Regular maintenance on
the equipment

1C Lower • Blower motor under • vessel under pressure • Regular

speed maintenance on the
equipment

1D Reverse • upstream under pressure • spoilage of blower • Check valve installed

• downstream overpressure • Immediate shut down
• Check up and regular
maintenance on the
equipment
•
2A Absorbent Flow No • Failures of Pump P-102 • No separation effect • Regular maintenance on
inlet • Control system fails to • Vessel under pressure the equipment and
(stream open valve V-50 control system elements
28) • replacement of pump
2B Higher • pump over speed • vessel overpressure • Regular maintenance on
the pump

30
2C Lower • pump under speed • vessel under pressure • Regular maintenance on
• low separation effect the pump
2D Reverse • upstream under pressure • spoilage of pump • Check valve installed
• downstream overpressure • Immediate shut down
• Check up and regular
maintenance on the
equipment
3A Vessel Temperature Higher • Ratio control system fails • Low separation efficiency • emergency shut down
to control the input of • Product gases wasted as • regular checkup and
absorbent to product not fully absorbed maintenance on the
gases • loss due to release of control system elements
• failures of upstream heat butadiene via flue gases • Maintenance or
exchanger and condenser replacement on wore
out equipment
3B Lower • Ratio control system fails • no significant effect • regular checkup and
to control the input of maintenance on the
absorbent to product control system elements
gases •
4A Pressure Higher • Ratio control system fails • vessel overpressure • Relief valve installed
to control the input of • insufficient amount of • regular checkup and
absorbent to product absorbent leads to low maintenance on the
gases separation effect control system elements
• fast flow of product gases • loss due to release of • by pass valve installed
input butadiene via flue gases
• Control system fails to
control the opening of
valve V-34
4B Lower • Ratio control system fails • under pressure • Relief valve installed
to control the input of • no significant effect • regular checkup and

31
 absorbent to product maintenance on the
gases control system elements
• slow flow of product
gases input
5A Level Higher • Level control system • low separation efficiency • regular checkup and
(sensor and transmitter) • loss due to release of maintenance on the
fails to control the butadiene via flue gases level control system
opening of valves V-21 • flooded, exceed level limit elements
• by pass valve installed
5B Lower • Level control system • low separation efficiency • regular checkup and
(sensor and transmitter) • loss due to release of maintenance on the
fails to control and open butadiene via flue gases level control system
the valve V-21 elements
• failures on pump P-102 • maintenance and
replacement for pump
6A Waste flue low No • Pressure control system • vessel overpressure • by pass valve installed
gas outlet fails to open the valve V- • regular checkup and
(stream 34 maintenance on the
20) pressure control system
elements
6B Higher • Pressure control system • fast flow of gas reduces • emergency stop
fails to control the closing the separation efficiency • regular checkup and
of the valve • loss of butadiene via flue maintenance on the
• valve opens too wide gas pressure control system
elements

6C Lower • Pressure control system • slow flow of gas released • relief valve installed
fails to control the • vessel overpressure after a • regular checkup and
opening of the valves period maintenance on the

32
 • valve opens to narrow pressure control system
elements

6D Reverse • pressure inside the • contaminated product • check valve

vessel is lower that the installed
environment pressure

7A Absorbent Flow No • Flow control system • liquid absorbent build • open drain valve
outlet fails to open the valve up the level inside the installed
(stream V-36 vessel up to the limit • regular checkup and
21) and flooded maintenance on the
• vessel overpressure flow control system
elements
7B Higher • Level control system • fast flow of absorbent • regular checkup and
fails to control the out from the vessel maintenance on the
closing the valve V-36 • less absorption level control system
• Valve opens too wide efficiency elements
7C Lower • Level control system • liquid absorbent rise to • regular checkup and
fails to control the the level limit and maintenance on the
opening the valve V- flooded after some level control system
36 times elements
• Valve opens too wide • less absorption • open drain valve
efficiency installed
7D Reverse • downstream • influence and interrupt • check valve
equipment over the separation and installed
pressure absorption efficiency

33
Stripping Tower

Process: Refinery of butadiene from absorbent

Section: Stripping Tower V-103
Item STUDY GUIDE
NOTE PARAMETER WORDS CAUSES CONSEQUENCES ACTION
1A Rich • pipeline clogged • vessel heat up without • by pass valve
Absorbent • level control system liquid circulation installed
inlet Flow No fails to control the • temperature rise
(stream opening of the valve
21) V-36
1B • upstream level control • fast flow of rich • regular checkup and
system fails to control absorbent increases maintenance on the
the closing of the the load of stripping level control system
Higher valve • low stripping elements
• valve opens widely efficiency
• low purity of
butadiene produced
1C • upstream level control • slow flow of rich • regular checkup and
system fails to control absorbent maintenance on the
Lower the opening of the • low stripping level control system
valve efficiency elements
• valve opens narrowly
1D • vessel over pressure • interrupt the • check valve
absorption and installed
Reverse
stripping process
entirely
2A Butadiene • Pressure control • vessel and pipeline • regular check up
Flow No
Outlet system fails to open over pressure and maintenance on

34
 (stream the valve V-38 • valve damage the pressure control
22) system elements
• by pass valve
installed
2B • Pressure control • fast flow of butadiene • regular check up
system fails to control out from the vessel and maintenance on
Higher the closing of the • lower purity of the pressure control
valve V-38 butadiene produces as system elements
• valve open widely shorten stripping time
2C • Pressure control • slow flow of butadiene • regular check up
system fails to control out from the vessel and maintenance on
the opening of the • lower purity of the pressure control
Lower valve V-38 butadiene produces system elements
• valve close widely (condensed) as
lengthen stripping
time
2D • vessel under pressure • increase striping work • check valve
load installed
• waste of fuel
Reverse
• low purity of
butadiene produced

3A • Temperature control • flooded vessel • regular check up

Return of
stripped
system fails to open • vessel overheat and maintenance on
the valve V-48 the temperature
absorbent Flow No
(stream • pipeline clogged control system
elements
26)
• by pass installed
3B Higher • temperature control • return of rich • regular check up

35
 system fails to control absorbent into and maintenance on
the closing of the absorption tower the temperature
valve • lower the absorption control system
• valve opens widely efficiency elements

3C • temperature control • low rate of absorbent • regular check up

system fails to control returned into the and maintenance on
Lower the opening of the absorption tower the temperature
valve • lower the absorption control system
• valve opens narrowly efficiency elements
3D • failures of pump P- • interrupt the • Maintenance and
Reverse 102 absorption and replacement of the
stripping process pump

36
Furnace

PROCESS: PROCESS HEATING OF RAW MATERIAL

SECTION: FURNACE
STUDY GUIDE
ITEM PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS
1A • Supply failure • Possible overheating and • Install check valve
Fuel inlet None • Blockage downstream of coking of heating coil
vaporizer • Vaporizer coil overheats
and may fail
1B • Oil delivered at higher • May overload vaporizer, • Install the flow sensor
Flow pressure resulting in insufficient
• Failure of low controller heating of oil stream,
More causing failure to vaporize
or superheat oil. Oil with
low temperature delivered
to process
2A • Failure of temperature • Too high temperature in •
Scheduled checking
transmitter and furnace on the heating
controller • Polymerization may occur system
Temperature Higher • Excessive fuel usage • Exploration or fire occurs • Maintenance of
control system
• Emergency
shutdown
2B • Failure of temperature • Low temperature detected • Maintenance of
Lower
transmitter and controller • Excessive input causes in control system and

37
 • Shortage of fuel usages adequate heating heating system
• Control valve failure
3A • Failure of relief valve • Pressure built up in the • Regular check-up held
• Excessive input of fuel furnace causing explosions on the valves involved
Pressure gas • High pressure gas at output • Recommend
Higher
stream consulting
• Changes in phase from gas manufactures to
to liquid establish effect
3B • Failure of pressure • Low pressure input to the • Consider diversity of
Lower
transmitter and controller mixer fuel supply
• Loss of fuel gas supply
4A • Failure of the inlet valve • The desired temperature • Install the flow sensor
None to open can’t be achieved and replace the broken
Chemical valve
4B Mixture • Failure of the inlet valve • The temperature of the • Install temperature
Flow to close output stream is lower than indicator before and
Inlet
High the desired temperature after the oxygen pipe.
• Install the temperature
alarm loggers.
4C • Pipe leakage • Rate of heat exchanged • Set the temperature
Low
become higher alarm
5A • The sensor of the pressure • The flow of the fluid • Change the old
Pressure High broke become faster. pressure sensor with
• The efficiency of the heat the new sensor
exchange become lower.

38
5B • The error in the sensor’s • The rate of heat exchanger • Change the old
Lower signal become higher pressure sensor with
the new sensor

39
Storage Tank

Section: Storage Tank

STUDY GUIDE
Item PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS

1A • Level Control Valve • Storage tank • Install high level alarm

(LCV) fails open or overfills on LIC and check sizing
LCV bypass open in of relief opposite fluid
error • Transfer of overfilling
Product
streamline 30
input • LCV closes, with C- subjected to full • Install kickback on C-
pipeline Level Higher 103 compressor is compressor 103 compressor
(Stream running delivery or surge
pressure • Install thermal
31) • Thermal expansion in expansion relief o
the LCV section due • Line fracture or
to fire or strong flange leak
sunlight

1B • Flow control valve fail • Pressure surges • Maintenance on

None close pipeline
• Draining
• Inlet flow stops • Install a bypass pipeline

1C • Inlet flow stops • Pressure surges • Install a by-pass

Less pipeline
• Flow control valve fail • Draining
• Maintenance on

40
 close pipeline

1D • Incorrect operation • Leakage • Regular inspection on

system the operation system
As well as • Other liquid
• Valve leaking enter the vessel

• The heating system of • Explosion • Install a high

Product the boiler providing temperature alarm
too much • Pressure will system at the outlet
input change bottom stream to alert
2A pipeline Temperature Higher • More steam flow in the temperature change
(Stream boiler
• Check on cooling water
31) • Cooling water system supply
failure in condenser

• Heating service of the • The phase of the • Install a temperature

boiler fails product will controller. Install a low
2B Lower change due to temperature alarm
the change of system at the outlet
temperature bottom boiler

• Inadequate volume of • Pressure build • Installation of relief

vents up can cause valve
3A Pressure Higher
explosion or
• Incorrect vent set • Regular check up on the
rupture the

41
 pressure for vents storage tank pipeline

• Relief valves isolated • Upset the • Pressure sensor placed

product quality on the inlet pipeline
• Thermal over pressure

• Low flow rate of the • Phase changing • The control system

reactant on the should be well designed
3B Lower production of and suits the operating
• Pressure drop the butadiene requirements of
existence in the equipment used
storage tank • Exploding

• Compressor over • Possible • Install a high flow

speed runaway detector alarm system at
the outlet stream to alert
• Explosion the operator
4A Flow Higher
• Efficiency of the • Install the check valve
compressor
decreases • Install the throttle valve
to release the pressure

• Leakage in the • Possible • Install a low flow

compressor runaway detector alarm system at
4B None
reaction the outlet
• Blockage in the
• Accumulation of • Install an interlock

42
 compressor inlet materials in the system to trigger the
compressor feed alarm system and shut
stream, builds down the plant if there
up pressure is no flow
which might end
up in runaway
reaction

• Compressor • Accumulation of • Install a one way valve

malfunction and the materials in the
pressure is too low compressor feed
Reverse
stream, builds
4C • Failure of reactant up pressure
source resulting back which might end
flow up in runaway
reaction

Low • Low reactant supply • Slower the • Install the flow sensor
4D pressure production line
of the plant

• Valve leakage • Low efficiency • Maintenance on

4E Part of of the plant pipeline
production

43
Pump

Section: Pump

STUDY GUIDE
Item PARAMETER CAUSES CONSEQUENCES ACTION
NOTE WORDS

• The controller fails • Possible runaway • Install a high

and open valve pressure detector
• Explosion alarm system at the
Outlet
• The throttle valve outlet stream to alert
pipeline malfunction
1A Pressure Higher the operator
(Stream
• Install an interlock
15)
system to trigger the
alarm system and
shut

• The controller fails • Materials not • Install a low pressure

and partially closes pumped to desired detector alarm
1B Lower valve pressure system at the outlet
stream to alert the
• Leakage in the pump operator
or its inlet stream

2A Flow Higher • Pump over speed, • Possible runaway • Install a high flow
detector alarm

44
 • Pressure is too high • Explosion system at the outlet
stream to alert the
operator

• Install the throttle

valve to release the
pressure

• Leakage in the pump • Possible runaway • Install a low flow

reaction detector alarm
• Blockage in the system at the outlet
pump inlet • Accumulation of
2B None materials in the pump • Install an interlock
feed stream, builds system to trigger the
up pressure which alarm system and
might end up in shut down the plant
runaway reaction if there is no flow

• Pump malfunction • Accumulation of • Install a one way

and the pressure is materials in the pump valve
too low feed stream, builds
2C Reverse
up pressure which
might end up in
runaway reaction

• Low water supply • Slower the quench • Install the flow

2D Low
pressure tower (V-101) sensor

45
 cooling process • Regular inspection
on the water supply

• Contamination of • Possible runaway • Regular inspection

water supply on the quality source
2E As well as • Upset the further of water
process

• Valve leakage • Low efficiency of • Maintenance on

2F Part of cooling process in pipeline
quench tower

46
6.2 Environmental Protection
6.2.1 Waste management and treatment plant

Table 6.3: The amount of waste generated in this plant is summarized as following:

Stream Amount
Waste Source State
No. (ton/hr)

Flue gas 20 Absorption Tower V-102 gas 31.52

Quench Tower V-101 and Condenser E-

Water 13 and 17 liquid 1243.11
102

6.2.1.1 Planned, Fugitive and Emergency Emission in the plant

Planned Emission

There are several types of waste emission

• Wastewater
• Light waste

As mentioned above, wastewater is being treated before discharging. Light gas is sell
out to flue gas treatment company. In this plant, no liquid waste is produced.

47
Fugitive Emission

The light gas waste may release or leak to surrounding when the occurrence of
the pipeline leakage of valve failure. Leaks from pressurized process equipment
generally occur through valves, pipe connections, mechanical seals or related
equipment. Fugitive emission also occurs at evaporative sources such as storage tanks.
This is because of large number or potential leak sources at large facilities and the
difficulties in detecting and repairing some leaks, fugitive emission can be significant
proportion of total emissions. Even though the quantities of leaked gases may be small,
leaks of gases that have serious health or environmental impacts can cause a significant
problem.

To minimize and control leaks at process facilities operators carry out regular
leak detection and repair activities. Routine inspections of process equipment with gas
detectors can be used to identify and estimate the leak rate in order to decide on
appropriate corrective action. Proper routine maintenance of equipment reduced the
likelihood of leaks. New technologies are under development that could revolutionize
the detection and monitoring of fugitive emissions. One technology, known as
differential adsorption light detection and ranging (DIAL) can used to remotely measure
concentration profiles of hydrocarbons in the atmosphere up to several hundred meters
from facility. Portable gas leaks imaging cameras are also a new technology that can be
used to improve leak detection and repair, leading to reduced fugitive emissions.

Emergency Emission

The leakage or exposure of flammable gas such as light hydrocarbon gases and
carbon dioxide from the pipeline will cause the occurrence of explosion. The failure of
the control action of the safety or control valve will lead to uncontrollable of pressure
and temperature occur in the reactor, causing the product spill, reactor rupture and
explosion.

The maintenance of the pipeline, valve and equipment are needed to prevent fire
and explosion to happen. Safety practices are given to personnel to increase their
48
awareness and emergency knowledge. The control action of all valves must always be
well controlled to prevent any accident to occur.

6.2.1.2 Waste Treatment

By-products

Waste treatment refers to process held to ensure the waste concentration meets
the standard requirement and has least practicable impact on environment. Besides
wastes are regenerated or treated for the firm usage as energy source, thus reduces the
utility cost of the firm. Treatment is also conducted for certain materials to produce less
hazardous materials or make the waste safer to transport, store or dispose. In this plant,
the waste gas such as carbon dioxide, nitrogen and oxygen were produced as by-product
in oxidative dehydrogenation of n-butene. The quality of effluents discharged met the
specification of Environmental Quality (Sewage and Industrial Effluents) Regulation
1979 and Environmental Act (Clean Air) Regulations 1978. In fact, it has been decided
to sell out the by-products from this firm to other company which uses the material as
raw materials or to the supplier company for proper pretreatment.

Catalyst

The catalyst used in the reactor is ferric sulfate which is the most suitable catalyst for
oxidative dehydrogenation of n-butene. Typical lifetime for catalyst is from 3-5 years
(Wilkinson et al., 2008). It has been estimated that the lifetime of the catalyst reduced to
approximately 4 years as average lifetime. In this plant, the waste catalyst will not be
processed as it will be send back to the supplier company for proper treatment before
disposal.

49
Liquid Waste Management

Wastewater treatment process is used to treat the wastewater effluents from the
industries to ensure the safe disposal into water sources. Disposal of wastewater without
treatment causes severe effects to the water sources affecting most of the populations
especially for the effluent that has high COD and BOD, large amount of suspended
solid and even containing toxicants.

In this plant, large amount of water is consumed. Water is used as steam and
cooling water. Cooling water mainly refers to the use of water at the heat exchangers
and condensers for cooling effects and it can be recycled. On the other hand, steam is
mixed with n-butene and catalyst to maintain adequate heat for the oxidative
dehydrogenation process which occurs in the reactor with alternately placed with
furnace. Since the steam is cooled and condensed out throughout the process, treatment
is necessary to reduce the release condition to harmless standard level. The standard
requirements for wastewater are pH 6-9, BOD ranged from 20-50 mg/L and COD from
120-200mg/L.

Since the wastewater from this plant did not reacts with the reactants or products
and separated in liquid phase from the gas phase products, simple wastewater treatment
is applicable to treat the waste water effluent. Even though the waste water discharged
is claimed to be pure water, it should be treated before discharge to ensure there is no
harmful components or hydrocarbon residues contained.

Basically, wastewater treatment process or activated sludge treatment can be

divided into three stages: preliminary (physical), primary (physical) treatment and
secondary (biological) treatment. Wastewater should receive primary (physical
removal/settling) and secondary (biological) treatment, which can be followed by
disinfection before discharge. More advanced processes (advanced or tertiary treatment)
may be required for special wastes. When the effluent from secondary treatment is
unacceptable, a third level of treatment, tertiary treatment, can be employed. There are
many basic types of sewage treatment plants employing both primary and secondary

50
treatment stages that are in use today for treating large quantities of sewage. The flow
diagram of the waste water treatment is as illustrated as attached.

Figure 6.2: Activated sludge wastewater treatment plant (Davis and Cornwell,
2008)

The flow, process unit designs and functions of wastewater treatment are as
summarized in the following table.

Table 6.4: Process units, designs and functions in activated sludge wastewater
treatment plant
Primary treatment

Unit Designs Functions

• grating of steel • screen and removes coarse and

bars spaced about floating solids from the sewage
2–4 cm on
centres
Bar Rack
• placed at an angle
to the flow of
sewage through
an open channel
• a chamber to • remove and settle out denser sand
Grit
reduce the and grit
Chamber
velocity of waste • organic suspended remains

51
 water flow to a
point
• a damp or large • improve the performance of the
basin to store treatment plant
wastewater • increase plant’s useful capacity
• pump is used to
Primary
pump wastewater
settling
to down stream
tanks
• agitator installed
to prevent odors
and deposition of
solids
• large tanks • to settle and remove settle able
• solids settle out substances
of water by • to skim off top layer of oils (if any)

Primary
gravity • 50-65% suspended solid removal

settling • settle-able solids • 30-40% five-day BOD removal

tanks are pumped away expected.

(as sludge), while
oils float to the
top and are
skimmed off
• a vessel • to encourage the growth of anaerobic
maintained at 30- bacteria (bacteria that live in an
35 ºC environment that does not contain
• Continual adding oxygen) on decomposing the sludge
Sludge of raw sludge
digester • only well-
digested sludge
should be
withdrawn,
leaving some ripe

52
 sludge in the
digester to
acclimatise the
incoming raw
sludge.
• could be sand or • to drain away water
Drying
Bed.
soil land • dried porous humus-like sludge cake
• rotary drum can be sold as fertiliser
Secondary treatment

• a tank with • promotes growth and high population

injection of air of microorganism that permits rapid
Aeration
and mixture of breakdown of the organic compounds
tank
activated sludge in the waste water
and raw water
• similar with • to settle and remove the sludge by
primary settling sedimentation
Secondary tank • returns of activated sludge maintains
Settling • return stream of the high population of
Tank activated sludge microorganisms inside the aeration
back to aeration tank.
tank installed
• a separate • kills pathogens
Disinfection chlorine contact
tank

For this plant, activated sludge is carried out for biological treatment on the
wastewater effluent. By using this treatment method, the microorganisms oxidize the
organic carbon in the wastewater to produce new cells, carbon dioxide and water.
Among all, the aerobic bacteria are the most common organisms, aerobic, anaerobic,
and/or nitrifying bacteria along with higher organisms can be present. The exact
composition depends on the reactor design, environment, and wastewater
characteristics. During aeration and mixing, the bacteria form small clusters, or flocs.

53
When the aeration stops, the mixture is transferred to a secondary clarifier where the
flocs are allowed to settle out and the effluent moves on for further treatment or
discharge. The sludge is then recycled back to the aeration tank, where the process is
repeated. Clearly, this wastewater treatment plant produces no harm to the environment
as no chemical absorbents, coagulants or flocculants are used. The waste sludge
produced is biodegradable and has extra benefits to be used as fertilisers shows that this
plant is able to be operated as zero discharge unit which follows the concept of green
technology.

Process Flow Diagram

Refer to attachment

54
6.2.2 The effect of Building and Operation on the Environment and Surrounding

In order to build this butadiene production plant, every activity involved in the
construction and operation of the plant needed to be assess to evaluate the impacts to
the environment and surrounding. Basically, the major contributors to the
environmental issues involved the plant construction and plant operation.

Plant Construction

In the building of a plant, there are several activities of construction to be done

such as land cleaning, construction of roads, construction of the buildings, landscaping
and earthworks. Table 6.5 shows the possible impacts of the construction activities and
the mitigation measures on solving the problems.

Table 6.5: Construction impacts and mitigation measures (Flor, 2012)

Activities Possible Impacts Measures
1. Construction • Air pollution • Avoid open burning of
works of roads caused by dust felled trees and construction
and buildings generation waste
• Limit speed of trucks
transporting construction
materials at 20 km/hr on
unpaved road
• Road watering operations at
least twice a day (frequently
for hot weather or dry days)
• Noise pollution • Confine normal work hours
during day-light hour (7am-
7pm) and notify the public
if the working hour
extension needed
• make sure the noise level is
within 75 dB for the
industrial area to minimize
the effect on residential area
• landscaping • prevent on using nearby
problems due to citizen roads
the damage of • build alternative roads for
nearby roads transportation to the plant
caused by truck
55
 transportation
2. Use of land • Damage of • use appropriate clearing
vegetation due to techniques
felling of trees • relocate protected species
of trees
• if relocation is not possible,
agreement with authorities
on the practical
compensation must be
done to protect the species
• Loss of fertile top • remove and store the fertile
soil top soil in an isolated area
away from the construction
areas and cover with
plastic or waterproof
materials to prevent
erosion
• Upon construction
completion, return the
topsoil and revegetate the
area
• soil erosion due to • proper geographical studies
inadequate of the site must be
landscape conducted by group of
professionals (geologist,
engineers and etc.) before
construction to assess the
land and to prevent
unfortunates
3. Use of water • water pollution by • Prevent removal of used
reaching the waste water into the water
construction sources
materials such as • Prevent the diesel or oil
diesel, oils, paints leakage
and etc. into the
nearby water
sources
• contamination on
sources of water
supply

56
Plant Operation

Industrial operation causes huge impacts to the environment and surrounding.

Pollutions caused by chemical industries endangers the lives not only human beings but
also the wildlife, aquatic life and the greens. The impacts of plant operations to the
environment, possible causes and mitigation measures are listed the Table 6.6.

Table 6.6: The impacts of plant operations, causes and mitigation measures
Impacts Causes Measures

Air Pollution due to: • equipment leakage • procedures and

• release of relief protocols will be in
Gaseous waste discharge
valve place to prevent
• contain combustible unplanned fugitive
hydrocarbons and emissions
poisonous gas that • gases released from
affect living relief valve in the
organisms and reactor will be
living things vented to flare to
In this plant, the gas prevent emission to
emitted are CO2 (harmful) , air
N2, and O2.

Water Pollution due to: • discharge of water • waste water

from water cooling treatment before
Waste water discharge
system discharge
• Contain • discharge of water • ensure the BOD,
hydrocarbons separated from the COD, and toxic
residue and catalyst product gases content (if any) is
perhaps effects the within the
ecological system acceptable
of the aqua life. limitation, safe to
In this plant, large amount discharge into water

57
of water is consumed for sources like river
the reaction ( in steam) and etc.
also the quenching process
( in liquid water) other than
cooling water for heat
exchangers. This waste
water has probability to
contain the residue of
hydrocarbons even though
assumption of pure water is
discharged.

58
6.2.3 Cost of total Waste Management system

Unit Capacity Specification Cost (RM))

Quantity: 1 Rotary Bar Screen Type 31485

Hx

Bar Screen MOC: Stainless Steel

− High automation
degree
− Low energy
consumption
− Easy maintenance
Quantity: 1 VORTEX Grite Chamber 47227

MOC: Stainless steel

Grit
− High grit separation
Chamber
efficiency
− Compact, space-
saving design
Quantity: 1 Horizontal Tank 78712

Equalization Length: 12m MOC: Carbon Steel

Basin Height: 8.5m

Diameter: 5.5m

Quantity: 2 Horizontal Tank 6400

Primary
Length: 12m MOC: Carbon Steel
Settling
Height: 4.5m
Tank
Diameter: 5.5m

Quantity: 2 Horizontal Tank 328826

Aeration
Length: 12m MOC: Carbon Steel
Tank
Height: 4.5m

59
 Diameter: 5.5m

Quantity: 2 Horizontal Tank 152702

Secondary Length: 12m MOC: Carbon Steel
Settling
Height: 4.5m
Tank
Diameter: 5.5m

Quantity: 1 MOC: Carbon Steel 94455

Chlorination − unaffected by pH
Chamber − nontoxic
− no secondary
pollution
Quantity: 1 Anaerobic digester 157425

Length: 12m MOC: Carbon Steel

Sludge
Digester Height: 4.5m − 85% removal rate
− 10 – 20 days
Diameter: 5.5m
digestion period
Quantity: 1 Drum Dryer 176945

MOC: Carbon Steel

Drying Bed − simple structure

− high capacity
− low-energy
consumption
Total 1.69 million

60
Layout of wastewater treatment plant

Primary
Settling
Tank
Wastewater Equalization
effluent Basin
Bar Grit
rack Chamber Primary
Settling
Tank

Return sludge line

Fertilizer
Drying
Bed Sludge Digester Secondary
Settling
Treated Tank
Effluent Pond Aeration Aeration
Disinfection Tank Tank
Secondary
Settling
Tank

61
6.3 Engineering Ethics in Plant Design

As members of the engineering profession, engineers are expected to exhibit the

highest standards of honesty and integrity. Engineering has a direct and vital impact on
the quality of life for all people. Accordingly, the services provided by engineers
require honesty, impartiality, fairness, and equity, and must be dedicated to the
protection of the public health, safety, and welfare. Engineers must perform under a
standard of professional behavior that requires adherence to the highest principles of
ethical conduct.

Based on the fundamentals principle, engineers should uphold and advance the
integrity, honor and dignity of the engineering profession by:

a. Using their knowledge and skill for the enhancement of human welfare.
b. Being honest and impartial, and serving with fidelity the public, their
employers and clients.
c. Striving to increase the competence and prestige of the engineering
profession.
d. Supporting the professional and technical societies of their disciplines.

The Fundamental Canons:

In the fulfilment of their professional duties, engineers shall:

1. Hold paramount the safety, health and welfare of the public

2. Perform services only in areas of competence
3. Issue public statements only in an objective and truthful manner
4. Act for each employer or client as faithful agents or trustees
5. Avoid deceptive acts
6. Conduct themselves honorably, responsibly, ethically and lawfully so as to
enhance the honor, reputation and usefulness of the profession

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Code of Ethics

Codes of ethics are written by specific groups of people for specific groups of
people, each group having its own purpose for existence and its own means of
accomplishing its purpose. Codes of ethics are to be reflections of the morally
permissible standards of conduct which members of a group make binding upon
themselves.

Malaysia Institute of Chemical Engineers (ICM)

The ethics adopted by ICM are similar to those introduced by the Board of Engineers
Malaysia (BEM). In general, there are total of 5 ethics:

1) A Registered Engineer shall at all times hold paramount the safety, health and
welfare of the public.
2) A Registered Engineer shall undertake assignments only if he is qualified by
education & experience in the specific technical fields in which he is involved.
3) A Registered Engineer shall issue public statements only in an objective and
truthful manner.
4) A Registered Engineer shall act for each employer or clients as faithful agent or
trustee.
5) A Registered Engineer shall conduct himself honourably, responsibly, ethically
and lawfully so as to enhance the honour, reputation and usefulness of the
profession

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6.3.1 Ethical Problem and Solution

The ethical arises when design the plant for example in calculating all the
theoretical data for every single unit due to the limited data given. The ethical problems
in plant design such as plant safety, public health and lawful in terms of allowable
parameter. The plant was design accordingly to the code of the ethics for engineer in
order to prevent the accident when the whole plant is applied or in a real industry.

As an engineer, we have to ensure that the design in black and white which can be
worked and constructed in real world as well as the efficiency in dealing with the
reliability of plant in the world. This could be done when the design of units is mostly
based on the sufficient data and information while the units that the data was limited are
no longer reliability since we lose a promoting method to scale up the whole plant in
reality and practically. Hence, we try to find all the information about the unit in library,
read the journal that have similar unit and even ask the related person who has precious
working experience in real plant in order to get a supportive data in our plant design.

On the other hand, we cooperate within our group members and try to come out
with the best solution together for example we take into account on each group
member’s opinion politely whenever there’s a conflict arises.

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6.3.2 Ethical Issues

Ethical issue is about the moral responsibilities of engineers in engineering design

process. During the environmental safety and health problem in operation of designed
plant lecture, the ethical issues involved are need to use knowledge and skill to increase
the public welfare, safety and health, being honest to the public and also being
responsible ethically and lawfully to enhance the honor, reputation and usefulness of the
profession.

During design plant, we are not ignoring the ethical issues when we put the public
safety above the cost of the plant. Additionally, the safety features such as safety
blanket should be incorporated within the storage tank for safety purpose. A sensitive
and efficient control system is necessary for all the units operation that operated at
temperature and pressure higher than ambient in order to maintain the operating
condition at safe level.

Besides that, all the equipment or unit operation are built and buy according to the
standard size and material made from. There is no more lie in construct this plant in
order to reduce the capital cost of the plant construction. Even though there may need to
spend for very long period of operation just to gain back the profit, the situation are still
accepted because the plant need to compensate for huge responsible if one day have
destroyed the health of public and ecosystem due to ignoring the ethical issues to make
profit.

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6.3.3 Good Ethics in Plant Design

Breaking the engineering ethics code could not be avoided due to lacking of time
especially when the design tasks need to be submitted in short period of time. Then, the
condition is worse as there are weekly assignments on plant design. Due to this
problem, some of the equipment is designed wrongly. Knowing that this should not be
practiced by professional engineer as it is not an act of honesty, the particular
equipment design are review back after the submission of the report so that the
correction on the equipment design could be made.

The code of ethics should be practiced when performing a plant design project.
This is because the fake value in the project can lead to the devastative consequence to
the constructed plant. The professional engineer should be responsible for the action
that he made and play an important role to conserve the environment by minimizing the
hazards of the plants towards the public health and environment. As an engineer, he will
be respected if one’s work is performed sincerely and honestly, take responsible on the
decision made, honest in writing design report without any cheating and put the public
safety and environment health on top of all stuff.

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References

Davis, M. L., and Cornwell, D. A. (2008). Introduction to Environmental Engineering

(4th Edition ed.): McGraw Hill.

Flor, R. (2012).). Environmental (and Social) Impact Assessment Instrument.

Retrieved from http://slideplayer.com/slide/8055387/ Accessed on 20
NOVEMBER 2017.

Wilkinson, S. K., Simmons, M. J. H., Stitt, E. H., and Watson, M. J. (2008).).

Understanding catalyst performance evolution during reactor start-up Retrieved
from https://www.birmingham.ac.uk/Documents/college-eps/chemical/eng-
d/projects/abstracts/engd-wilkinson.pdf Accessed on 22 NOVEMBER 2017.

ATTACHMENT
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