Table 8.

13: HAZOP for Reactor R-102

Project Name: Production of 10000 Metric Tonnes Date: 05/05/2020 Page: 2 of 6 Assigned to: Safety,
of Bioethanol Health and Environment
Department
Process: Neutralization of hydrolysate from Sulphuric acid by using Calcium Hydroxide
Section: R-102 Prepared by: Mohamad Afie bin Rosman
Item Study Node Process Deviation Possible Causes Possible Consequences Action Require
Parameter
1. Continuous Flow No  Inlet line rupture  Neutralization not  Periodic
  Stirred Tank  Fail to open the occur (high content maintenance of
Reactor control valve of sulphuric acid) control valves
(CSTR), system  Blast and rupture of  Visual inspection
Neutralizer R-  Blockage happen in pipeline may occur of pipelines
102 the piping system
   Low  Plugging and  Neutralization take  Installation of
broken pipe longer time to alarm or indicator
 Blockage happen complete for flow in the
in the piping  Outlet pipeline
system concentration of  Periodic
 Control valve Sulphuric acid maintenance of
system for higher control valves
reactants flow not  Visual inspection
 working properly of pipeline
High  Control valve  Loss of reactant due  Installation of
system for to overflow alarm or indicator
reactants flow not  Increase of reactor for temperature in
working properly temperature the pipeline
 Ineffective  Periodic
neutralization maintenance of
process control valves
 Blast and rupture of  Visual inspection
the reactor may of pipeline
happen
 2.  Continuous  Temperatur  Low  Excessive removal  Reduce reaction  Installation of
  Stirred Tank e of heat due to low rate hence reaction alarm or indicator
Reactor   flow of steam for take longer time for temperature in
(CSTR), the reactor  Not able to achieve the reactor
Neutralizer R-  Control valve desired reaction  Increase steam
102 system for the temperature flow to the
  steam flow not  Ineffective reactor’s heating
working properly neutralization system
process  Periodic
maintenance of
control valves
  High  Excessive  Increase of reactor  Installation of
introduction of temperature alarm or indicator
heat due to high  Ineffective for temperature in
flow of steam for neutralization the reactor
the reactor process  Decrease steam
 Control valve  Blast and rupture of flow to the
system for the the reactor may reactor’s heating
steam flow not happen system
working properly  Periodic
maintenance of
control valves
 3.  Continuous  Level  Low  Control valve  Ineffective  Installation of
  Stirred Tank   system for neutralization alarm or indicator
Reactor reactants flow not process for level in the
(CSTR), working properly  Increase the reactor reactor
Neutralizer R-  Blockage may temperature  Periodic
102 happen in the  Quality of product maintenance of
  pipeline reduced control valves
 Leakage of the  Visual inspection
piping system of pipeline
 High  Control valve  Reactant and  Installation of
system for product losses alarm or indicator
 reactants flow not  Reaction for level in the
working properly temperature not reactor
 Outlet pipeline achieved  Periodic
clogged  Product quality not maintenance of
achieved control valves
 Visual inspection
of pipeline
 4.  Continuous  Agitation  No  Agitator motor  Slow reaction rate  Motor to be
  Stirred Tank   mixing failure  Product quality not checked
  Reactor    Shaft seal failure achieved periodically
(CSTR),  Proper lubrication
Neutralizer R- of motor
102  Slow  Corrosion of the  Proper mixing does  Proper

  mixing impeller not happen maintenance of

   Wear or tear on the  Product quality not motor

agitator motor achieved  Proper lubrication
 Gear, belt or shaft of motor
damage
 More  Gear failure  Impeller runs in  Proper inspection
mixing high rpm and maintenance