Focusing on the four critical nodes as specified in the assignment: air
compression, methanol preheating, the reactor, and the reactor effluent
heat exchanger.
Node 1: Air Compression (C801 and E-802)
Deviations, Causes, Consequences, Safeguards, and
Recommendations
Deviatio Conseque Safegua Recommenda
Cause
n nce rd tion
Pressure
No air Regular
and flow
Compress supply to maintenance,
alarms,
No Flow or failure, reactor, install
backup
blockage process redundant
compress
shutdown compressor
or
Improve
Pressure
Equipment control
Over- relief
damage, system,
High compressi valves,
safety regular
Pressure on, control pressure
valve calibration of
failure control
activation pressure
system
sensors
Regular
Insufficient Inefficient cleaning of
Temperat
Low preheating reaction, heat
ure
Temperat , heat incomplete exchanger,
sensors,
ure exchanger methanol optimize
alarms
fouling conversion preheating
system
Node 2: Methanol Preheating (P-801 and E-801)
Deviations, Causes, Consequences, Safeguards, and
Recommendations
Deviatio Conseque Safegua Recommend
Cause
n nce rd ation
No
Regular
methanol Flow
Pump maintenance,
supply to alarms,
No Flow failure, install
reactor, backup
blockage redundant
process pump
pump
shutdown
Improve
control
Overheat Methanol Temperat
High system,
ing, decomposit ure
Temperat regular
control ion, safety sensors,
ure calibration of
failure hazard alarms
temperature
sensors
Insufficient Regular
Pump methanol inspection for
Pressure
Low inefficien supply, leaks,
sensors,
Pressure cy, reduced optimize
alarms
leakage reaction pump
rate performance
Node 3: Reactor (R-801)
Deviations, Causes, Consequences, Safeguards, and
Recommendations
Deviatio Conseque Safegua Recommend
Cause
n nce rd ation
Temperat
Exother ure Enhance
mic Catalyst control cooling
High
reaction damage, system, system, install
Temperat
runaway, potential emergen additional
ure
cooling explosion cy temperature
failure shutdow sensors
n
Insufficie Reaction
Optimize
nt Reduced monitorin
reaction
Low reaction formaldeh g,
conditions,
Conversi time, yde yield, catalyst
regular
on catalyst economic regenera
catalyst
deactivat loss tion
replacement
ion schedule
Improve
Pressure
Equipment control
Gas relief
damage, system,
High buildup, valves,
safety regular
Pressure control pressure
valve calibration of
failure control
activation pressure
system
sensors
Node 4: Reactor Effluent Heat Exchanger (E-803)
Deviations, Causes, Consequences, Safeguards, and
Recommendations
Deviatio Conseque Safegua Recommend
Cause
n nce rd ation
Overheatin
Regular
g of Flow
Blockage maintenance,
reactor alarms,
No Flow , pump install
effluent, backup
failure redundant
process pump
pump
shutdown
Insufficie Degradatio Regular
nt n of cleaning of
Temperat
High cooling, downstrea heat
ure
Temperat heat m exchanger,
sensors,
ure exchang equipment optimize
alarms
er , safety cooling
fouling hazard system
Regular
Inefficient
Leakage, inspection for
heat Pressure
Low pump leaks,
transfer, sensors,
Pressure inefficie optimize
reduced alarms
ncy pump
cooling
performance
Summary
This HAZOP analysis identifies potential deviations in the formaldehyde
production process, their causes, consequences, existing safeguards, and
recommendations for improvement. By addressing these issues, you can
enhance the safety and operability of the process.
To perform a HAZOP (Hazard and Operability) analysis for the
formaldehyde production process, you will need to focus on the four
critical nodes specified:
1. Air Compression (C-801 and E-802)
2. Methanol Preheating (P-801 and E-801)
3. Reactor (R-801)
4. Reactor Effluent Heat Exchanger (E-803)
HAZOP Report Structure
1. Air Compression (C-801 and E-802)
Deviatio Recommendation
Causes Consequences Safeguards
n s
Regular
High Blockage in Equipment Pressure
maintenance and
Pressure downstream failure, leaks relief valves
checks
Inadequate air Alarms, Implement
Low Compressor
supply to backup redundancy in
Pressure failure
reactor compressor design
2. Methanol Preheating (P-801 and E-801)
Deviation Causes Consequences Safeguards Recommendations
Decomposition of Temperature
Overheatin Control Review control logic
methanol, fire sensors,
g failure and safety systems
risk alarms
Low Flow Pump Incomplete Flow meters,
Install backup pumps
Rate failure preheating alarms
3. Reactor (R-801)
Consequence Recommendatio
Deviation Causes Safeguards
s ns
Exothermic Equipment Cooling
High Ensure regular
reactions, damage, system,
Temperatur calibration of
insufficient runaway temperature
e sensors
cooling reaction monitoring
Schedule regular
Low Catalyst Catalyst
Reduced yield catalyst
Conversion deactivation monitoring
replacement
4. Reactor Effluent Heat Exchanger (E-803)
Recommendation
Deviation Causes Consequences Safeguards
s
Damage to Evaluate heat
High Outlet Insufficient Temperature
downstream exchanger
Temperature cooling monitoring
equipment efficiency
Reduced heat Regular Implement
Fouling,
Blockage transfer, cleaning improved filtration
debris
overheating schedules systems
