PRELIMINARY HAZARD AND OPERABILITY (HAZOP) ANALYSIS

Study node selected:

Sulfonator ( R 101 )

(e.g. line, equipment, pump, etc.)

Design intent:

The reactor is being used as a vessel wherein the Polystyrene-Powdered

Activated Carbon is being reacted with Sulfuric Acid achieved through
agitation at a constant temperature of 60oC and speed of 300rpm. A heating
jacket is used to supply heat since the process is endothermic.

Process parameter selected:

Reaction temperature

(e.g. flow, temperature, pressure, pH, etc.)

Applicable guide words:

Less, More

Summary Table
No.

Guide word

Deviation

Less

Decrease in the
reaction
temperature (T <
60oC)

1. Heater Controller Fail

Increase in the
reaction
temperature (T >
60oC)

1. High supply of heat

from boiler

More

Possible causes

2. Vessel Jacket Failure

2. Vessel Jacket Failure

Consequences

Corrective/Preventive
Measures

1. Reaction will
not proceed to
completion

1. Increase Heat supplied

in the boiler
2. Check the heater control
3. Vessel Jacket
Replacement

1. Unnecessary
energy
consumption

1. Check the heater control

2. Jacket Replacement
3. Switch jacket service
from heating to cooling to
achieve reaction
temperature.