Production of LPG From Natural Gas

CHAPTER 5

MATERIALS STORAGE & HANDLING

5.1 Introduction to material storage

Adequate storage facilities for raw materials, intermediate products, final products,
recycle materials, off grade materials and fuels are essential for the operation of plant.
Storage of the intermediate products is necessary during plant shut down for emergency
repair while storage of final products makes it possible to supply the customer even during
a plant difficulty or unforeseen shut down.
Bulk storage of liquid is generally handed by closed spherical or cylindrical
tanks to prevent the escape volatilities and minimize contamination. Since safety is an
important consideration in storage tank design; The American Petroleum Institute &
National fire Protection Association publish rate for safe design and operation. Gases are
stored at atmospheric pressure in wet or dry seal gas holders. The wet gas holder maintains
a liquid seal of water or oil between the top movable inside tanks and seal between two
tanks is made by means of flexible rubber or plastic curtain. Recent development in bulk
natural gas or gas product storage shows that the pumping into underground storage is the
cheapest method available. High pressure gases are stored in spherical or cylindrical
pressure vessels.

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5.2 STORAGE TANKS

It is important to know at this stage that there are two ways liquefied gases are
stored Pressurized storage where gas is in liquid phase under pressure at ambient
temperatures and Cryogenic or low temperature storage (generally at atmospheric
pressure) LPG is often stored in pressurized containers although it is also stored under
cryogenic conditions. Fig. 5.1 shows two types of pressurized LPG storages - sphere and
bullet. LNG is always stored under cryogenic conditions .At such temperatures, steel
becomes brittle like glass. The storages are made of special nickel steel as normal steel
becomes brittle at that low temperature. They are often double walled with concrete outer
shells utilized as additional resistance to tank damage and as containment in the unlikely
event of tank leakage. This type of tank with containment of leakage is the most costly, and
has most often been used for the storage of LNG.

Figure 5.1 LPG Storage

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Figure.5.2 LNG Receiving Terminal

The LNG tankers can have a carrying capacity from 20,000 cubic meters to 135,000 cubic
meters. A large LNG storage tank can be holding around 100,000 cubic meters of LNG.
For this capacity, the tank would be about 70 meters in diameter. Japan is the world's
largest importer of LNG and imports 94% of its gas as LNG.

5.3 Introduction to material handling

Solid may be handled by conveyers, bucket elevators, chutes, lift trucks and
pneumatic system. The selection of material handling equipment depends upon cost and
the work to be done.

Factors that must be considered in selecting such equipment include :

1. Chemical and physical nature of material being used.

2. Quantity of material moved per unit time.

3. Nature of feed and discharge from material handling equipment.

4. Continuous or intermittent nature of material handling.

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5. The major movement of liquid or gaseous raw material and product with in a plant
from a point of shipment is done by pipeline.

Movement of product & product outside of the plant is usually handled by rail,
ship, truck and air transportation depending upon the raw material and product s must be
provide in the design of the plant.

5.4 LIKELY HAZARD SCENARIOS AND RECOMMENDED

CONTROL STRATEGIES:

It is essential to recognize the various possible hazards in the operation of the plant
so that the remedial measures can be planned. Following are some of the common safety
hazards encountered in the LPG recovery unit.

All petroleum products give out vapors in amount depending upon the type of
product. These vapors, in a confined space, will tend to make the atmosphere leaner in
oxygen content – thus making it difficult to sustain normal breathing (asphyxiation).

5.4.1 Classification of Hazardous Area

5.4.1.1 Hazardous Area: Hazardous area means an area where hazardous atmosphere
exists or likely to occur

5.4.1.2 Hazardous Atmosphere: Hazardous atmosphere means an atmosphere containing

any inflammable gas in a concentration capable of causing ignition.

5.4.1.3 Zone Zero: It means an area in which hazardous atmosphere is continuously

present.
5.4.1.4 Zone -1: It means an area in which hazardous atmosphere is likely to occur under
normal operating conditions

5.4.1.5 Zone -2: It means an area in which hazardous atmosphere is likely to occur under
abnormal operating conditions
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5.4.2 Physiological effects

The hydrocarbon vapors heavier than air collect at low points near ground level.
These vapors have anesthetic effects. If air with hydrocarbon concentration of 0.1% is
inhaled for about 5 minutes, the person feels giddy. If concentration increases to 0.5% and
a person inhales such air for about four minutes, he exhibits symptoms similar to
alcoholism.

5.4.3 Explosion-fire

When the proportion of hydrocarbon in the hydrocarbon-air mixture falls within the
explosive limits, an explosion or fire could occur in presence of a source of ignition, such
as spark or an open flame. A hydrocarbon-air mixture can move on the ground over a
considerable distance and catch fire when in contact with a spark or an open flame.
Explosion could initiate another explosion or fire at a distance of ten to a hundred meters
because of its physical nature. Explosion is generally followed by a fire.

Explosive Limit (LEL, Higher Explosive

Product Lower % vol/vol Air) Limit (HEL, %
vol/vol Air)

Hydrogen 4.1 74.2

Methane 5.5 14.0

Ethane 3.2 12.5

Propane 2.37 9.5

Butane 1.6 8.5

Pentane 1.45 7.5

Hexane 1.2 6.9

Naphtha 1.10 6.0

Table 5.1 Explosive limits of hydrocarbon

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5.4.4 Auto-ignition

For combustion, three conditions are necessary. These are combustible material,
sufficient quantity of oxygen and a source of heat. In free air, there is no risk of ignition if
the hydrocarbon vapor temperature is less than the ignition temperature. However, if the
temperature of hydrocarbon vapors can catch fire on mixing with oxygen from the
atmosphere, even without the help of a flame or a spark is known as auto ignition.

5.4.5 Sparks

Ignition of hydrocarbon vapors and air mixture can be produced by a spark which may
cause an explosion or fire. The possible sources of sparks are.
 Rubbing of ferrous metals between themselves or with other hard materials like
concrete.
 Falling of iron tools.
 Sparks from loose electrical fittings.
 Hot job like gas cutting, grinding, welding, stress relieving etc.

5.4.6 Lightning

Lighting can fall on metallic objects such as chimneys, towers, tanks and tall
buildings these can damage the structures or lead to ignition of hydrocarbons-air mixtures,
if present. The vent/safety relief valve discharges at high points to the atmosphere are
especially vulnerable to lightning.

5.4.7 Static electric charges

Static electric charges can be produced by rubbing different bodies between

themselves and these can accumulate and produce sparks strong enough to initiate a fire or
an explosion. Such charges can be produced by rubbing of petroleum products on the
internal surfaces of pipes, tanks and various equipments. Static charges can also be
produced by other operations such as a driving belt, cleaning with silk or nylon cloth and

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fine mesh screens and filters etc. A proper system of grounding is essential for such
operations.

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Recommended Control Strategy

 Ensure all storage areas and/or facilities are secure and appropriate.

 Provide appropriate equipment and materials to clean up a spillage.

 Cover any loads of LPG products whilst in transit.
 Ensure that deliveries of LPG products are made at appropriate times.
 Do not accept any containers of LPG products that are damaged and/or leaking.

 Ensure that any spillages that occur during delivery are cleaned up appropriately.
 Keep LPG products covered and/or sealed
 Clean up spillages promptly
 Keep “in use” stocks to the minimum required

 Staff responsible for storage areas and/or facilities to will ensure that the drift of
dust beyond the perimeter is kept to a minimum.
 Keep floor surfaces swept clean to prevent tracking by people and/or vehicles
beyond the perimeter.

 Sweep up and dispose of spillages in a timely and appropriate manner

 Maintain an accurate storage manifest/register.
 Keep products and blends are segregated at all times.
 Ensure all storage bays and bins are clearly labeled.
 Ensure all storage, loading and blending plant and equipment is cleaned from all
residues when changing from one product to another.

 Do not store product in bags that are not correctly stamped.

 Contact between LPG products, people and livestock will be minimized.
 Risk Assessments are required to be conducted on the procurement, storage and
handling of LPG products.
 Managers will develop, implement and monitor the effectiveness of hazard
management procedures.

 Managers are to ensure that staff and students are made aware of any State,
Federal, local and industry regulations which have to be observed.

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 Managers must ensure that appropriate safety warning signs and/or information is
displayed/available regarding nature of hazards and risk control measures.
 Conduct regular inspection & testing of equipment and infrastructure to identify
what maintenance requirements
 Staff will undertake appropriate training.

5.5 Types of LPG Storage Tanks

LPG tanks are only supplied as Cylinders or Toroidals (Polo Mint Shaped).All LPG
tanks are pressure vessels. They have to be designed to withstand the pressure held within.
That means no corners, and, consequently no square or rectangular tanks.

Tank 'life' Although static LPG storage tanks and proprietory gas cylinders
('bottles') have manadatory test periods (Ten years and Fifteen years respectively),
Automotive LPG tanks are not subject to these checks. It has been assumed that any
Automotive LPG tank will be scrapped along with the vehicle at the end its life, which is
Ten years on average.

5.5.1Cylinders

This is a standard cylinder tank .The cylinder is the most popular choice as it is the
cheapest to produce, which is reflected in its purchase price. Cylinder tank capacity can be
as little as 25 litres or so right up to 200 litres although you must not forget to deduct 20%
of the capacity for expansion space.

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Figure 5.3 Toroidal (Polo mint shaped)

Here is a spare wheel replacement toroidal (doughnut shaped) tank. The tank in the
picture is designed to take the place of an underslung spare wheel. The toroidal tank can be
a good solution for those wanting to maintain load or boot space. The spare may not be
carried at all if the tyres are treated with puncture sealant (either all tyres are treated by a
specialist or a can of puncture 'foam' is carried in the vehicle). Although this type of tank
has great benefits it can be much more expensive to buy than a cylinder as it is much more
difficult to produce.

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