Training program is implemented to ensure ensures employees understand all health and
safety hazards.
Mandatory Process Hazard Analysis (PHA) must be completed along with Hazards
Operability Study (HAZOP).
Every 5 years after an initial analysis, the employers of the plant must complete an
updated PHA.
Ethanol plant will have at least two PHAs because its tentative run-length is ten years.
Safety Features
1st
level
Primary Safety
Features
(Designs, Plans,
Procedures)
-Process safety
management
procedures along
with a risk
management plan
-PHA and HAZOP
-Emergency Plans
-Establish
acceptable
levels of risk
-A risk
assessment and
analysis should
be completed
2nd
level
Secondary Safety
Features
-Sprinkler systems to
prevent the occurrence of
fire.
- Pressure relief systems to
prevent overpressure
(Rupture Discs, Safety
Relief Valves) in the pipes,
storage tanks, reactor,
etc
-Fire alarms,
monitors, control
systems
-Gas detection
systems which
detect flammable
gases at low
concentrations.
-Backup
generators (to
support utilities
and alarms).
3rd
level
Containment
Systems
4th
level
Emergency
shutdown systems
Ethane C2H6
Ethanol CH3CH2OH
Ethylene C2H4
PEL= 5mg
(Zr)/m3
Hazards Flammable,
harmful if inhaled
Flammable, volatile,
harmful if inhaled,
ingested
Flammable, volatile,
harmful if inhaled, contact
with skin
Mechanica
l irritation
Safety
Feature
s in
Ethanol
Plant
-Trenches built in
appropriate areas within
the plant to deal with
ethanol spill.
-Trenches minimize the
amount of vapor
released from spills and
prevents the ethanol
from collecting around
the leaking tanks.
Limits
Water H2O
-Steam causes
burns, may
rupture pipes,
pressure relief
system
necessary.
-Thermal
insulation
must be
installed on
metallic
equipment
which heats to
60oC or higher
to prevent
Zirconiu
m
tungstate
(Zr(WO4)2
)