PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Study Parameter Guide Deviation Causes Consequence Action required

node word
Bioethanol Static More Accumulation of  Circulation of liquid in the  Possible risk of explosion  Valves and flanges that are completely painted
storage electricity static electricity valve. if difference in electrical should be conductively bridged and earthed.
tank to ( due to tank  Bad earth grounding. potential occur
Feed filling)
Preparatio
n(Includin
g Feed
Pump)
Bioethanol Level High High level in  Overfill  Ethanol spill  Manual observation
storage storage Tank  Level Indicator Transmitter  Fire or explosion.  Ensure LI/LIT functioning
tank to (LIT) failure during ethanol  Safety Hazard  Spill containment dikes are required to contain
Feed loading to the tank. the volume of the largest tank plus rainfall within
Preparatio  LI failure the contained area & Draining provision to
n(Includin closed system
g Feed  Fire & Safety system to be provided
Pump)  High level alarms to be provided.
 Gas detection system may be provided.
Low Low level in  No/Less tank loading  Pump dry run leading to  Manual observation of tank on daily basis
storage Tank  LI failure Cavitation &Trip  Ensure LI/LIT functioning
 Flange/Tank Leakage  No flow to downstream  Interlock provision for automatic pump
 Leakage due to corrosion Process trip/downstream process
 Suitable corrosion allowance to be provided as
generally tank are made of carbon steel for low
capital cost.
 Preventive inspection and maintenance.
 Low level alarms to be provided.

Pressure High High pressure in  External heat source (fire)  Possible explosion and  Pressure Relief Valve (PSV) with standby to be
bioethanol tank. fire due to rising build-up installed & drain should be ensured to Closed

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

of pressure in the tank. system.

 PI/PAH to be provided
 Provide flame arrestor, grounding/ bonding, and
lightening protector to the tank to protect from
fire risk and subsequent pressure built up in the
tank.
 Suitable design pressure of Tank
Low Low pressure in Not Envisaged
bioethanol tank.
Temperature High Not Envisaged  Possible explosion and  Pressure Relief Valve (PSV) with standby to be
fire due to rising build-up installed & drain should be ensured to Closed
of pressure in the tank. system.
 PI/PAH to be provided
 Provide flame arrestor, grounding/ bonding, and
lightening protector to the tank to protect from
fire risk and subsequent pressure built up in the
tank.
Suitable design pressure of Tank
Low Not Envisaged
Loss More Ethanol loss as  Atmospheric heating Ethanol loss   Internal Floating Roofs on the tanks to control
Vapor the vapour emissions
 Proper insulation to be provided
Feed 
Preparatio
n
Section(Fe
ed
Evaporator
& Feed
Heater)
Feed Level High NA 
Evaporator

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

(Feed
Side)
Low NA 
Pressure High High Pressure in  More LP Steam flow  Bioethanol will not  PI to be provided
Feed Evaporator  Pump failure/disfuction vaporise Causing  PSV to be Provided
destabilising flow in feed
heater

Low Low Pressure in  Less LP Steam flow  Bioethanol will not  PI to be provided
Feed Evaporator  Less Feed Flow vaporise Causing  TI to be provided
 Pump failure/disfuction destabilising flow in feed  TT to be provided & LP steam flow to be
heater interlocked with TT so as to Stop feed flow at
very High Temperature
Temperature High High Temperature Less Feed Flow  Coking in evaporator  TI to be provided
in Feed tube & Feed heater at  TT to be provided & LP steam flow to be
Evaporator downstream interlocked with TT so as to Stop feed flow at
very High Temperature
Low Low Temperature Less LP Steam flow  Bioethanol will not  TI to be provided
in Feed vaporise Causing  TT to be provided & LP steam flow to be
Evaporator destabilising flow in feed interlocked with TT so as to Stop feed flow at
heater very High Temperature

Flow (Feed) No No flow to  Inlet Control valve failure  No heat exchange occurs  PI to be provided
evaporator and  Pump faulty  Economic loss  FI/FT to be provided & interlock with steam flow.
HEX  Pipe blockage  Pipe rupture  TI to be provided
 TAH to be provided

Less Less flow to HEX  Feed control valve partially  Off Spec product.  PI to be provided
closed.  Less yield of desired  FI/FT to be provided & interlock with steam flow.
 Leakage in the inlet pipeline. product.  TI to be provided
 Faulty pump  Production loss  TAH to be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

More More flow to HEX  Feed control valve failure.  Off Spec product.  Fractionation section have take care of off spec
 Control is saturated  Lower Outlet temperature product.
 High flow alarm
Feed   
Evaporator
(Steam
Side)
Level High NA 
Low NA 
Pressure High High Steam  Disruption in steam header  More Bioethanol heating  PI to be provided
Pressure in Feed leading to higher  TI to be provided
Evaporator temperature.  PSV to be Provided
 Coking in evaporator
tube & Feed heater at
downstream
 Pressure will rise

Low Low Steam  Disruption in steam header  Bioethanol will not  PI to be provided
Pressure in Feed  Steam leakage vaporise Causing  TI to be provided
Evaporator destabilising flow in feed  TT to be provided & LP steam flow to be
heater interlocked with TT so as to Stop feed flow at
very High Temperature
Temperature High High Temperature Disruption in steam header  Coking in evaporator  TI to be provided
in Feed tube & Feed heater at  TT to be provided & LP steam flow to be
Evaporator downstream interlocked with TT so as to Stop feed flow at
very High Temperature
Low Low Temperature  Disruption in steam header  Bioethanol will not  TI to be provided
in Feed Steam leakage vaporise Causing  TT to be provided & LP steam flow to be
Evaporator destabilising flow in feed interlocked with TT so as to Stop feed flow at
heater very High Temperature

Flow (Feed) No No flow to  Inlet Control valve failure  No heat exchange occurs  PI to be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

evaporator and  Pipe blockage  Off spec product  Steam flow/Pressure to be interlocked with
HEX Feed pump & Control valve
 TI to be provided
 TAH to be provided

Less Less flow to HEX  Steam control valve partially  Off Spec product.  PI to be provided
closed.  Less yield of desired  Steam flow/Pressure to be interlocked with
 Leakage in the inlet pipeline. product. Feed pump & Control valve
 Production loss  TI to be provided
 TAH to be provided

More More flow to HEX  Steam control valve failure.  Off Spec product.  Fractionation section have take care of off spec
 Higher Outlet product.
temperature  High flow alarm
 PI to be provided
Feed   
Heater
Level High NA 
Low NA 
Pressure High High Steam Higher Burning fuel flow  Pressure will rise.  PI to be provided
Pressure in Feed   Pressure may exceeed  PSV to be Provided
Heater design pressure.

Low Low Steam  Low feed rate  Less bioethanol  PI to be provided

Pressure in Feed conversion  Unreacted ethanol recovery
Heater
Temperature High High Temperature Higher Burning fuel flow  Coking in evaporator  TI to be provided
in Feed Heater Lower Feed rate tube & Feed heater at  TT to be provided
downstream  Feed By pass to be provided
 Pressure increase  Flow meter at feed
 Side reactions increase

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Low Low Temperature Higher Feed flow  Bioethanol will not  TI to be provided
in Feed Lower Burning fuel rate vaporise Causing  TT to be provided
Evaporator destabilising flow  Flow meter at feed
 Lower ethylene  Unreacted ethanol recovery
conversion

Flow (Feed) No No flow to Feed  Inlet Control valve failure  No heat exchange occurs  PI to be provided
heater  Pipe blockage  Off spec product  Steam flow/Pressure to be interlocked with
 Pump failure/cavitation  High tube skin Feed pump & Control valve
temperature leading to  TI to be provided
tube collapse  TAH to be provided
 Burner control

Less Less flow to Feed  Inlet Control valve failure  No heat exchange occurs  PI to be provided
heater  Pipe blockage  Off spec product  Steam flow/Pressure to be interlocked with
 Pipe leakage  High tube skin Feed pump & Control valve
 Pump failure/cavitation temperature leading to  TI to be provided
. tube collapse  TAH to be provided
  Burner control
More More flow to Feed  Control valve failure.  Less bioethanol  TI to be provided
heater conversion because of  TT to be provided
less temperature  Flow meter at feed
 Unreacted ethanol recovery
Reactor   
Temperature High High temperature  Higher Feed Temperature  Offspec product  TI to be provided with alarm
in reactor  Higher fuel flow  Reaction rate increases  PSV to be provided
 Higher reactor pressure  Control valve inlet to be interlocked with TI
 Fractionation section will take care of offspec
product and off spec gas may be recycled to
fuel to heater.

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Low Low temperature  Poor heating supply to the  Less product yield due  Control valve inlet to be interlocked with TI
in reactor. reactor. to endothermic reaction  Bioethanol will be recycled.
 Lower fuel flow  TI to be provided
Pressure High High pressure in  Higher reactor temperature  Reactor collapse  PI to be provided with alarm
reactor  CV Outlet failure  Less product yield  PT to be provided and interlocked to open vent
valve.
 PSV to be provided
 Fractionation section will take care of offspec
product and off spec gas may be recycled to
fuel to heater. Regular maintenance of flow
lines.

Pressure Low Low pressure in  Lower reactor temperature  Reaction moves in  PI to be provided with alarm
reactor  CV inlet failure forward direction.
Flow Low Low flow to the  Blockage in the inlet or outlet
 No product formed in the  Routinely check ethanol feed and product feed
reactor/ Low flow lines. reactor. lines for build-up or corrosion.
to the separator  CV failure  Pressure built up in the  Routinely check the level of ethanol in storage
from the reactor reactor. tank.
 Implement safe shut down of the reactor when
feed stream fail.
 High pressure alarm in reactor.
High High flow to the  Malfunctioning of flow control  Poor conversion of the  Regular maintenance and calibration of
reactor valve. ethanol (Steam supply instrument safety systems.
will be inadequate to the
rate of ethanol flow)
Catalyst Other Catalyst  Long reaction time  Less ethylene yield  Catalyst to be regenerated
deactivation than deactivation  High temperature  New catalyst fed.
 Coking
 Higher pressure
Quenching   
Temperature High High temperature  Higher feed temperature to  Lower separation  TI to be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

in quenching reactor & hence in  TT to be provided

column downstream  TT to be linked with water flow so as to increase
 Low flow of cooling media in the water flow
the quenching tower.  Regular inspection and maintenance of cooling
water supply systems.
 Secondary supply systems and emergency
back-up for the pumps.

Low low temperature in  Lower feed temperature to  More water will be added  TI to be provided
quenching column reactor & hence in than required  TT to be provided
downstream  More loading of waste  TT to be linked with water flow so as to
water treatment unit decrease the water flow

Pressure High High Pressure in  Higher feed pressure to  More efficiency in  PI to be provided
quenching column reactor & hence in separation due to
downstream increase in absorption of
gas at higher pressure
Low Low Pressure in  Lower feed pressure to  Less efficiency in  PI to be provided
quenching column reactor & hence in separation due to  PT to be provided
downstream increase in absorption of  PT to be linked with water flow so as to increase
gas at low pressure the water flow
Flow High High flow to  CV failure  Less efficiency in  FI to be provided
quenching column separation due to  FT to be provided
increase in absorption of  FT to be linked with water flow so as to
gas at higher pressure decrease the water flow

Low low flow to  CV failure/malfunctioning  More water will be added  FI to be provided
quenching column  Pipe leakage than required  FT to be provided
 Pipe Blockage  More loading of waste  FT to be linked with water flow so as to
water treatment unit decrease the water flow
 Poor quenching,  Regular inspection and maintenance of pipes
compression, causing and valves.

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

wash and drying process.

 Poor grade of chemical
ethylene.
Compress 
or
Pressure Less/N Less outlet  Supplier  Economic loss  Gas detection to be provided
o pressure  Valve partly or completely  Ethylene liquefaction  Fire fighting system to be provided
closed difficult  PI/PT to be provided
Low  Compressor damage  Compressor recirculation line to be provided
lubrication in  Rise in temp
 piston  Fire & explosion
 Human error  Maintenance problems
 Strainer is choked  Less ethylene recovery
 Leakage or puncture in the
pipeline
 Breaking of gasket
 Presence of Oil &
condensate
in the pipeline.
Pressure More More outlet  Valve Shut down  Pressure exceeds more  PI/PT to be provided
pressure than Design Pressure  PRV to be provided
 Compressor Trip  Interlock with vent valve at high Pressure
 Economic loss.

Air ingress Part Not hazardous 

of till no leak
takes place
Temperature Less/N Low T at Inlet No hazard 
o -Seasonal effect
More Insufficient cooling Low compressor  TG
Suction pressure low efficiency  TT with interlock at High T for compressor trip
Less ethylene recovery

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

 Ethylene liquefaction will

be difficult
 Fire & explosion

Flow No/ No or less flow of  NO flow from feed  No feed at compressor  PI to be provided
less to compressor  CV failure/Malfunction inlet leading to  FT at feed to be linked with compressor trip
 Rupture of pipeline or minor compressor dry run  Recirculation of compressor to be started on no
leak from pipeline.  Overheating flow in feed line
 Vibration of compressor

More More flow of to  CV malfunction  Less compressor  PI to be provided

compressor efficiency leading to  Compressor bypass line to be opened for
lower pressure at outlet pressure equalisation
 Less liquefaction
efficiency
 Overheating
 Vibration of compressor

  
Carbon   
Dioxide
removal
Temperature High High temperature  Higher feed temperature to  Lower separation of  TI to be provided
in Caustic wash reactor & hence in carbon dioxide  TT to be provided
column downstream  TT to be linked with caustic solution so as to
increase the caustic solution flow

Low Low temperature  Lower feed temperature to  More caustic solution will  TI to be provided
in Caustic wash reactor & hence in be added than required  TT to be provided
column downstream  More loading of waste  TT to be linked with caustic solution so as to
water treatment unit decrease the caustic solution flow


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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Pressure High High Pressure in  Higher feed pressure to  More efficiency in  PI to be provided
Caustic wash reactor & hence in separation due to
column downstream increase in absorption of
gas at higher pressure
Low Low Pressure in  Lower feed pressure to  Less efficiency in  PI to be provided
Caustic wash reactor & hence in separation due to  PT to be provided
column downstream increase in absorption of  PT to be linked with Caustic wash solution flow
gas at low pressure so as to decrease the Caustic wash solution
Flow High High flow to  CV failure  Less efficiency in  FI to be provided
Caustic wash separation due to  FT to be provided
column increase in absorption of  FT to be linked with water flow so as to increase
gas at higher pressure the water flow

Low Low flow to  CV failure/malfunctioning  More water will be added  FI to be provided
Caustic wash  Pipe leakage than required.  FT to be provided
column  Pipe Blockage  More loading of waste  FT to be linked with Caustic wash solution flow
water treatment unit so as to decrease Caustic wash solution flow
Low Low Low caustic flow  Low caustic level in  Ineffective use of caustic  PH gauge to be provided.
drum/tank. to scrubber.  Secondary containment for the drum/tank.
 Chemical addition line  Unable to supply to  Daily inspection.
failure. caustic to scrubber.  Conduct preventive inspection of piping.
 Chemical metering pump Potential leak at caustic
unable to maintain PH level. tank.
  Spray caustic.
 Poor grade of chemical
ethylene.
  
  
Cooling   
section 1
Product Level High NA 
Side

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Low NA 
Pressure High High Pressure in  CV failure  Pressure will rise.  PI to be provided
Chiller 1  Compressor malfunction  Pressure may exceeed  PSV to be Provided
design pressure.

Low Low Pressure in  CV failure  Less Separation  PI to be provided

Chiller 1  Compressor malfunction efficiency leading to less
pure ethylene production

Temperature High High Temperature  High temperature at heater  Less cooling leading to  TI to be provided
in Chiller 1 outlet less ethylene recovery  TT to be provided
 Compressor overpressure  Unrecovered ethylene along with bottom to be
leading to over heating sent to fuel gas
 Scaling on heat exchanger  Heat exchanger cleaning
tubes
Low Low Temperature  High compression by  No hazard  TI to be provided
in chiller compressor
Flow No No flow to Chiller  Inlet Control valve failure  No heat exchange occurs  FI to be provided
(Product) 1  Pipe blockage  Off spec ethylene  Unrecovered ethylene along with bottom to be
 Compressor failure product sent to fuel gas


Less Less flow to Chiller  Inlet Control valve failure  No heat exchange occurs  FI to be provided
1  Pipe blockage  Off spec ethylene  Unrecovered ethylene along with bottom to be
 Pipe leakage product sent to fuel gas
 Compressor failure

More More flow to  Control valve failure.  Less ethylene recovery  TI to be provided
Chiller 1 because of higher  Unrecovered ethylene along with bottom to be
product temperature at sent to fuel gas
chiller outlet

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Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Refrigerant   
Side
Level High NA 
Low NA 
Pressure High High Pressure in  CV failure  Pressure will rise.  PI to be provided
Chiller 1  Refrigerant Compressor  Pressure may exceeed  PSV to be Provided
malfunction design pressure.  Environmental hazard of loss of refrigerant

Low Low Pressure in  CV failure  Less cooling efficiency  PI to be provided

Chiller 1  Compressor malfunction leading to less pure
ethylene production

Temperature High High Temperature  High temperature at heater  Less cooling leading to  TI to be provided
in Chiller 1 outlet less ethylene recovery  TT to be provided
 Refrigerant Compressor  Unrecovered ethylene along with bottom to be
overpressure leading to over sent to fuel gas
heating 

Low Low Temperature  High refrigerant compression  No hazard  TI to be provided
in chiller1 by compressor  Heat exchanger cleaning
 Scaling on heat exchanger
tubes
Flow No No flow to Chiller 1  Inlet Control valve failure  No cooling of product  FI to be provided
 Pipe blockage occurs  Environmental hazard of loss of refrigerant
 Compressor failure  Off spec ethylene  Ensure maintenance procedures and schedules
product for pumps, valves and pipe lines.

Flow Less Less flow to Chiller  Inlet Control valve failure  No cooling of product  FI to be provided

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Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

1  Pipe blockage occurs  Environmental hazard of loss of refrigerant

 Compressor failure  Off spec ethylene  Ensure maintenance procedures and schedules
product for pumps, valves and pipe lines.

Flow More  More flow to  Control valve failure  More cooling of product  FI to be provided
Chiller 1  Compressor failure occurs  Environmental hazard of loss of refrigerant
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

Seperation   
Column 1
Level High High level in  CV failure  Offspec product due to  LI to be provided
column less separation and  LT to be provided
heavy bottom will come
along with ethylene
product
 Column flooding

Low Low level in  CV failure  less production of  LI to be provided

column ethylene  LT to be provided
 Downstream chiller will  LI to be linked with refrigeratnt flow in chiller 2.
go dry run

Pressure High High Pressure in  CV failure  Pressure will rise leading  PI to be provided
column  Compressor malfunction to less cooling and  Unrecovered ethylene along with bottom to be
separation efficiency in sent to fuel gas
column

Low Low Pressure in  CV failure  More cooling leading to  PI to be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

column  Compressor malfunction more ethylene purity

 No hazard

Temperature High High Temperature  High temperature from  Less cooling leading to  TI to be provided
in column upstream less ethylene recovery  TT to be provided
 Unrecovered ethylene along with bottom to be
sent to fuel gas

Low Low Temperature  Low temperature from  No hazard  TI to be provided

in column upstream
Flow No No flow to column  Inlet Control valve failure  No ethylene production  FI to be provided
(Product)  Pipe blockage  Column dry out.  FT to be provided
 Compressor failure   FT to be linked with refrigeratnt flow in chiller 2
 Install low level alarm.
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

Less Less flow to C  Inlet Control valve failure  Less ethylene production  FI to be provided
column  Pipe blockage  Poor stripping and off  FT to be provided
 Pipe leakage spec product  FT to be linked with refrigeratnt flow in chiller 2
 Compressor failure  Install low level alarm.
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

More More flow to  Control valve failure.  Less ethylene recovery  LI to be provided
column because of higher level in  LT to be provided
column  LI to be linked with refrigeratnt flow in chiller
 Flooding in the column 2.TI to be provided
 Changes in product  Install low level alarm.
quality  Ensure maintenance procedures and schedules
 Changes in operation for pumps, valves and pipe lines.

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Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

parameters
Cooling   
section 2
Product Level High NA 
Side
Low NA 
Pressure High High Pressure in  CV failure  Pressure will rise.  PI to be provided
Chiller 2  Compressor malfunction  Pressure may exceeed  PSV to be Provided
design pressure.

Low Low Pressure in  CV failure  Less Separation  PI to be provided

Chiller 2  Compressor malfunction efficiency leading to less
pure ethylene production

Temperature High High Temperature  High temperature at heater  Less cooling leading to  TI to be provided
in Chiller 2 outlet less ethylene recovery  TT to be provided
 Compressor overpressure  Unrecovered ethylene along with bottom to be
leading to over heating sent to fuel gas
 Scaling on heat exchanger  Heat exchanger cleaning
tubes
Low Low Temperature  High compression by  No hazard  TI to be provided
in chiller2 compressor
Flow No No flow to Chiller 2  Inlet Control valve failure  No heat exchange occurs  FI to be provided
(Product)  Pipe blockage  Off spec ethylene  Unrecovered ethylene along with bottom to be
 Compressor failure product sent to fuel gas


Less Less flow to  Inlet Control valve failure  No heat exchange occurs  FI to be provided
Chiller2  Pipe blockage  Off spec ethylene  Unrecovered ethylene along with bottom to be
 Pipe leakage product sent to fuel gas
 Compressor failure

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

More More flow to  Control valve failure.  Less ethylene recovery  TI to be provided
Chiller2 because of higher  Unrecovered ethylene along with bottom to be
product temperature at sent to fuel gas
chiller outlet
Refrigerant   
Side
Level High NA 
Low NA 
Pressure High High Pressure in  CV failure  Pressure will rise.  PI to be provided
Chiller 2  Refrigerant Compressor  Pressure may exceeed  PSV to be Provided
malfunction design pressure.  Environmental hazard of loss of refrigerant

Low Low Pressure in  CV failure  Less cooling efficiency  PI to be provided

Chiller 2  Compressor malfunction leading to less pure
ethylene production

Temperature High High Temperature  High temperature at heater  Less cooling leading to  TI to be provided
in Chiller 2 outlet less ethylene recovery  TT to be provided
 Refrigerant Compressor  Unrecovered ethylene along with bottom to be
overpressure leading to over sent to fuel gas
heating 

Low Low Temperature  High refrigerant compression  No hazard  TI to be provided
in chiller2 by compressor  Heat exchanger cleaning
 Scaling on heat exchanger
tubes
Flow No No flow to Chiller 2  Inlet Control valve failure  No cooling of product  FI to be provided
 Pipe blockage occurs  Environmental hazard of loss of refrigerant
 Compressor failure  Off spec ethylene  Ensure maintenance procedures and schedules
product for pumps, valves and pipe lines.

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

Flow Less Less flow to Chiller  Inlet Control valve failure  No cooling of product  FI to be provided
2  Pipe blockage occurs  Environmental hazard of loss of refrigerant
 Compressor failure  Off spec ethylene  Ensure maintenance procedures and schedules
product for pumps, valves and pipe lines.

Flow More  More flow to  Control valve failure  More cooling of product  FI to be provided
Chiller 2  Compressor failure occurs  Environmental hazard of loss of refrigerant
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

Seperation   
Column 1
Level High High level in  CV failure  Offspec product due to  LI to be provided
column 2 less separation and  LT to be provided
heavy bottom will come
along with ethylene
product
 Column flooding

Low Low level in  CV failure  less production of  LI to be provided

column 2 ethylene  LT to be provided
 Downstream chiller will  LI to be linked with refrigeratnt flow in chiller 2.
go dry run

Pressure High High Pressure in  CV failure  Pressure will rise leading  PI to be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

column 2  Compressor malfunction to less cooling and  Unrecovered ethylene along with bottom to be
separation efficiency in sent to fuel gas
column

Low Low Pressure in  CV failure  More cooling leading to  PI to be provided

column 2  Compressor malfunction more ethylene purity
 No hazard

Temperature High High Temperature  High temperature from  Less cooling leading to  TI to be provided
in column 2 upstream less ethylene recovery  TT to be provided
 Unrecovered ethylene along with bottom to be
sent to fuel gas

Low Low Temperature  Low temperature from  No hazard  TI to be provided

in column 2 upstream
Flow No No flow to column  Inlet Control valve failure  No ethylene production  FI to be provided
(Product) 2  Pipe blockage  Column dry out.  FT to be provided
 Compressor failure   FT to be linked with refrigeratnt flow in chiller 2
 Install low level alarm.
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

Less Less flow to C  Inlet Control valve failure  Less ethylene production  FI to be provided
column 2  Pipe blockage  Poor stripping and off  FT to be provided
 Pipe leakage spec product  FT to be linked with refrigeratnt flow in chiller 2
 Compressor failure  Install low level alarm.
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

More More flow to  Control valve failure.  Less ethylene recovery  LI to be provided
column 2 because of higher level in  LT to be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

column  LI to be linked with refrigeratnt flow in chiller

 Flooding in the column 2.TI to be provided
 Changes in product  Install low level alarm.
quality  Ensure maintenance procedures and schedules
 Changes in operation for pumps, valves and pipe lines.
parameters
Waste   
water
Treatment
Unit
Level High High level in waste  Higher water flow from  Higher loading on waste  LI to be provided
water storage separation section water  LT to be provided
vessel  Loss of water  Seperation column to be operated properly
 Less water treatment  Environmental hazard of water
efficiency wastage/contaminated water

Low Low level in waste  CV failure  Waste water spillage  LI to be provided

water storage  Pipe leakage  Dry run of waste water  LT to be provided
vessel  Pipe blockage treatment unit  Install low level alarm.
 Plant shut down  Ensure maintenance procedures and schedules
 Plant at low operation for pumps, valves and pipe lines.
 Waste water line bypass must be provided.

Pressure High High Pressure in  Not envisaged  PI to be provided
waste water 
storage vessel
Low Low Pressure  No flow from seperation  No hazard  PI to be provided
section

Temperature High High Temperature  High temperature from  Waste water to be  TI to be provided
in waste water upstream drained at higher  TT to be provided
storage vessel temperature leading to  Separation column to be operated properly

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

environmental hazard  Heat exchanger to be provided for cooling to

normal temperature before draining of hot water
 Open storage area to be provided for
atmospheric heating of cooled water
Low Low Temperature  Low temperature from  No hazard  TI to be provided
in waste water upstream  Open storage area to be provided for
storage vessel atmospheric heating of cooled water

Flow No No flow to waste  Inlet Control valve failure  Waste water spillage  LI to be provided
(Product) water storage  Pipe blockage  Dry run of waste water  LT to be provided
vessel  Compressor failure treatment unit  FT to be provided
 Low level in waste water  Seperation column to be operated properly FI to
storage vessel be provided
 Install low level alarm.
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

Less Less flow to waste  Inlet Control valve failure  Waste water spillage  LI to be provided
water storage  Pipe blockage  Dry run of waste water  LT to be provided
vessel  Pipe leakage treatment unit  FT to be provided
 Compressor failure  Low level in waste water  Seperation column to be operated properly FI to
storage vessel be provided
 Install low level alarm.
 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.

More More flow to waste  Control valve failure.  Higher loading on waste  LI to be provided
water storage  Higher water flow from water  LT to be provided
vessel separation section  Loss of water  FT to be provided
 Less water treatment  Seperation column to be operated properly FI to
efficiency be provided

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 PROCESS HAZARD ANALYSIS

Document Title: Document No. Rev:

HAZOP Report – Production of Ethylene from Bioethanol. CP310: Process Design and Simulation 0

 Install low level alarm.

 Ensure maintenance procedures and schedules
for pumps, valves and pipe lines.
 Environmental hazard of water
wastage/contaminated water

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