Safety & Economic Supervised By: Prof. Mohamed Fahim Eng. Yusuf Ismail Presented by Hessa Al-sahlawi Beshayer Al-Dihani Latifah Al-Qabandi

Agenda. Environmental Consideration.. Plant Safety.. Economy.

Environmental Considerations Environmental Protection Agency (EPA):Environmental Protection Agency (EPA): The role of the EPA is to protect the environmental from the effects of human activity. For the chemical processing industries, this role relates to emissions to harmful or potentially harmful materials from the plant site to outside by air or by water. There are three classes of such emission: (1). Planned emissions. (2). Fugitive emissions. (3). Emergency emissions.

In our process syngas production from the steam reforming of natural gas entails the disposal of the following waste effluent streams: 1- In stream 8 (Output from Compressor K-102) which is Gaseous flue gas mixture, containing mainly CO2 and H2O, but with traces of CO, SO2 and nitrogen oxides which discharge to the atmosphere. We study the chance that we have a harmful emission of CO, we found the concentration of CO was mg/m ³. From Gaussian Dispersion Model: C = Q/(2πσyσZ u)*[ exp(-(z-H)²/2 σZ²)+exp(-(z+H) ²/ 2 σz ²)]

Assumption: u= 4 m/s, z= 10 m/s, x= 10 Km (downwind) Class → C, H= 25 m From HYSYS: Q= Kg/hr get σy & σZ from figure σy = 850 m, σZ = 500 m C = mg/m ³ By Comparing the value with EPA standard values we found it’s very low, then CO that product from our plant does not cause environmental hazards.

2- In stream 12, Gaseous, CO2 Purge stream which discharge to the atmosphere. 3- In stream 24, Aqueous, Condensate purge from the cooled syngas stream. Traces of dissolved H2, with CH4, CO and CO2 send to waste water treatment. 4- In absorber [C-101] a zinc oxide system is environmentally desirable. Thus, no H2S is discharge to the atmosphere and the spent zinc oxide adsorbent is returned to the supplier to carry out the regeneration offsite.

PLANT SAFTY Each plant shall develop and implement a safety program incorporating all of the following elements: Safety Representative Reporting Safety Statistics Safety Goals and Objectives New Employee Safety Orientation Safety Rules/Protective Equipment Policies Personal safety programs Industrial Hygiene programs Process and equipment safety programs

What is HAZOP? A Hazard and Operability (HAZOP) study is a structured and systematic examination of a planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment, or prevent efficient operation. When to perform a HAZOP? The HAZOP is usually carried out as a final check when the detailed design has been completed.

The following information should be available When study HAZOP: Process flow diagrams. Piping and instrumentation diagrams (P&IDs). Layout diagrams. Material safety data sheets. Provisional operating instructions. Heat and material balances. Equipment data sheets

Worksheet entries Guide Word: No flow – More of – Less of – Part of – As well as – other than - Reverse …. 1.Deviation 2. Cause 3. Consequence 4. Action

Our process : E-101 Heat Exchanger Intention: To provide feed to tubular reactor at 538˚C

ActionConsequenceCauseDeviation Guide Word Consider an interlock on fuel gas flow Fluid in E-101 overheats Blockage in line No flow (stream 4) No Interlock with sudden pressure drop alarm and shutdown ExplosionHeat tubes burst No flow Out put Stream No AlarmUnstable operationSurge of K-103 More flow in (stream 4) More of Pressure relief system on tubes Tube failureDown stream blockageHigher pressureMore of Alarm on low pressure or low flow Explosion and toxic release Burst pipe down stream Less pressure in tubes Loss of Monitor E-101 temperatures Impurities in product and/or catalyst deactivation Impurities in feed or overheating in tubes Impurities in Out put Stream Other than Maintain spare compressor K-101 CO:H2 ratio off to R- 101 K-103 not working Low CO2 in Stream 4 Part of

Section 1: Fixed Capital Investment Plant 1 % of Delivered Equipment Direct Costs $40,455,312100% Purchased equipment- delivered $19,013,99747% Purchased-equipment installation $14,563,91236% Instumentation and controls $27,509,61268% Piping $4,450,08411% Electrical $7,281,95618% Buildings $4,045,53110% Yard improvments $28,318,71870% Service facilities $145,639,123360% Total direct plant cost

Indirect Costs $13,350,25333% Engineering and supevision $16,586,67841% Construction expenses $1,618,2124% Legal Expences $8,900,16922% Contractor's fee $17,800,33744% Contingency $58,255,649144% Total Indirect Plant Cost

$203,894,772504% Fixed capital investment $36,005,22889% Working capital $239,900,000593% Total capital investment $239,900,000 Total Fixed Capital Investment for Plant

Total product cost $84,761,420 Manufacturing cost = Direct production cost + Fixed charges + Plant overhead costs I $67,807,000 Direct production costs (about 36.5% of total product cost) A $20,418,200 Raw materials (11% of the total product cost)1 $9,281,000 Operating labor (5% of the total product cost)2 $928,100 Direct supervisory and clerical labor (10% of operating labor) 3 $18,562,000 Utilities (10% of total product cost)4 $14,394,000 Maintenance and repairs (6% of fixed capital investment) 5 $1,439,400 Operatint supplies (10% of cost of maintenance and repairs) 6 $928,100 Laboratory charges (10% of operating labor)7 $1,856,200 Patents and royalties (1% of total product cost) 8

$3,961,020 Fixed charges (2.1% of total product cost) B $1,330,840 Depreciation (about 4% of fixed capital investment and 2% of utlities) 1 $959,600 Insurance (0.4% of fixed capital investment) 2 $1,670,580 Rent (9% of utilities)3 $12,993,400 Plant overhead cost (7% of total product cost) C $42,692,600 General expenses = administrative costs + distribution and selling costs + research and development costs II

$5,568,600 Administrative costs (3% of total product cost) A $27,843,000 Distribution and selling costs (15% of total product cost) B $9,281,000 Research and development costs (5% of total product cost) C $185,620,000 Total product cost = Manufacturing cost + General expenses III

Pay Back Period i = 15% $239,900,000 Fixed Capital Investment = $185,620, Total manufacturing cost = $271,300,000Total Product Sales = 20 yrLife of Plant =

End of year Balance Total Product Sales Total Manufacturing CostFixed Capital InvestmentYear -$239,900,000$0 $239,900,0000 -$190,205,000$271,300,000$185,620,000$0 1 -$133,055,750$271,300,000$185,620,000$0 2 -$67,334,113$271,300,000$185,620,000$0 3 $8,245,771$271,300,000$185,620,000$0 4 $95,162,636$271,300,000$185,620,000$0 5 $195,117,032$271,300,000$185,620,000$0 6 $310,064,586$271,300,000$185,620,000$0 7 $442,254,274$271,300,000$185,620,000$0 8 $594,272,416$271,300,000$185,620,000$0 9 $769,093,278$271,300,000$185,620,000$0 10 $970,137,270$271,300,000$185,620,000$0 11 $1,201,337,860$271,300,000$185,620,000$0 12 $1,467,218,539$271,300,000$185,620,000$0 13 $1,772,981,320$271,300,000$185,620,000$0 14 $2,124,608,518$271,300,000$185,620,000$0 15 $2,528,979,795$271,300,000$185,620,000$0 16 $2,994,006,765$271,300,000$185,620,000$0 17 $3,528,787,779$271,300,000$185,620,000$0 18 $4,143,785,946$271,300,000$185,620,000$0 19 $4,851,033,838$271,300,000$185,620,000$0 20

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