VINYL CHLORIDE

PRODUCTION Process Safety

Patrick Carter

Amar Seran

Pranav Khattar

Maher Shamshoom

David DeRubeis

Agenda

• Implement basic process control systems

• HAZOP analysis to identify threats

• Corrective action

Process Overview

• Typical Vinyl Chloride monomer production plant

• Comprised of five main sections

• Direct chlorination of ethlyene to form EDC

• Oxychlorination section: ethylene reacted with recycled HCl and O2

• Purification of EDC (Cracking, Quenching, etc.)

• Thermal cracking of EDC to form VCM and HCl

• Purification of VCM

• Our Focus: EDC Purification and VCM Purification

Basic Process Control System

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Pure EDC

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Basic Process Control System

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Additions to PFD

• Required for basic safety

• Pressure Control

• Temperature Control

• Level Control

• Flow Control

PFD: Basic Process Control System

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Pressure

Keyword: Low

200

psig

Temperature

Cause Action

Insufficient heating Secondary heating

element

Pipe leak Alarm on ∆P between

drum and PC

PC fails open Flow monitor with high

level alarm

Cause Action

TC fails at inlet to

flash drum

Secondary heating

element

Ambient air temp

changes

Insulation on pipe

500 °C

Flow

Keyword: Low

200

psig

Cause Action

Decrease in vapour

pressure

Draw-down drum to

store product

Pipe leak Alarm on ∆P between

drum and PC

PC valve fails closed Bypass valve that

opens if PC value is

too high

500 °C

Pressure

Keyword: High

200

psig

Temperature

Cause Action

PC valve fails closed Bypass valve that

opens if PC value is

too high

Bottoms of flash drum

valve close Pressure relief valve

at top of drum Temperature rises

Cause Action

TC fails at inlet to

flash drum

Cut steam feed to

preheater (SIS)

Ambient air temp

changes

Insulation on pipe

500 °C

Flow

Keyword: High

200

psig

Cause Action

Vapour pressure

inside tank increases

Flow control valve.

LT fails causing drum

to fill with liquid

Redundant LT.

Independent from

Process control

500 °C

PC

PA

H

FA

H

LT

LC

Heating

Element

TT

TC

Draw

Down

Drum

Tim Mastalerz

Joseph Pang

Eric Chong

Brian Shuter

Dan Da Silva

Process Flow Diagram

Equipment Estimated Cost ($) Range of Cost ($)

Mash Tun (60 hL) 323,352 227,746 – 422,957

Lauter Tun (60 hL) 368,127 257,689 – 478,564

Brewing Kettle (40 hL) 93,560 74,848 – 112,272

Heat Exchanger 23,302 16,312 – 30,293

Fermentation Tank (26 Tanks) (450 hL)

1,104,960 per tank 773,472 – 1,436,449

Diatomaceous Earth Filtration 257,675 180,373 – 334,978

Aging Tank (4 Tanks) (450 hL) 294,017 per tank 205,812 – 382,222

Sterile Pad Filtration 157,861 110,503 – 205,219

Calandria 73,058 51,141 – 94,976

Total 31,203,974 21,852,138 – 40,555,811

24 Bottles (341mL) = $44.95

24 Cans (500 mL) = $61.95

20 L Keg = $100.95

30 L Keg = $122.95

50 L Keg = $196.95

*All prices include taxes

- Minimum cost for 24 bottle case is $29.35 (in Ontario)

- Current Tax Rate for Beer Made in Microbrewers in Ontario:

Draft Beer Non – Draft Beer

20.30 ¢/L 22.36 ¢/L

Example:

341 mL bottle of Steamwhistle

Tax = (341/1000) * 0.2236

Tax = $0.0714

*As of March 1st 2012 until February 28th 2013

1. Barley $0.24574 CAD/kg $ 657.06 CAD for 5894.73 lbs for Malted Barley

2. Hops $ 2.7625 CAD/ lbs $ 11.13 CAD for 4.03 lbs for Centennial Hops

3. Spring Water $ 1.47 / m3 $ 4.78 for 3250 L of Water

4. Yeast $ 0.05454 /billion yeast cells $ 2912.93 for 53409.1 billion Yeast Cells

5. Operators $ 70,000 * 12 = $ 840,000

6. Steam $ 0.00604 /lb at a rate of 936.96 kg/hr $ 5.66 /hr

Water fed to heat exchanger after brew kettle needs to be at 6.5ᵒC

Feed water exits hot, which reduces heating duty in Mash Tun

If Water is not cool enough, there are cold streams that can be used to cool it elsewhere

Spent steam from calandria can be reused in Mash Tun, circulated through the building for heating, used to maintain tank of heated feed water, etc.

Time from Start of Mash Tun to Start of

Fermentation: 8 hours

Time between batches: 4 hours

Kettle Boiling time: 1.5 hours

Fermentation period: 6 to 7 days

Aging Period: 21 to 25 Days

Kettle cleaned daily, Tuns cleaned weekly

Possible Normal Operation: - Monday to Thursday: 3 batches - Friday: 2 batches

Max number of batches: 5 per day

In case of Process interruption, large number

of fermentation and aging tanks allows for

consistent output

- Increase number of batches once process is

running again

Have 800 hL in aging tanks

Bottling rate is 60 hL per day

How many weeks can the process afford to be out of commission?

Planning to do renovations in 2 months

Renovations will last 1 month

No excess beer currently stored in aging tanks

Currently operating at usual schedule

How many additional batches per week must be scheduled to account for 1 month down time

Specify weekday batches and weekend batches

Reminder: - 1 batch = 30 hL - Bottling rate = 60 hL per day - Weekend overtime costs more than weekday overtime

GOLD EXTRACTION Hawra Al-Kazwini Amina Al-Saigh Mohamed Ali Eunice Cheou

Gold Processing

Extraction Overview • Gold Cyanidation: process where cyanide is used to

extract gold from crushed ore •  The use of cyanide is banned in Canada, some US states,

and other countries • Cyanide is used due to low cost, effectiveness, and

selectivity for gold over other metals

HCN is Highly Poisonous!

Desired

Undesired

•  HCN has a vapor pressure of 100 kPa at 26 °C •  HCN gas is released if pH is below 10.2 •  Must use proper pH sensor:

•  Finely ground ore can abrade glass electrode •  Lime can form a hard coating on pH sensor •  High concentration of CN can penetrate sensor and cause error

•  Monitoring cyanide during and after gold recovery is essential •  Disposal of cyanide is done by reaction with H2O2

Critical safety concern: Control pH

Leaching P&ID

Carbon Elution • Reversing the leaching process • Carbon is washed with dilute HCL to remove soluble

salts •  Then, it is soaked with sodium cyanide at a temperature

of 100 °C - 120 °C and 230 kPa

• Hot water is pumped through the carbon to eluate the gold

• Pregnant solution goes to electrowinning • Baren carbon goes to thermal regeneration

Carbon Elution P&ID

A Glance at Economics…

Leaching

Services facilities

General site facilities

General piping utilities

Tailings dam

Adsorption

Thickening

General electrical

Gold refining

Elution

Waste reclamation and delivery

Ore-delivery

Primary crushing

Ores storage

Reagent make-up and dosing

Process control

Residue disposal

Capital Costs

CLASS ACTIVITY