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Hazop Example

This document summarizes the production of diammonium phosphate (DAP) through the reaction of phosphoric acid and ammonia. It notes that an incomplete reaction can produce excess ammonia, while too little ammonia results in an undesirable product. The project team was tasked with investigating hazards from the phosphoric acid delivery line. The HAZOP study identifies deviations such as no flow, less flow, and more flow in the line and considers their consequences, like excess ammonia release, as well as possible causes and recommended actions.

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MARCOPOLO24
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© Attribution Non-Commercial (BY-NC)
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2K views

Hazop Example

This document summarizes the production of diammonium phosphate (DAP) through the reaction of phosphoric acid and ammonia. It notes that an incomplete reaction can produce excess ammonia, while too little ammonia results in an undesirable product. The project team was tasked with investigating hazards from the phosphoric acid delivery line. The HAZOP study identifies deviations such as no flow, less flow, and more flow in the line and considers their consequences, like excess ammonia release, as well as possible causes and recommended actions.

Uploaded by

MARCOPOLO24
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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Diammonium Phosphate (DAP) Production Phosphoric acid and ammonia are mixed, and a non-hazardous product, diammonium phosphate

(DAP), results if the reaction of ammonia is complete (see Fig. 3). If too little phosphoric acid is added, the reaction is incomplete, and ammonia is produced. Too little ammonia available to the reactor results in a safe but undesirable product. Valve A

Phosphoric Acid study line 1 phosphoric acid delivery line Valve C

Ammonia

Valve B Diammonium Phosphate (DAP)

Reactor

Fig. 3. Continuous process for the production of DAP

ASSESSMENT (HAZID) Both chemicals will be used in large quantities and in concentrated form. Due to the highly corrosive nature of both chemicals, the project team was assigned to investigate the hazards posed to staff from the reaction resulting from study line 1 (phosphoric acid delivery line).

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H AZOP STUDY RECORD SHEET SYSTEM: DAP PRODUCTION PROCESS PARAMETER: FLOW (Primary keyword) LINE: STUDY LINE 1 NO. 1 GUIDE WORD NO DEVIATION NO FLOW

PROJECT: AMMONIA PLANT PRESENT: HAZOP TEAM MEMBER LIST CHAIRED: HAZOP LEADER CONSEQUENCES Excess ammonia in reactor and release to work area. SECRETARY: TEAM MEMBER POSSIBLE CAUSES Valve A fails closed. Phosphoric acid supply exhausted. Pipe ruptures Valve a partially closed. Partial plug or leak in pipe. Team member to calculate toxicity vs flow reduction. Set point determined by toxicity vs flow calculation. Automatic closure of valve to reduce flow from phosphoric acid supply. ACTION REQUIRED Automatic closure of valve B on loss of flow from phosphoric acid supply.

DATE: DD/MM/YY PAGE: 1 TOTAL PAGES:1 PERSON DONE (sign off)

LESS

LESS FLOW

Excess ammonia in reactor and release to work area. With amount released related to quantitative reduction in supply. Team member to calculate toxicity vs flow reduction. Excess phosphoric acid degrades product. No hazard to work area. Excess ammonia in reactor. release to work area, with amount released related to quantitative reduction in supply. Depends on substitution. Team member assigned to test availability of other materials.

MORE

MORE FLOW

PART OF

Normal flow of decreased concentration of phosphoric acid.

Vendor delivers wrong material or concentration. Error in charging phosphoric acid supply tank.

Check phosphoric acid supply tank concentration after charging.

OTHER THAN

Material flow other than phosphoric acid in Line A.

Wrong delivery from vendor. Wrong material chosen.

Plant procedures to provide check on material chosen before charging phosphoric acid supply tank.

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