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Sustainability 2017, 9(1), 49; doi:10.3390/su9010049

Optimal Design of Safety Instrumented Systems for Pressure Control of Methanol Separation Columns in the Bisphenol a Manufacturing Process

Department of Safety Engineering, Incheon National University, Incheon 22012, Korea
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Author to whom correspondence should be addressed.
Academic Editor: Bhavik Bakshi
Received: 25 August 2016 / Revised: 12 December 2016 / Accepted: 21 December 2016 / Published: 30 December 2016
(This article belongs to the Section Sustainable Engineering and Science)
View Full-Text   |   Download PDF [2329 KB, uploaded 30 December 2016]   |  

Abstract

A bisphenol A production plant possesses considerable potential risks in the top of the methanol separation column, as pressurized acetone, methanol, and water are processed at an elevated temperature, especially in the event of an abnormal pressure increase due to a sudden power outage. This study assesses the potential risks in the methanol separation column through hazard and operability assessments and evaluates the damages in the case of fire and explosion accident scenarios. The study chooses three leakage scenarios: a 5-mm puncture on the methanol separation column, a 50-mm diameter fracture of a discharge pipe and a catastrophic rupture, and, simulated using Phast (Ver. 6.531), the concentration distribution of scattered methanol, thermal radiation distribution of fires, and overpressure distribution of vapor cloud explosions. Implementation of a safety-instrumented system equipped with two-out-of-three voting as a safety measure can detect overpressure at the top of the column and shut down the main control valve and the emergency shutoff valve simultaneously. By applying a safety integrity level of three, the maximal release volume of the safety relief valve can be reduced and, therefore, the design capacity of the flare stack can also be reduced. Such integration will lead to improved safety at a reduced cost. View Full-Text
Keywords: relief system; safety instrumented system; pressure relief valve; safety integrity level; minimize design capacity relief system; safety instrumented system; pressure relief valve; safety integrity level; minimize design capacity
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Lee, I.-B.; Woo, I. Optimal Design of Safety Instrumented Systems for Pressure Control of Methanol Separation Columns in the Bisphenol a Manufacturing Process. Sustainability 2017, 9, 49.

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