Chemical Process Safety Presentation

1. Phosphoric Acid Production Jacqueline Alcantar Jennifer Pratt Chemical Process Safety 5-1-06

2. Mill Phosphate Rock Dilute H 3 PO 4 Reactor 93% H 2 SO 4 Absorption Tower Gases H 2 SiF 6 Filter CaSO 4 H 3 PO 4 CaSO 4 -2H 2 O Evaporator Dilute H 3 PO 4 75% H 3 PO 4 Wet Process Flow Diagram

3. Hazardous Operations Analysis High Temperature Alarm/Sensor, automatically close all inlets Runaway Reaction, Explosion Loss of cooling in reactor Air Pump Fails, supply exhausted, break/plug in line/valve Flow No Air Automatically close all inlets, LLA, maintenance, install check valves, training, flow meters, tester/measuring device Pressure Buildup, eqmpt failure Foam backs up into inlet pipes Break in line/valve failure/plugging, supply exhausted Flow No Defoamer Automatically close all inlets, LLA, maintenance, install check valves, training, flow meters, tester/measuring device Process upset, eqmt failure Product Acid won't be concentrated enough Failure of filtration/ break in line/valve, supply exhausted Flow No Dilute H3PO4 Automatically close all inlets, LLA, maintenance, training Process upset, eqmt failure Unwanted reactions occur, no phosphoric acid produced Rock bin clogged, conveyer/feeder failure, supply exhausted Flow No Phosphate Rock Automatically close all inlets, LLA, maintenance, install check valves, training, flow meters, tester/measuring device Process upset, eqmt failure No phosphoric acid produced Break in line, valve failure/plugging,supply exhausted Flow No H2SO4/Process H2O Reactor Measures Hazard Consequences Possible Causes Deviations Guide Word Study Node