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Qualitative Hazard Analysis for a Batch Radical Reaction Process using HAZOP Method

HAZOP 기법을 이용한 회분식 라디칼 반응 공정에 대한 정성적 위험성 평가 방법 연구

  • Park, KyungMin (Department of Chemical Engineering, Keimyung University) ;
  • Lee, DongKyu (Department of Chemical Engineering, Keimyung University) ;
  • Lee, JoonMan (Division of Cosmetics Chemistry, Yeungnam Univeresity College) ;
  • Ahn, WonSool (Department of Chemical Engineering, Keimyung University)
  • 박경민 (계명대학교 화학공학과) ;
  • 이동규 (계명대학교 화학공학과) ;
  • 이준만 (영남이공대학교 화장품화공계열) ;
  • 안원술 (계명대학교 화학공학과)
  • Received : 2018.10.29
  • Accepted : 2019.02.01
  • Published : 2019.02.28

Abstract

Potential fire, explosion and safety hazards exist in medium- or small-scale chemical plants using radical batch reaction processes due to the various conditions of materials, works or products. To minimize the potential damage, a study was conducted on qualitative hazard analysis using the HAZOP technique, which is a typical method for a qualitative risk assessment and analysis of the potential risks encountered in these chemical plants. For this purpose, a domestic chemical plant, which produces the acrylic resin by a radical batch reaction process, was selected and a risk assessment and analysis according to the procedure of HAZOP method was performed for the process. As the result of the study, to prevent the hazard, the input of inert gas and the installation of a pressure gauge were indispensable. In addition, the initiator and monomer should also be separated, and inhibiting substances and equipment are also necessary to prevent a runaway reaction.

라디칼 회분식 반응 공정을 사용하는 있는 중 소규모 화학공장의 경우, 취급 물질, 작업 내용 및 제품 등의 여러가지 상황 변화에 따른 잠재적인 화재, 폭발 및 안전의 위험성이 상존해 있다. 이러한 화학공장에서 마주치는 잠재적인 위험성에 대하여, 정성적인 위험성 평가 및 분석을 위하여 대표적으로 많이 사용되는 평가 방법인 HAZOP 기법을 이용하여 위험성 평가 연구를 진행하였으며, 이를 바탕으로 피해 크기를 최소화할 수 있는 방안을 모색하였다. 이를 위하여 국내의 중소화학 공장 중, 라디칼 회분식 반응 공정에 의하여 아크릴 수지를 생산하는 중 소규모의 화학공장을 선택하여 현장 설비, 배관 계장도 및 공정에 대하여 HAZOP 기법의 절차에 따라 위험성 평가 및 분석을 진행하였다. 연구의 결과로서, 위험성을 예방하기 위한 구체적인 조치로서는 불활성기체의 투입 및 압력 게이지 설치가 반드시 필요하며, 또한 반응 개시제와 모노머는 따로 분리하고, 폭주반응을 막기 위한 반응억제 물질과 설비를 추가로 설치하는 것이 반드시 필요함을 도출할 수 있었다.

Keywords

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Fig. 1. Typical representation of process flow diagram for the acrylic resin reaction

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Fig. 2. Utility flow diagram of radical reaction process for the acrylic resin.

Table 1. Information on the review section for the risk assessment

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Table 2. Deviation matrix for the process step review

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Table 3. Likehood (L) Criteria

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Table 4. Severity (S) Criteria

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Table 5. Risk (Severity and frequency matrix) Criteria

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Table 6. Risk assessment worksheet using HAZOP technique for the batch process of an domestic acrylic resin maker

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