HAZOP/SIL Analysis Review Meeting for the Ethylene Glycol Unit of Yulin Chemical’s “Demonstration Project on the Utilization of Coal at Different Quality Levels to Produce New Chemical Materials” Held

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Meeting on HAZOP/SIL Analysis Review for the Ethylene Glycol Unit of Shaanxi Coal Yulin Chemical’s “Demonstration Project on Utilizing Coal in Different Ways to Produce New Chemical Materials” Held / Author/Source: Coal Chemical Industry 114 Forum / Date: June 19, 2020 / Views: 5. From June 9 to 15, meetings for the HAZOP/SIL analysis review, hazard identification (HAZID) analysis review, and intrinsically safe design (ISD) review of the ethylene glycol production plant with an annual capacity of 1.8 million tons – including the compressors, all external piping throughout the plant, and utility systems – were successfully held at Donghua Engineering Technology Co., Ltd. The review will be conducted by the independent third-party consulting firm Beijing Risk Control Engineering Technology Co., Ltd. Beijing Xinggao Chemical Technology Co., Ltd., Donghua Engineering Technology Co., Ltd., Xi’an Shanggu Power Co., Ltd., Shenyang Turbine Machinery Co., Ltd., Hangzhou Steam Turbine Co., Ltd., John Crane Technology (Tianjin) Co., Ltd., and Shuangliang Energy Saving Systems Co., Ltd. attended the meeting. At the meeting, the lead analyst from Beijing Risk Control Engineering Technology Co., Ltd. provided professional training on HAZOP/SIL analysis, Hazard Identification (HAZID) analysis, and Inherently Safe Design (ISD) analysis. Donghua Engineering Technology Co., Ltd. provided a detailed report on the analysis content and design details. The deputy manager of the company’s Technical Management Department outlined the technical requirements and arrangements for the review meeting in conjunction with the procedural documents ； The deputy manager of the ethylene glycol department made specific arrangements and requirements for this review, aiming to improve safety efficiency through the review meeting, achieve intrinsic safety, reduce operational failures, and lay a solid foundation for the long-term, safe, and stable operation of the facility. From June 9 to 12, the review team conducted a thorough HAZOP/SIL analysis of failure scenarios and protective measures for systems such as the process gas system, drive steam system, condensate discharge system, air condensation system, and dry gas seal system in the CO cycle compressor, nitric acid reduction compressor, H2 cycle compressor, and propylene compressor systems. Corresponding LOPA protection layers were established for measures, facilities, or solutions aimed at reducing risks through control, prevention, and mitigation approaches. On June 13-14, the review committee conducted an analysis and review of the Hazard Identification (HAZID) analysis and Inherently Safe Design (ISD) for the ethylene glycol plant. On June 15, a HAZOP/SIL analysis review was conducted on all the external pipes and utility systems of the ethylene glycol plant, with in-depth analysis of failure scenarios and protective measures for systems such as the steam pipeline network and instrument air system. To ensure the effectiveness of this analysis and evaluation, the company brought together professional technicians in areas such as processes, equipment, and instrumentation to participate in the review meeting, and employed a risk matrix to conduct a thorough PID analysis. The compressor process in the ethylene glycol plant, as well as the processes related to external pipelines and utility systems across the entire facility, were examined section by section and node by node to identify potential risk points. The causes of these risk points were analyzed, parameter deviations were sought out, and it was assessed whether the existing safety measures meet the prevention requirements set out in the company’s safety risk matrix regarding the acceptable level of accident consequences. The evaluation and analysis team also conducted SIL (Safety Instrument Level) assessments, determined the instrument levels through LOPA analysis and verification, assessed whether the safety instruments met the safety standards set by the international electrotechnical organization IEC, and provided specific recommendations for improvements. At the same time, a comprehensive analysis was conducted on the Hazard Identification (HAZID) and Inherent Safety (ISD) of the ethylene glycol plant, and specific corrective actions and measures were proposed. The successful holding of the HAZOP/SIL analysis review meetings, the Hazard Identification (HAZID) analysis review meetings, and the Inherently Safe Design (ISD) review meetings for the ethylene glycol plant (compressor units, all external piping in the plant, and utility systems) helped to identify the key areas where potential hazards exist. This made safety oversight more aligned with the actual operations of the plant, improved the efficiency of safety monitoring, reduced operational failures, and laid a solid foundation for the long-term, safe, and stable operation of the plant after it goes into production. The \"Demonstration Project on the Utilization of Coal at Different Grades to Produce New Chemical Materials\" carried out by Yulin Chemical of Shaanxi Coal Group is currently the largest coal chemical project under construction in the world. The project covers an area of approximately 13 square kilometers, with an estimated total investment of 125 billion yuan. As a coal conversion demonstration project with the largest coal processing capacity, the highest degree of industrial integration, the most complex technology integration, and a supply chain that is closest to the end market, this project represents, to a certain extent, the highest level of development in the coal chemical industry. It will have a profound impact on the further development and direction of China’s coal chemical industry, as well as determine the extent to which China’s coal chemical industry supply chain can be expanded in the future. The project is constructed in two phases and four stages, comprising a total of 27 process units along with associated utility systems. These mainly include the medium- and low-temperature pyrolysis of 15 million tons of coal, the production of 5.6 million tons of methanol, 1.8 million tons of ethylene glycol, 2 million tons of MTO, as well as downstream products derived from these intermediates. The first phase of the project requires an investment of around 70 billion yuan; it will involve the construction of facilities for producing 1.8 million tons per year of ethylene glycol, 5.6 million tons per year of methanol, and 2 million tons per year of olefins, as well as a large volume of fine chemical products derived from these olefins. The investment for the first phase of this project is around 70 billion yuan, which will be used to build facilities for producing 1.8 million tons per year of ethylene glycol and 2 million tons per year of olefins, as well as a large number of fine chemical products derived from olefins. The facility for producing 1.8 million tons per year of ethylene glycol is part of the first stage of this project, and it represents the largest coal-based ethylene glycol production facility under construction globally. The estimated investment for this facility is 26.5 billion yuan. The project utilizes Collin’s patented dry powder gasification technology and Japan’s patented technology for producing ethylene glycol from syngas. Shaanxi Coal Group Yulin Chemical Co., Ltd. and Nippon Kako Kagaku Co., Ltd. jointly invested in establishing Shaanxi Coal Group Yulin Chemical Yugao Chemical Co., Ltd. to build and operate facilities for the production of oxalate esters as well as for the hydrogenation of oxalate esters to produce ethylene glycol.