Discussion on Methanol Plant Accidents
Thread Content
Let’s all talk about what accidents have occurred at your plant during the commissioning and operation of the methanol plant (Say a high reward of 8 points)
Once, a fire and explosion accident occurred due to a crack in the weld of a high-pressure pipeline.
During operation, the gas compressor experienced a fire accident due to air leakage at the flange connections.
Due to the excessive decrease in the oxygen content in the air, the nitrogen content in the system surged. This ultimately led to a significant increase in the circulation volume of the synthesis system; the filter at the compressor inlet was drawn into the impeller, which caused the compressor to shut down and catch fire. There was an internal leak in the methanol-water cooler; a hydrogen flash explosion occurred when on-site circulating water was used for flushing
Tripping of the compressor due to excessively low exhaust pressure; incorrect operation resulting in compressor tripping caused by low liquid level in the synthesis drum drain
I heard from a friend that during the 5.12 earthquake, a pipe (apparently one for steam) broke, resulting in an emergency shutdown; fortunately, no one was injured. According to reports from Sinopec News Network (Wang Changwei, Huang Jin), as a result of the 7.8-magnitude earthquake in Wenchuan on May 12, a steam pipe in the methanol production unit of the Sichuan Vinylon Factory broke, which led to an emergency shutdown of the facility at 2:30 p.m. that day. After 21 hours of continuous repairs, production was resumed at 10:18 a.m. on May 13. When the earthquake occurred, the Sichuan Vinylon Plant felt significant shaking. A steam pipe inside the waste heat boiler of the dimethyl ether unit in the methanol workshop was damaged by the shock, preventing the unit from operating normally and forcing an emergency shutdown. The Dispatch Center of the Production Technology Department at Chuanwei Factory immediately held an emergency meeting, activated the emergency response plan, and arranged tasks for the period following the earthquake: first, to organize proper duty assignments for the personnel working at various facilities; second, to require those personnel to promptly inspect the equipment on site; third, to develop accident response plans tailored to this special situation of an earthquake. Once the facility was ready for maintenance, the dimethanol plant immediately entered maintenance mode to weld the cracked steam pipes in the R201 waste heat boiler; the workshop also organized Party members and league members to clean up the maintenance site. After 24 hours of continuous repairs, the facility resumed production at 10:18 a.m. on the 13th.
1. Sudden combustion and damage occurred during the catalyst pressure testing due to excessive pressure； 2. During the catalyst reduction process, the circulation pump stopped operating; the system was vented without the hydrogen valve being closed, which caused a sharp rise in temperature and led to excessive water production. 3. Parking caused catalyst pulverization due to excessive system venting
The anti-surge valve of the syngas compressor opened automatically, causing a sudden rise in pressure in the conversion system; this led to the rupture of the steam pipeline used for burner protection, damaging the burners. As a result, the methanol plant had to be shut down, the burners were destroyed, and losses amounted to nearly one million.
While driving, the flange gasket failed due to medium-pressure superheated steam at 2.55 MPa; fortunately, no one was injured. The high-pressure steam safety valve activated and could not be reset, and air leakage occurred in the converter’s pigtail pipe.