HAZOP ANALYSIS ON ETHYLENE OXIDE REACTOR (R-

100)
The Ethylene Oxide reactor converts ethylene to ethylene oxide using oxygen and a sliver
catalyst. The operating temperature of the reactor is 280 o C and operating pressure is 8 atm.
Ethylene oxide is very dangerous, carcinogenic, flammable and explosive. When it reaches its
decomposition temperature of approximately 400 o C, a very deadly explosion may occur.

Figure 1: Simple Diagram Showing Ethylene Oxide Reactor Streams

BFP -Back-flow Prevention (Non-Return Valve)

Oxygen and ethylene is combined and forms the feed stream. Oxygen inlet concentration and
ethylene inlet concentration is dependent on the oxygen and ethylene supply respectively as
shown in the diagram. The combined feed rate, feed compositions and coolant streams will be
analysed. The reactor products stream only needs a non-return valve to prevent backflow of
reactor products to the reactor.
Deviations Property Possible Causes Possible Consequences R
(Guide Words)

COMBINED FEED TO THE REACTOR (R-100)

No Oxygen Inlet  Control valve  Technological Problem.
Concentration failure. Ethylene Oxide Conversion
(EO) is 0.

More Oxygen Inlet  Control valve  Thermal runaway effect

Concentration failed to close (Reactor Temperature
Increase) and possible
explosion due to Ethylene
Oxide decomposition.

Less Oxygen Inlet  Control valve  Technological Problem and

Concentration failed to open Conversion is too low.
Other Than Oxygen Inlet  Wrong reagent  Vessel Rupture
Concentration or raw material.  Formation of undesirable
Products.
 Decreased conversion
As Well As Oxygen Inlet  Impurities in  Technological Problem in
Concentration raw material Reactor
No Ethylene Inlet  Ethylene  Technological Problem and
Concentration pipeline may be conversion is zero.
clogged.
 Control valve
failure.

More Ethylene Inlet  Control valve  A very high wt. % of ethylene

Concentration failed to close may form explosive mixtures
of hydrocarbon and oxygen.
 Low selectivity.
Less Ethylene Inlet  Control valve  Technological Problem and
Concentration failed to open Conversion is too low
Other Than Ethylene Inlet  Wrong reagent  Vessel Rupture
Concentration  Formation of undesirable
or raw material.
Products.
 Decreased conversion
As Well As Ethylene Inlet  Impurities in  Technological Problem in
Concentration raw material Reactor
No Flow  Flow Controller  Loss of feed to reaction section
failure. and no output
 Line fracture.
 Line blockage.

More Flow  Flow Controller  Increased EO Conversion.

failed to close  High concentrations of
 Low flow ethylene oxide and oxygen
controller valve leading to explosive mixtures.
bypass failed to
close.
Less Flow  Flow Controller  Less EO Conversion
failed to open
As Well As Flow  Water  Out of spec. supply
Contamination
 Impurities
Other Than Flow  Wrong Feed  Decreased conversion.
 Increased formation of
Delivered
undesirable products
Reverse Flow  Pump failure,  This may form explosive
non-return valve mixtures since ethylene is
failure, flammable and explosive in the
  Over- presence of high levels of
pressurisation of oxygen.
reactor.
More Temperature  Temperature  O2 concentrations increases
Controller and forms potential explosive
Failure. mixture of hydrocarbons and
 External Fire. oxygen.
 Decreased conversion and
selectivity.
 Increased Reaction
Temperature leading to
runaway effect.

Less Temperature  Temperature  Decreased Selectivity.

 Low Pressure.
Controller
Failure

COOLING (COOLANT) STREAM PASSING THROUGH REACTOR (R

Higher Inlet and Outlet  Cooling water  Thermal runaway effect and
Temperature valve possible explosion
malfunction or
failure.
Lower Inlet and Outlet  Control valve  The temperature of the reactor
Temperature failure, operator may become very cool
fails to take
action on alarm

No Flow  Cooling water  Runaway effect and possible

valve or flow explosion
controller
malfunction.
 Cooling water
service failure.
More Flow  Control valve  The reactor becomes very cool
failure, operator and reactant concentration
fails to take builds up and potential
action on alarm. runaway effect on heating.

Less Flow  Pipe Leakage.  Temperature of process fluid

 Temporary remains constant or increases
Water Source  Thermal runaway effect
Failure.
 Partially
clogged cooling
line.

Part of Flow  Partially  Less Cooling, Potential

clogged cooling runaway effect.
line.
As Well As Flow  Contamination  Decreased Conversion.
(Presence of
Reactor
product) in
cooling tubes
Reverse Flow  Failure of water  Less cooling, runaway effect
source or high and explosion
backpressure
resulting in
backward flow
 REACTOR PRODUCTS LEAVING THE REACTOR (R-100)
More Temperature  Temperature  O2 concentrations increases
Controller and forms potential explosive
Failure. mixture of hydrocarbons and
 External Fire. oxygen.
 High Reaction  Increased Ethylene Oxide
Temperature. Temperature leading to
runaway effect.

Less Temperature  Temperature  Low Reactor Pressure.

Controller
Failure
No Flow  Flow Controller  No production of ethylene
failure. oxide.
 Line fracture.
 Full Line
blockage.
 Wrong Catalyst
or Catalyst is
fully consumed.

More Flow  Feed Flow  More production of ethylene

Controller failed oxide.
to close.  High concentrations of
 Low feed flow ethylene oxide and oxygen
controller valve leading to explosive mixtures.
bypass failed to
close.
Less Flow  Feed Flow  Less production of Ethylene
Controller failed oxide.
to open
As Well As Flow  Water  Out of spec. supply to the
Contamination reactor.
 Impurities
Other Than Flow  Wrong Feed  Decreased Ethylene oxide
Delivered to the production.
 Stream may contain a large
Reactor
 amount of undesirable
products.
Reverse Flow  Pump failure,  This may form explosive
non-return valve mixtures since ethylene is
failure, flammable and explosive in the
 Over- presence of high levels of
pressurisation of oxygen.
reactor.

OPERATING CONDITIONS OF REACTOR (R-100)

More Reactor Pressure  Increased steam  Reduced Yield.
 Formation of undesirable
flow rate.
 Relief valve products.
fails closed.  Development of Temperature
Gradients with localized hot
spots leading to impairment of
the catalyst to produce
ethylene oxide.
 Vessel overpressure or rupture.

Less Reactor Pressure  Release valve  Decreased Conversion.

fails open.
 Filling hose
ruptures.

More Temperature  Temperature  O2 concentrations increases

Controller and forms potential explosive
Failure. mixture of hydrocarbons and
 External Fire. oxygen.
  Decreased conversion and
selectivity.
 Increased Reaction
Temperature leading to
runaway effect.
Less Temperature  Temperature  Decreased Selectivity.
 Low Pressure.
Controller
Failure
Thermal runaway

An exothermic reaction can lead to thermal runaway, which begins when the heat produced
by the reaction exceeds the heat removed. The surplus heat raises the temperature of the
reaction mass, which causes the rate of reaction to increase. This in turn accelerates the rate
of heat production. Thermal runaway can occur because, as the temperature increases, the
rate at which heat is removed increases linearly but the rate at which heat is produced
increases exponentially. Once control of the reaction is lost, temperature can rise rapidly
leaving little time for correction. The reaction vessel may be at risk from over-pressurisation
due to violent boiling or rapid gas generation. Executive temperatures may initiate secondary,
more hazardous runaways or decompositions. An over-pressure may result in the plant failing
catastrophically resulting in blast or missile damage. A release of flammable materials from
the process could result in a fire or an explosion in the workroom. Hot liquors and toxic
materials may contaminate the workplace or generate a toxic cloud that may spread off-site.
There can be serious risk of injuries, even death, to plant operators, and the general public
and the local environment may be harmed. At best, a runaway cause loss and disruption of
production, at worst it has the potential for a major accident.